Machinery Lubrication

January-February 2016
This issue sponsored by:
TM
Royalmfg.com
Contents
12
COVER STORY
Are Oil Leaks Costing You Money?
Companies waste thousands of dollars each year because oil leaks have become accepted. Learn which key factors
most often cause system leakage and what you should do once an oil leak has been detected.
January-February 2016
2AS I SEE IT
Understanding How Engines Consume Oil 40 LUBE-TIPS
Our readers offer advice on a host of lubrication-related issues,
including tips on oil sampling from critical gearboxes.
44
Some degree of oil consumption is to be expected in all engines.
What is considered normal will vary based on the application and
LESSONS IN LUBRICATION
8
the design of the engine.
The Right Way to Lubricate Worm Gears
FROM THE FIELD Of all the different types of gear configurations, worm gear systems
Why Education is the Secret to Successful Change are considered to be some of the most problematic because they
present unique lubrication challenges.
50
While there are several important areas to focus on when imple-
menting change at your plant, educating your workforce may be the
most critical factor in achieving success.
PERSPECTIVE
18
Selecting Lubricants Based on Specifications
MAINTENANCE AND RELIABILITY Effective lubricant selection must strike a balance between quality,
application and affordability. Lubricant specification documents
4 Common Maintenance Problems and can help you achieve and maintain this balance.
54
How to Resolve Them
Many maintenance departments today “fight fires” instead of TRAINING AND CERTIFICATION
approaching their problems systematically. This article will reveal How to Address the Skilled Worker Shortage
the four common types of maintenance problems with the goal of The demand for skilled workers is increasing, and this demand is
helping you to prevent each type. not being met for a variety of reasons. Unfortunately, the resulting
24
shortage will likely persist or even get worse.
62
OIL ANALYSIS
Surprising Findings from Oil Analysis BACK PAGE BASICS
of Automotive Engines The Importance of Lip Seals
Used oil analysis is a great tool, but you need to understand how in Controlling Contamination
to properly manipulate the data and interpret the results. You must Lip seals are commonly used throughout industry to keep lubri-
know not only the averages but also if there are any abnormalities cants in and contaminants out. However, taking proper care of
embedded in those averages and how large is the standard deviation. these seals is seldom a high priority.
MoreEditorial Features
36 GET TO KNOW
Departments
34 PRODUCT NEWS
38 PRODUCT SUPERMARKET
41 BOOKSTORE
42 NOW ON MACHINERYLUBRICATION.COM 43 TEST YOUR KNOWLEDGE 60 ASK THE EXPERTS
Automotive
FROM
AS I SEE THE
IT FIELD
J im F itch | N oria C orporation
UNDERSTANDING
How EnginesCONSUME OIL
H igh consumption of engine

oil is almost always a
symptom or consequence
of another condition of even greater impor-
correlation and meaning of common trends
and how they might be useful for trouble-
shooting purposes.
through valves or upward past the piston
ring-pack.
Oil Mobility and Consumption Through
Engine Valves
tance. This article will address this issue Causes of High Oil Consumption Oil collecting on the stems of intake
from the standpoint of oil loss through Understanding oil transport mecha-
combustion pathways (versus leakage). valves is sucked into the combustion
nisms is necessary to prevent oil from going chamber during normal operation. Hot
While the focus will be more on diesel
where it shouldn’t. Loss of engine oil is exhaust gases burn oil on stems of the
engines used in industrial and commercial
influenced by the engine’s design and the exhaust valves. If there’s too much clear-
service, much of what will be discussed
operating conditions. Oil consumption ance between the valve stems and guides,
applies equally well to personal automobiles
and natural gas engines. primarily occurs near or through the the engine will suck more oil down the
By itself, oil consumption is a well-known combustion chamber, either downward guides and into the cylinders. This could be
source of harmful emissions to the atmo-
sphere (see the sidebar on page 4). Unburned
or partially burned oil is released through the
exhaust path in the form of hydrocarbons
and particulate contamination (soot). Addi-
tionally, motor oil anti-wear additives are
known to poison or at least impair the
performance of catalytic converters. The
more oil consumed through the combustion
chamber, the greater this poisoning risk/
effect. This escalates the environmental
impact further.
The causes of high oil consumption are
many and complex. Because this consump-
tion is symptomatic of other conditions,
there is a need to be aware of changes in the
oil consumption rate. These changes should
be viewed in the context of other data and
factors, including oil analysis, visual exhaust,
engine service life (from last rebuild), boost
pressures, running temperature, load/RACK,
blow-by and operating conditions. Oil anal-
ysis will be discussed in terms of the Figure 1. Piston ring-pack oil flow (Ref. Shell)
2 January - February 2016 | www.machinerylubrication.com

Machinery
Lubrication ML
PUBLISHER
Mike Ramsey - mramsey@noria.com
GROUP PUBLISHER
Volatiles (evaporation) Brett O’Kelley - bokelley@noria.com
EDITOR-IN-CHIEF
Jason Sowards - jsowards@noria.com
SENIOR EDITOR
Oil Thermal-oxidative degradation Deposits Jim Fitch - jfitch@noria.com
TECHNICAL WRITERS
Jeremy Wright - jwright@noria.com
Wes Cash - wcash@noria.com
Figure 2. The sequence of piston ring-pack deposit formation Alejandro Meza - ameza@noria.com
Bennett Fitch - bfitch@noria.com
Michael Brown - mbrown@noria.com
Garrett Bapp - gbapp@noria.com
caused by valve guide wear and seals that are economy (more oil consumption). One way this CREATIVE DIRECTOR
worn, cracked, missing, broken or improperly happens is through carbon jacking. In this Ryan Kiker - rkiker@noria.com
installed. The engine may still have good phenomenon, carbon buildup occurs in the ring GRAPHIC ARTISTS
compression but will burn a lot of oil. grooves (fed by soot and oil degradation prod- Patrick Clark - pclark@noria.com
Terry Kellam - tkellam@noria.com
Oil Flow Through the Piston Ring-pack ucts). The corresponding ring movement Josh Couch - jcouch@noria.com
restriction increases wear, blow-by and oil Greg Rex - grex@noria.com
Engine oil is designed to produce an oil film on
consumption with the rhythm of the piston. ADVERTISING SALES
the cylinder walls. While the oil control ring on
Tim Davidson - tdavidson@noria.com
the piston squeegees much of it off, a thin film Cylinder Wall Oil Evaporation 800-597-5460, ext. 224
will still remain. When the engine decelerates, As much as 17 percent of total oil consump-
MEDIA PRODUCTION MANAGER
high negative pressures suck oil in the combustion is associated with liner wall evaporation. Ally Katz - akatz@noria.com
tion chamber and out the exhaust manifold. The more distorted (out-of-round) and rough CORRESPONDENCE
The problem is more pronounced when rings (surface finish) the cylinder liner, the more oil You may address articles, case studies,
or cylinders are badly worn or damaged, but it film that will remain on the liner after the power special requests and other correspondence to:
can also occur if the cylinders were not honed Editor-in-chief
stroke. High liner surface temperatures (80-300 MACHINERY LUBRICATION
properly (out-of-round or surface finish defects) degrees C) will cause a loss of this oil by misting Noria Corporation
when the engine was built (or rebuilt) or if the and evaporation. Light oil molecules are more 1328 E. 43rd Court • Tulsa, Oklahoma 74105
Phone: 918-749-1400 Fax: 918-746-0925
rings were installed improperly. prone to evaporation. These light molecules are Email address: jsowards@noria.com
Much of the oil that is transported through the first to deplete, and as a result, there is less
the piston ring-pack and along the liner usually evaporative loss toward the end of the lubri-
occurs during the compression stroke. The oil cant’s service interval.
control ring scrapes the oil from the cylinder Not all oils of the same viscosity are equal MACHINERY LUBRICATION Volume 16 - Issue 1 January-February
wall. The scraped oil flows to the ring drain from the standpoint of volatility (risk of evapo- 2016 (USPS 021-695) is published bimonthly by Noria Corporation,
1328 E. 43rd Court, Tulsa, OK 74105-4124. Periodicals postage paid at
holes/cavities. Oil left behind on the cylinder rative loss). Some lubricants may exhibit as Tulsa, OK and additional mailing offices. POSTMASTER: Send
wall is needed to lubricate the compression much as a 50-percent greater loss from vola-
address changes and form 3579 to MACHINERY LUBRICATION, P.O.
BOX 47702, Plymouth, MN 55447-0401. Canada Post International
rings. Once oil moves past the compression tility than others. This is influenced by the base Publications Mail Product (Canadian Distribution) Publications Mail
Agreement #40612608. Send returns (Canada) to BleuChip Interna-
rings, it is difficult for the oil to return to the tional, P.O. Box 25542, London, Ontario, N6C 6B2.
sump. However, blow-by gases can provide a SUBSCRIBER SERVICES: The publisher reserves the right to accept or
reject any subscription. Send subscription orders, change of address and
transport medium to help recycle the oil back to all subscription-related correspondence to: Noria Corporation, P.O. Box
the sump (see Figure 1). 47702, Plymouth, MN 55447. 800-869-6882 or Fax: 866-658-6156.
Copyright © 2016 Noria Corporation. Noria, Machinery Lubrication

Piston Ring-pack Deposits and Movement and associated logos are trademarks of Noria Corporation. All rights
reserved. Reproduction in whole or in part in any form or medium
Piston ring-pack deposits can sharply reduce without express written permission of Noria Corporation is prohibited.
Machinery Lubrication is an independently produced publication of
ring movement and flexing. Likewise, ring move- Noria Corporation. Noria Corporation reserves the right, with respect to
submissions, to revise, republish and authorize its readers to use the tips
ment can greatly influence where deposits form and articles submitted for personal and commercial use. The opinions
and the lubricant motion (transport) within the of those interviewed and those who write articles for this magazine are
not necessarily shared by Noria Corporation.
ring-pack. This ring motion defines the resi- CONTENT NOTICE: The recommendations and information provided in
dence time of the lubricant in the ring-pack, Machinery Lubrication and its related information properties do not
purport to address all of the safety concerns that may exist. It is the respon-
which in turn affects the rate of lubricant degra- sibility of the user to follow appropriate safety and health practices. Further,
Noria does not make any representations, warranties, express or implied,
dation and where deposits will form (see Figure regarding the accuracy, completeness or suitability of the information or
recommendations provided herewith. Noria shall not be liable for any inju-
2). Ring-pack temperatures can range from ries, loss of profits, business, goodwill, data, interruption of business, nor
195-340 degrees C. for incidental or consequential merchantability or fitness of purpose, or
damages related to the use of information or recommendations provided.
Collectively, these conditions can accelerate
piston-ring-liner (PRL) wear, impair combustion 5
efficiency, increase blow-by and reduce oil

AS I SEE IT
Oil Change Interval Effect

5,000 Extended oil drains are an ever-growing
OIL CONSUMPTION:MILES PER QUART
4,500 trend. While there are clear advantages (lower
Engine C Long-haul oil change costs, higher productivity, environ-
4,000
Class 8 Truck mental benefits, etc.), there are also engine
3,500
life risks, fuel economy risks and oil economy
3,000
penalties. A recent study on the effects of the
2,500 Engine B
oil change interval on miles per quart of oil is
2,000 shown in Figure 3. Three different engines
1,500 (Class 8, long-haul service) at different oil
change intervals show a clear relationship
1,000
Engine A between oil health and oil consumption. One
500
can conclude that as oil ages, the effects of
0 aging (high soot, loss of dispersancy, additive
1 5 9 13 17 21 25 29 33 37 41 45 49
depletion, insolubles, viscosity-index shear,
THOUSANDS OF MILES SINCE OIL CHANGE
dirt load, etc.) impair the ability of the engine
to retain the oil during service.
Figure 3. Effects of the oil change interval on miles per quart of oil (Ref. Carver, Exxon)
Oil Consumption Issues

oil’s molecular weight distribution. loss through misting and evaporation.
Of course, temperature plays a key role. A
Revealed by Oil Analysis
It is worth noting that too little viscosity
low liner temperature translates to a low Monitoring oil levels and makeup rates
induces a plethora of dangers as well. The
evaporation rate. Liner temperature is influ- offers a reliable indication of oil consump-
optimum reference viscosity (not too low or tion and relative oil economy. If oil
enced by load, combustion efficiency and high) is always desired. This “optimum” is
cooling. Approximately 74 percent of vapor- consumption is low, it can be assumed
pushed and pulled by numerous engine that while many things could be going
ization occurs during intake and compression
design and operation factors, including the wrong, they are not going wrong simply
strokes (no speed effects have been found).
desire to mitigate oil consumption. because engine oil consumption is within a
Blow-by from Ovaloid Cylinder Bores
Ovaloid cylinder bores are usually
caused by machining issues as well as How Oil Consumption Influences
thermal and pressure distortions. Piston
Tailpipe Emissions and Health
rings can conform to out-of-roundness
As engines age and wear, they become greater consumers of crankcase oil. Solid contam-
cylinders to a certain extent. Still, reverse inants combined with soot and other oil suspensions influence engine wear, deposits and
blow-by gases and oil mist can follow the oil economy (oil consumption rate). When oil is consumed, it enters the combustion
pathway across these cylinder bore distor- chamber, burns with the fuel and is pushed out with exhaust gases as particles and
volatile hydrocarbons.
tions by moving more easily against the
ring’s running face. Oil mist is carried with Fresh new lubricants have more volatile light-end molecules and are more prone to
hydrocarbon emissions. As the oil ages, the hydrocarbon emission levels off but can pick
reverse blow-by gases into the combustion up again if the oil becomes contaminated with fuel (fuel dilution), such as from short
chamber and outward with the exhaust. run times or long idles. However, in general, the service life of the oil has no significant
influence on carbon monoxide and nitric-oxide emissions.
High Ring Float Conditions
The level of exhaust emissions can increase considerably over time, corresponding to
Researchers have found that lower oil engine wear and deposit formation. This leads not only to greater exhaust particulates
viscosity can reduce the oil control ring’s but also to a higher percentage that are hydrocarbon, which is a byproduct of oil
“float” conditions. “Float” basically means consumption. It has been observed that lubricating oil is a significant contributor to the
particulate emissions signature as the engine ages, especially with diesel engines. The
there is too much film thickness between the obvious strategy to control/reduce hydrocarbon emissions is to decrease oil consump-
oil control ring and the cylinder wall. Conse- tion. This, in large part, is accomplished only by controlling combustion efficiency,
quently, this excessive viscosity fights the wear and deposits (especially through good lubrication and filtration practices).
ring’s ability to squeegee (downscrape) the Nitrogen oxides (NOx) consist of nitric oxide (NO) and nitrogen dioxide (NO2). These
oil sufficiently from the cylinder wall and ozone precursors also lead to smog when exposed to hydrocarbon gases and sunlight. As
a health hazard, NOx can potentially cause irritation and damage to lung tissue as well
return it to the sump. As a result, too much as paralysis. Because of regulatory requirements and environmental protection pressures
oil is left on the cylinder wall that then can to lower both particulates and NO2, increased pressure has been placed on lubricant
move toward the compression rings or formulation, engine design and filter performance.
remain adherent to the liner, increasing oil
4 | January - February 2016 | www.machinerylubrication.com

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AS I SEE IT
OIL ANALYSIS AND WAYS IT CAN WAYS HIGH OIL WAYS IT CAN OCCUR
OTHER REPORTABLE WHAT IT CAUSE HIGH OIL CONSUMPTION CAN CONCURRENT WITH HIGH
CONDITIONS COULD MEAN CONSUMPTION CAUSE IT OIL CONSUMPTION
High blow-by, water
Corrosion of piston- Low oil level prematurely High blow-by gas ingestion
Low base number/ contamination,
ring-liner (PRL), piston depletes overbase deter- due to poor compression/
high acid number distressed base oil,
ring-pack deposits gents and antioxidants combustion efficiency
high sulfur fuel
High soot load,
High blow-by (soot) due to
wrong oil, glycol in High ring float, piston Fractional evaporative
High oil viscosity poor compression/combustion
oil, hot oil, extended ring-pack deposits light-end oil loss
efficiency
oil drain, oil oxidation
Fuel dilution,
Evaporative light-end Incomplete combustion and
Low oil viscosity wrong oil, VI
oil loss, PRL wear blow-by (fuel dilution)
improver shear
High blow-by, extended High ring float from
High blow-by (soot) due to
oil drain, exhaust gas elevated viscosity, Low oil level
High soot load poor compression/combustion
recirculation (EGR), piston ring-pack concentrates soot
efficiency
long idle, etc. deposits, PRL wear
Water contamination, High blow-by (soot) due to poor
high soot load, fuel Piston ring-pack Low oil level depletes compression/combustion effi-
Low soot dispersancy
dilution, extended oil deposits dispersant prematurely ciency, incomplete combustion
drain, coolant leak and blow-by (fuel dilution)
Coolant leak, short
High blow-by and short
Water contamination intermittent opera- PRL corrosion
intermittent operation
tion, cold temperature
Extended oil drain, Low oil level raises
Sludge and oxide base oil oxidation, Piston ring-pack sump temperature and
insolubles poor dispersancy, deposits, PRL wear prematurely depletes
depleted detergency antioxidants
High blow-by, PRL PRL wear and
wear, extended oil blow-by, premature Incomplete combustion and
Fuel dilution
drain, injector issues, base oil oxidation blow-by (fuel dilution)
overfueling/lugging (piston-ring deposits)
Coolant leaks from
High ring float from
defective seals, High blow-by gas ingestion
Coolant (glycol) elevated viscosity, PRL
cavitation, corrosion, due to poor compression/
contamination corrosion, PRL wear,
damaged cooler core, combustion efficiency
piston ring-pack deposits
head gasket leak, etc.
Dirty air induction,
High oil consumption
Dirty oil (silica) defective oil filter, PRL abrasive wear High blow-by gas ingestion
carrying particles causes
and other solid dirty fuel, dirty new/ causes high oil brings in induction air dirt and
excessive PRL abrasive
contaminants backup oil, wear and consumption fuel dirt
wear and more particles
corrosion debris
normal and safe range. Therefore, it is logical to track oil levels knowledge to its fullest extent. The strategies described in this
and makeup oil consumed between scheduled oil changes. article offer several plausible ways that this can be achieved.
The table above not only details how high oil consumption About the Author
might accompany certain reportable oil analysis conditions but Jim Fitch has a wealth of “in the trenches” experience in lubrication,
also provides examples of what these conditions may mean. oil analysis, tribology and machinery failure investigations. Over the past
Understanding how engines consume oil is still a work in prog- two decades, he has presented hundreds of courses on these subjects.
Jim has published more than 200 technical articles, papers and publica-
ress and is the subject of ongoing research by many organizations.
tions. He serves as a U.S. delegate to the ISO tribology and oil analysis
It is important to slow down or arrest the problem as much as working group. Since 2002, he has been director and board member of
possible. Undoubtedly, much progress will be made in the years to the International Council for Machinery Lubrication. He is the CEO and a
come. In the meantime, it will be beneficial to use the current co-founder of Noria Corporation. Contact Jim at jfitch@noria.com.

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Lubrication Programs
FROM THE FIELD

J eremy W right | N oria C orporation
Why
EDUCATION is the Secret
toSUCCESSFUL CHANGE
M
any organizations
analyze return on
investment (ROI) for
nearly every initiative
they begin, but when
was the last time you saw an ROI calcula-
tion for education? The power of an
educated workforce can help a company on
many fronts. Whether it is a lubrication and
reliability program or a health and wellness
program, education is critical to the overall
likelihood of a program’s success.
According to a recent report from the
American Society of Training and Develop-
ment, U.S. businesses spent in excess of $175
billion on employee learning and develop-
ment. Surely these companies have a grasp
on their return for this huge investment — or but what about finding the value of more team members and monitoring business
do they? The results of simple training on a intangible training programs like lubrication performance. Even though these financial
process can be easily measured in things like and machinery reliability? There are so many benefits can be massive, when set aside,
productivity and efficiency of that process, variables to the success or failure of these there is still compelling evidence as to why
programs that it becomes difficult to an educated workforce is a major advan-
pinpoint exactly what percentage of the tage for any company.
success can be attributed to education.
While it seems most everyone under- Greater Efficiency
40
stands the importance of training, no one Training helps a company run better.
can put a number on it. In a survey Trained employees will be better equipped
of Machinery conducted by the ROI Institute, 96 percent to handle issues that arise, address
Lubrication.com
of Fortune 500 CEOs said they were customer inquiries, make a sale or use
visitors say training
of personnel is the extremely interested in learning about the computer systems. The more knowledge
most important business impact of training programs, but employees have about a given subject, the
P E R C E N T
factor for continuous only 8 percent could see this happening in more successful and efficient they can be
improvement of their their own companies. completing tasks related to that subject.
lubrication program
There are techniques to isolate the
financial benefits of training programs, Better Recruiting
including establishing control groups, Today’s young workers want more than
agreeing on performance contracts with just a paycheck. They are geared toward

FROM THE FIELD
seeking employment that allows them to

learn new skills. You are more likely to
attract and keep good employees if you can Whether it is a lubrication
offer development opportunities through a
great training program. and reliability program
Job Satisfaction or a health and wellness
Nurturing employees to develop more
rounded skill sets will help them
program, education is critical
contribute to the company. The more
to the overall likelihood of a
program’s success.
engaged and involved they are in working
for your success, the better your and their
rewards will be.
Employee Retention
Training can instill loyalty and commit- time recouping their knowledge if they genuinely want to learn more because they
ment from good workers. Personnel looking suddenly leave the company. are fascinated by the subject matter.
for the next challenge will be more likely to Frequently, they will take this knowledge
stay if you offer ways for them to learn and Obtain Buy-in and spread it among their peers. This then
grow while at your company. Don’t give Training helps garner buy-in for new becomes the catalyst for change within an
them a reason to move on by letting them initiatives. It’s human nature to resist organization and leads to easier adoption
stagnate once they’ve mastered initial tasks. change. One way to overcome this obstacle of new programs.
is with a simple training that explains the About the Author
Added Flexibility whys of the change and how the change
Jeremy Wright is the vice president of technical
You can cross-train employees to be affects them.
services for Noria Corporation. He serves as a
capable in more than one aspect of the busi-
ness. Teach them to be competent in sales, Promote Innovation senior technical consultant for Lubrication
Program Development projects and as a senior
customer service, administration and oper- Training is a central promoter of innova-
instructor for Noria’s Machinery Lubrication I
ations. This will keep them interested and tion. It’s easy to understand how knowing
help you when setting schedules or filling in and II training courses. He is a certified mainte-
more about a subject can help drive innova-
for absences. Cross-training also fosters the nance reliability professional through the
tion in strategies or products.
sense of team, as employees appreciate the Society for Maintenance and Reliability Profes-
As an educator and a technical consul-
challenges their co-workers face. sionals, and holds Machine Lubricant Analyst
tant, I often get a front-row seat in the
change-implementation process. By Level III and Machine Lubrication Technician
Knowledge Transfer educating a program’s stakeholders, you Level II certifications through the International
It is very important to share knowledge not only can gain momentum and recruit Council for Machinery Lubrication. Contact
among your staff. If only certain individuals soldiers for your cause, but you also can Jeremy at jwright@noria.com to learn how
have special skills, you will have a tough find the true champions — those who Noria can help you educate your workforce.

ML
A R E O I L L E A K S
COSTING YOU
MONEY?
By Al Smiley, GPM Hydraulic Consulting
O
il leaks are expensive. Consider
a leak that drips once per INSTALLATION AND threads from the end. When sealant is over-
applied, it ends up in the hydraulic system,
second can result in a loss of HARDWARE ERRORS which causes leakage at the O-rings and
405 gallons of oil in one year. I When using pipe to plumb a hydraulic cylinder rod seals as well as the hydraulic
am often asked to visit plants system, schedule 80 and 160 pipe should be pump and motor seals.
that have excessive amounts employed for pressure lines, while schedule 40 When it’s necessary to connect two pipes
of oil leakage in order to make pipe should be utilized in the return and drain in a high-pressure line, always utilize socket
some recommendations. I’ve also seen lines. Using schedule 40 pipe in the pressure weld flanges. Pipe unions should never be
several operations that have little or no oil line can result in leakage at the threads. used, as they are not designed to handle the
leakage. While there is no single answer as A good hydraulic sealant should be used shock and vibration in high-pressure lines.
to why a system leaks, it usually is caused to seal pipe threads. Pipe dope and Teflon The line from the pump to the valve
by a few key factors, such as poor installa- tape are not recommended simply because manifold should not be piped rigid, partic-
tion, high temperatures, shock and they are usually overapplied. Instead, apply ularly when closed center directional valves
improper maintenance. sealant to the male fitting starting two are used. Oil moves through a pressure line
normally at 20 feet per second. The fluid
speed may be higher or lower depending
on the pipe size and system pressure.
When the solenoid on a closed center valve
is de-energized, the oil flow from the pump
is rapidly dead-headed at the valve. Since
oil is relatively non-compressible, a pres-
sure spike will occur. This spike can be two
to three times the maximum operating
pressure.
HOSE LEAKS
A hose should be installed immediately
downstream of the pump and just prior to Pipe unions should never be used to connect pipes in a high-pressure line.
COVER STORY
entering the manifold. Hoses can help

absorb a pressure spike. You should never
pipe rigid into a cylinder except in the case
of a suspended or vertical load. If a velocity
fuse is mounted at the cylinder port, then a
hose can be used. The velocity fuse will
close if the hose ruptures, preventing a free-
falling load condition.
The length of the hose generally should
not exceed 3 to 4 feet. The only exception is
if the cylinder or motor is mounted on a
movable carriage. During operation, the
length of the hose can change by nearly 10
percent. Hoses that are too long end up
rubbing against another hose, beam,
catwalk or machine part. Even if the initial
system installation used the proper length,
the hose may “magically” increase in length
over several years. This usually occurs
because maintenance personnel cut the
Improper clamping is one of the main causes of oil leaks.
hose a little longer each time they replace it.
A hose that is too long will prematurely clamp is used. Beam and conduit clamps polyethylene. Clamps should be tightened
fail and cause a significant loss of oil from are not designed to prevent lines from periodically, as the bolts that connect
the reservoir. If hose rubbing cannot be moving when oil flow rapidly starts and each half can vibrate loose over a period
avoided, a sleeve or protective cover should stops in the line. Clamps made specifi- of time. To prevent the clamp base from
be installed. Many companies make sleeves cally for hydraulic pipes and tubing loosening, it should be welded (not
that can be purchased by the reel. To avoid should be used and spaced approximately bolted) to the beam.
a considerable loss of oil from the reservoir, every 5 feet. A clamp should also be Hydraulic pumps and motors often leak
ensure the level switch is set just below the installed within 6 inches of where the pipe at the shaft seals. Shaft seals in single-direc-
lowest level that the oil reaches when the or tube terminates. tion pumps are usually rated at 10 psi.
cylinders are extended. Common materials used in clamps Shaft seals in hydraulic motors that have
Another cause of leaks is improper include santoprene, polypropylene or external drain lines are generally rated from
clamping. Many times the wrong type of other types of ultra-high-molecular-weight 25 to 50 psi. The drain lines of pumps and
motors should be run directly back to the
tank and not in with the system return line.
Filters and coolers are frequently located in
return lines and will create some back pres-
sure as the oil returns to the reservoir. In
addition, high-flow surges in the return line
can cause pressures to exceed the rating of
the shaft seals.
HIGH TEMPERATURES
Most hydraulic systems are designed
to operate at 120 degrees F, with a
maximum temperature of 140 degrees F.
High oil temperatures can create a variety
of problems within a system, with one of
those being leakage. At high tempera-
tures, O-rings tend to flatten out, become
pitted and leak.
The most common cause of heat in a
hydraulic system is improper pressure
Hoses that are too long often rub against another hose or machine part resulting in leakage. settings. When a hydraulic problem

COVER STORY
common problem with relief valves is that Accumulators are excellent devices for
the spring pressures are generally set too absorbing shock in hydraulic systems.
high. The system relief is usually located Generally, bladder or diaphragm types
near the hydraulic pump and should be set are used for absorbing shock. Threaded,
200 psi above the maximum operating in-line shock suppressors that are
pressure if a fixed displacement pump is pre-charged with dry nitrogen have also
employed. If using a relief valve with a become popular within the last few years.
pressure-compensating pump, a setting of When an accumulator is used to
250 psi above the compensator setting is absorb shock, there are a few basic
appropriate. When properly set, the relief guidelines that should be followed. For
spool will open for a moment, dumping instance, you should use a small accu-
the pressurized fluid back to the tank. mulator (normally 1 gallon or smaller)
Crossport relief valves are commonly and install it as close as possible to
This relief-valve tank line should have been found on the hydraulic motor drives of where the shock occurs. Also, be sure to
at ambient temperature. Because the com- cranes, knucklebooms, and debarker and pre-charge the accumulator with dry
pensator setting was increased, the excess washer drives. These valves will open nitrogen approximately 100 psi below
pump volume dumped over the relief valve momentarily when the load starts moving the pressure required to move the
when it was not used in the system.
and then decelerate the load when stop- maximum load.
ping. When oil is initially ported to drive Remember, any time there is oil
occurs, usually every knob in the system is
turned. The first adjustment made typi-
cally is on the pump’s compensator. When
the compensator’s setting is reached and
no volume is required in the system, the
pump will de-stroke and deliver only
enough oil to maintain the compensator
setting. If this adjustment is set above the
system’s relief valve, the pump volume will
return to the tank through the relief valve
instead of being reduced to a flow rate of
almost zero gallons per minute. This
causes the temperature to rise above 140
degrees, resulting in O-ring failure as well
as pump, motor and cylinder seal leakage.
I recently consulted with a paper mill
that had heat and leakage problems on its
debarker. The unit was running at 205
degrees F. The system was leaking at the
directional valve manifold, pump shaft
seal and cylinder rod seal. When the pres-
sures in the system were set properly, the
temperature dropped to 130 degrees F
several hours later. Unfortunately, the An accumulator can be used to absorb shock in a hydraulic system.
damage to the O-rings and seals had
already been done. The mill had to replace the load, an initial pressure spike will leakage in a system, there’s a reason for it.
the pump, cylinder and valve O-rings. occur. In the case of debarker and planer The entire system should be analyzed, and
feedrolls, the spike is generated as the log the problem for the leaks identified. Compa-
SHOCK AND or board is fed in. The crossport relief nies waste thousands of dollars each year
because oil leaks have become accepted.
PRESSURE SPIKES should be set to open when the pressure
spike rises approximately 400 psi above Maintenance personnel must be trained on
As mentioned previously, hoses can what is required to drive the largest log or proper piping, clamping and hose installa-
absorb some of the shock that is generated board. Improperly set crossports not only tion procedures. Everyone in the plant
in a hydraulic system. The other two result in leakage at the system fittings but should also be educated on the negative
devices normally used to reduce shock are can also cause damage to the motor, effects that random “knob turning” can
relief valves and accumulators. The most machine and other system components. have on machine operation.
MAINTENANCE AND RELIABILITY
4Common Maintenance
Problems and How to
Resolve Them
B y Thomas L. L antz
Many maintenance departments
today “fight fires” instead of
approaching their problems
systematically. Prevention is a far better
goal than trying to solve problems as they
arise. While this strategy may be a little
costly at first, it is not nearly as expensive as
allowing problems to occur.
Maintenance problem-solving is
primarily concerned with four areas: main-
taining critical systems, fixing the problem
quickly and faster than the last time, deter-
mining what is causing the breakdown to
happen so frequently, and identifying the
20 percent of breakdowns that are
consuming 80 percent of your resources.
This article will focus on the four
common types of maintenance problems
with the ultimate goal of helping you to good planning, then the situation goals or only general ones will magnify those
prevent or at least minimize each type. confronting you should be termed a “diffi- problems. Often a disturbance (problem)
culty” rather than a problem. Of course, if will force you to ask, “What (unrecognized)
Problems vs. Difficulties you are experiencing many of these difficul- goal do I have that is being thwarted by this
A problem is a situation that can be char- ties, there may be a common root cause that situation?” Asking this question may cause
acterized by a gap between your existing could define a problem. you to reassess the goal.
circumstances and where you do or do not
want to be. The gap cannot be eliminated or Where Problems Originate 4 Types of Maintenance
maintained through obvious methods. Some Problems are caused by your goals or a Problems
analysis and creativity are required to define lack of them. You may have an overall goal of
The four common types of maintenance
a situation as a “problem.” Visualizing a wanting your plant to run efficiently with
problems can be categorized as identifica-
problem as a gap can be a useful technique. few interruptions, but unless you translate
tion, cause/effect, means and ends. Let’s
Usually you want to overcome the gap, but that general goal into viable subgoals, you
discuss each of these in turn.
sometimes you wish to maintain it. An will experience problems. Establishing
example would be painting an object to specific subgoals is essential if you wish to Identification
prevent deterioration. control the magnitude and number of the When you don’t understand a natural
If you can see a solution and all it takes is inevitable problems. Otherwise, having no phenomenon, a question or a method of

Kepner-Tregoe Method
of Problem-solving
1. Compare “what should be” with “what
actually is.”
2. The deviation is the problem.
3. Identify the problem in terms of what,
where (the “is”), when and extent.
4. Identify what lies outside the problem in
terms of what, where (the “is not”), when
and extent.
5. Compare the “is” with the “is not” to
identify changes and distinctions.
6. Find the most likely cause. The most likely
cause of a deviation is one that exactly
explains all the facts in the problem. If one
fact can’t be explained, omit that cause.
7. Look for something that has changed from
normal operation.
doing things, your natural inclination is one of spending most of our time on and how achieve a goal. The problem of selecting a
curiosity. Industrial maintenance is the same could we minimize it?” goal or end has already been solved, so you
way. You must identify (understand) every- are now focusing on how to achieve it.
Cause and Effect
thing in your department or plant or have Typical questions that characterize
To properly solve cause-and-effect means problems include how to reduce
someone on staff who does. When a problem
problems, you must first learn how to excessive lubricant failures, how to decrease
occurs, you need to identify where and when
distinguish between cause and effect. lubricant costs while maintaining good
it happened as well as where and when it did
Effects are things you perceive with your quality, how to lessen machine downtime,
not. More importantly, you need to identify
senses or detect through condition moni- how to improve safety and how to change
why you do things a certain way while always
toring techniques. They accompany or the department mindset to prevention
on the hunt for a better approach.
precede a machine failure. mode. Solving a means problem often
In school, you are taught the canned
Typical effects are excessive heat, vibra- involves finding an expert, but you should
approach to solving problems. While this
tion and noise. A failed bearing or gear is never assume the current method is the final
is important, it only covers problems that
also an effect. Simply changing the compo- answer. Improvement is always possible.
are recognized. What about the real-world
nent is concentrating on the effect. While
situations? Industrial maintenance often
this often must be done to restore opera-
Ends
presents situations that are so confusing Problems of ends or goals can be char-
tion, forgetting about the reason for the
that problems are camouflaged. Sorting acterized by the question, “What goal
failure is neglecting the cause. For instance,
out the mess means finding the basic should I pursue?” As mentioned previously,
excessive heat in a hydraulic system is an
problem that spawns all the other effects. your goals may be very general at first but
effect and a predictor of problems.
This is not easy, as you may solve the must be translated into detailed subgoals
Concentrating on cooling the system
wrong problem or try to alleviate symp- to truly matter. Common questions to ask
rather than discovering the cause of the
toms caused by the basic problem. For might include which metrics should be used
excessive heat is an invitation to problems
example, you may put coolers on hot to gauge progress, which 20 percent of the
but an all too common solution. Attack
hydraulic systems instead of locating the problems are generating 80 percent of the
the symptom, but don’t forget to unearth
valve or cylinder that is allowing fluid to efforts, what are the critical parts of
the root cause. Remember, symptom is a
flow back to the tank. systems that must be constantly monitored,
synonym for effect.
Identification problems become relevant and how are problems categorized (critical,
not only when trying to understand a situa- Means important and projects for correction).
tion but also when confusion reigns and the Means problems are generally character-
problem is hidden by a mass of effects. The ized by questions beginning with “how” Levels of Problem-solving
former should be attacked by curiosity and such as “How can I accomplish that?” or In addition to recognizing the four
the latter by analysis. These types of prob- “How can I improve that?” They leave the problem types, you must also be aware that
lems can also appear when a manager choice of means open-ended. With a means problem-solving can be divided into four
finally asks the question, “What are we problem, you are trying to decide how to levels of sophistication:
SYSTEM PROCESS
Strainer alarms OK? Extra water on mill Possible Known

causes effects
Hole in return line? Change in product mix
System extra dirty? Change in nozzle position
Too much pressure Bearing seal water deflec.
Bad mercoids Bearing seals bad

Extra man-hours
Bad relief setting Loose spreader bars to handle alarms
Regulator malfunction Loose seats on sleds System alarms
Too wide pres. fluct.

Regulator malfunction Extra material
cost
Bad mercoids Too many
ripped “F” Lost mill time
system
Poor-quality wire cloth Change in cleaning strainer
baskets
procedure at hot mill
Extra repair
Wire cloth strength limits Change in personnel shop work
80" hot mill

Poor supplier workmanship Extra oil cellar
Repair shop work
Change in procedure
at repair shop Shortened
How many is bearing life
MATERIAL WORKMANSHIP “too many?”
An example of an Ishikawa diagram of lube oil system strainer basket failures
• • reaction or acting on the problem when it occurs and then there are different levels of objectives. These objectives are the
forgetting about it until the next time; ones you set for yourself or your department. The farther down
• adaptation
• or learning to live with the problem by you move on the following list, the smaller the resultant prob-
adjusting to the symptoms; lems should be.
• • anticipation, which includes attacking root causes with Short-term Routine Objectives (Supervision)
preventive techniques; and Routine objectives include maintaining things as they are,
• • a proactive approach, which involves changing the condi- handling normal (expected) problems, reacting quickly,
tions that spawned the problem in the first place. having lots of spares and adapting to the problem (learning
to live with it).
These four levels merely describe approaches that can be
used on maintenance problems. One is not better than the Medium-term Corrective Objectives (Management)
others but must be selected based on the severity of the Corrective objectives usually involve the elimination of
problem. Of course, if a maintenance department always accepted problems or modifying a design to solve an
focuses on reaction, it might consider moving to a higher level inherent problem.
for recurring problems.
Long-term Improvement Objectives (Leadership)
Categories of Objectives Improvement objectives might consist of requesting new
Your objectives will determine the problems you experience. Just equipment, changing the way things are done, concentrating
as there are different levels of sophistication in problem-solving, on prevention and providing better training.
ML
Most problems have an immediate By contrast, the Kepner-Tregoe method A New Mindset
phase (or crisis) and must be addressed relies on describing what the problem is, what it
now. However, managers who want to Prevention requires maintenance manage-
is not, where it occurs and where it does not. In
move to the leadership objectives will try ment to develop a new mindset and make a
effect, you are building a fence around the
to prevent or minimize a recurrence. problem to keep important information inside conscious decision to move away from fighting
While supervisors and management are (and under review) while keeping out extraneous fires. By understanding the four basic types of
concerned with doing things right, leader- information. Your main thrust is to identify what problems, the different levels of prob-
ship concerns itself with doing the right has changed. The true cause will account for all lem-solving and the three categories of
things. Remember, setting objectives effects. If one effect could not be caused by the objectives, you will be better prepared to
determines the problems you will Syngear Gear Oils_Layout 1 1/13/2016 1:26achievePM Pagethis 1new mindset.
selected cause, that cause must be discarded.
encounter. Setting the right objectives will
minimize those problems. In the typical
plant, supervisors and management
trump leadership.
Preventing Maintenance
Problems
SynGear
Your prevention efforts must be compre- Synthetic
hensive and cover all areas from which
Gear
problems may arise, such as personnel, main-
tenance practices, hardware and systems.
These categories are most useful when solving
Oils
cause/effect problems. However, they may
also be used to keep a manager focused on all
aspects of maintenance.
Cause-and-Effect Methods
Two important techniques for estab-
lishing a problem’s true cause are the
Ishikawa diagram and the Kepner-Tregoe Free Technical
method. These techniques are especially
Support & Used
useful with cause/effect problems that
defy solution. Oil Analysis
The Ishikawa diagram helps you focus
on the different aspects of a problem so Summit Syngear Series and Syngear FG Series synthetic lubricants provide
the listed causes will not be concentrated for a wide range of gear and bearing applications. These lubricants have
in one or two areas. For instance, most excellent oxidation and thermal stability, which signiﬁcantly reduces thermal
problems can be broken down into four degradation and deposit formation when compared to conventional lubricants.
areas: personnel, maintenance practices,
Synthetic lubricants offer extended drain intervals while providing increased
hardware and systems. Some problems
may be divisible into more than four, but wear protection, longer life, less downtime, and higher productivity.
with some imagination, most should
yield at least these four. These categories Summit Syngear FG Series gear oils are NSF H1 registered, ISO 21469
force you to look at a situation from certified, Kosher, Halal and CFIA approved. They are available in a variety of
multiple perspectives to generate viscosity grades. Call Summit today for more information .
possible causes.
Some refer to these diagrams as fish-
bone diagrams or cause-and-effect (C-E)
diagrams. They encourage you to list as
many causes as possible. To do this, you
Summit
must withhold judgment until the listing
is complete to assure no one jumps
800.749.5823
www.klsummit.com
to conclusions.
OIL ANALYSIS
Surprising Findings from

Oil Analysis of
Automotive
Engines
B y David E. Newton, Carrier Corporation /UTC
Used oil analysis is a tool, and like
most tools, it can be properly
used or misused, depending on
the application, user, surrounding conditions,
etc. A number of articles and publications
explain how to interpret the information in an
oil analysis report, but most fail to address
one very important issue: statistical normalcy.
What is “normal” in a data set represents the
typical average values and expected variation
within that group. It’s a matter of how to view
a series of used oil analyses and how the
results can shape your view of a healthy or
ailing piece of equipment as well as the
viability of continued lube service.
Most people have heard of the Six Sigma
approach using statistics and other similar
concepts. These are applicable to the world
of lubricants as much as any other topic.
Statistical analysis can be applied in both
small and large viewpoint formats. Typically,
these are referred to as micro-analysis and
macro-analysis. Micro-analysis looks at one
specific entity and lets data develop as inputs
affect it. An example of this would be
performing a series of used oil analysis tests
on one engine with reasonably consistent
usage patterns. All inputs (lubricant, fuel,
filtration, sample cycle, etc.) are held constant
or with minimal change so the natural devel-
opment of information can be seen. This is
done to establish ranges and to allow for any
trends to develop. Over time, this method-
ology can be used to decide which product
or process excels over another for a
specific application.
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OIL ANALYSIS
It is important to note that even when

OIL VEHICLE
experiencing extremely consistent condi- ALUMINUM CHROMIUM IRON COPPER LEAD
MILES MILES
tional and resource inputs, there is
5,002 49,997 3 1 14 4 3
variation, even when the process is in
control. You need a considerable amount of 5,028 104,993 3 1 11 3 3
data from this single source to define what 5,065 154,941 2 3 14 5 6
is average and normal. This takes time, 5,019 204,983 5 1 13 3 4
money and patience. 5,019 254,836 2 3 12 2 4
Macro-analysis does not look at just one 4,960 284,815 3 2 13 6 4
entity but all those in a desired grouping. It
predicts the behavior (results) of the mass
population’s reaction to changing condi- OIL VEHICLE
ALUMINUM CHROMIUM IRON COPPER LEAD
tions (multiple inputs). With this method, MILES MILES
you can look at a large group of data that 4,996 N/A Average 3.7 1.4 14.4 4.2 4.0
represents a piece of equipment (engine, Standard
52 N/A 1.3 0.6 2.1 1.7 1.5
gearbox, differential, transmission, etc.) Deviation
from different points of origin and deter- Upper
5,151 N/A 7.6 3.2 20.7 9.3 8.6
mine what is “normal” across a broad base Limit
of applications. Macro-analysis comes 5,102 284,815 Max. 6.0 3.0 18.0 8.0 8.0
much quicker because multiple sources are PPM per
accepted. However, caution must be used 1,000 0.7 0.3 2.9 0.8 0.8
to ensure that illogical conclusions are not Miles
drawn based upon false presumptions or in Table 1. An example of micro-analysis for a V-6 gasoline engine
confusing correlation with causation.
products presented no additional risk of Notice how the average lead count
Micro-analysis of Data accelerated wear. It cannot be concluded dropped more than 57 percent, and the
that this result would be true in all potential standard deviation decreased by nearly a
from a Single Engine circumstances, only that it is true when factor of 10. Only three samples of 548
Table 1 is a good example of micro-anal- applied to a 5,000-mile oil change interval were responsible for such an overt act of
ysis for a V-6 gasoline engine. Oil changes with the given operating conditions. Signifi- skewing the data. This is where math and
were performed religiously, the inputs cantly longer oil change intervals likely may common sense come together to form a
were consistent and the owner was dedi- have shown a statistical difference between reasonable conclusion that some interven-
cated to the testing parameter protocol. the two lube/filter choices, but that was not tion of the data is warranted. By removing
The vehicle saw very typical use in its life part of the test protocol. only 0.5 percent of the lead data popula-
cycle and environment, including weather, tion, the range shifted significantly. This
driving cycles, etc. Macro-analysis of Data indicates that those three samples were
In this example, the data created was not “normal,” and the remaining 99.5
consistent and could be used to make a from Numerous Engines percent were.
sound decision for the stated operating The following examples of macro-anal- In macro-data, when the standard devi-
conditions. No abnormalities were revealed. ysis illustrate how mass-market data can be ation is some multiple larger than the mean,
The standard deviations were all well below used. The first set of data is from a there is cause to believe abnormalities are
the means, which was as expected and V-8 gasoline engine. imbedded in the data stream. When the
desired in a controlled micro-data set. In Table 2, note the two columns for lead deviation is smaller, it indicates the mass-
The vehicle went from a steady diet of a (Pb). One is the raw data, while the other is the market population is representing the
synthetic oil with a premium filter to a same data stream with three data points variability of inputs as desired and not
quality conventional oil with an off-the- removed because they were affecting the being affected by spoilers. Unfortunately,
shelf filter. The data shows that the average “normalcy” of the data. Most of the lead counts there is no hard and fast rule. Training,
wear metals shifted less than a point after in all the other samples were well below 35 parts experience and knowledge of the subject
this change. All shifts were well within one per million (ppm), but three samples had lead matter will help define and delineate when
standard deviation for each distinct metal. counts of 68 ppm, 204 ppm and 602 ppm. and where to intervene.
What can be surmised from these results When the individual results were reviewed, there In examining the results through the
is that there was no tangible benefit to was no reasonable explanation as to why the years, there clearly were not any significant
using the high-end products for this main- lead was so high in these three reports. In Table changes over time. For example, the
tenance plan and operational pattern. 3, you can see how greatly those three data average iron wear rate was reasonably
Conversely, the typical quality baseline points were skewing the results. consistent and varied by less than 1 part

OIL ANALYSIS
4.6L ENGINE OIL MILES VEHICLE MILES AL CR FE CU PB PB'

5,516 94,078 Average 3.3 0.9 14.6 4.8 2.8 1.2
5,159 62,211 Std. Dev. 2.4 0.6 9.7 4.7 27.4 2.8
5 years and
20,992 280,710 Upper Limit 10.4 2.7 43.6 19.0 85.0 9.7
548 samples
85,372 487,625 Max. 42.0 4.0 88.0 46.0 602.0 34.0
Per 1,000
0.6 0.2 2.6 0.9 0.5 0.2
Miles
4,492 79,906 Average 2.7 0.6 10.2 4.9 0.4 0.4
2,602 62,244 Std. Dev. 1.0 0.6 5.9 5.6 0.7 0.7
2007: 38
12,297 266,637 Upper Limit 5.6 2.5 27.9 21.7 2.4 2.4
samples
12,926 300,362 Max. 5.0 2.0 27.0 27.0 3.0 3.0
Per 1,000
0.6 0.1 2.3 1.1 0.1 0.1
Miles
4,687 89,521 Average 2.9 0.8 14.0 4.3 9.5 1.5
2,980 62,861 Std. Dev. 1.1 0.6 10.3 4.9 63.3 4.3
2008: 100
13,626 278,103 Upper Limit 6.1 2.5 44.8 19.0 199.5 14.3
samples
20,000 452,602 Max. 6.0 4.0 68.0 40.0 602.0 28.0
Per 1,000
0.6 0.2 3.0 0.9 2.0 0.3
Miles
4,931 87,685 Average 2.8 0.7 12.7 4.1 1.3 1.3
3,893 64,726 Std. Dev. 1.3 0.6 8.5 3.6 2.4 2.4
2009: 94
16,610 281,861 Upper Limit 6.7 2.4 38.2 14.8 8.6 8.6
samples
22,541 487,625 Max. 9.0 2.0 65.0 21.0 17.0 17.0
Per 1,000
0.6 0.1 2.6 0.8 0.3 0.3
Miles
5,320 96,641 Average 3.4 0.9 14.6 5.4 1.1 1.1
3,078 61,329 Std. Dev. 3.8 0.7 8.8 6.0 1.6 1.6
2010: 123
14,555 280,628 Upper Limit 14.7 3.0 41.0 23.3 5.8 5.8
samples
18,186 280,817 Max. 42.0 4.0 49.0 46.0 9.0 9.0
Per 1,000
0.6 0.2 2.7 1.0 0.2 0.2
Miles
5,720 96,805 Average 3.9 0.9 15.9 5.0 1.5 1.5
3,409 57,271 Std. Dev. 2.4 0.6 10.4 3.7 3.4 3.4
2011: 125
15,948 268,620 Upper Limit 11.2 2.6 47.1 16.1 11.9 11.9
samples
16,400 359,000 Max. 23.0 3.0 88.0 31.0 34.0 34.0
Per 1,000
0.7 0.2 2.8 0.9 0.3 0.3
Miles
8,157 109,594 Average 3.7 1.0 18.1 5.1 1.6 0.6
11,520 66,474 Std. Dev. 1.8 0.7 10.6 4.5 8.3 1.4
2012: 68
42,718 309,017 Upper Limit 9.1 3.1 50.0 18.7 26.5 4.7
samples
85,372 351,645 Max. 12.0 4.0 57.0 31.0 68.0 9.0
Per 1,000
0.5 0.1 2.2 0.6 0.2 0.1
Miles
Removed 204.0
three 602.0
samples 68.0
Table 2. A macro-analysis example from a V-8 gasoline engine

ML
AVERAGE STANDARD OIL VEHICLE CU

LEAD DEVIATION AL CR FE CU PB
MILES MILES PRIME
Full Data 7,261.2 100,398.8 Average 2.7 0.3 16.3 16.0 3.4 2.1
2.8 27.4
Set 4,006.1 76,147.9 Std. Dev. 1.2 0.5 10.5 53.0 4.3 2.5
Revised
1.2 2.8 Upper
Data Set 19,279.6 328,842.6 6.4 1.8 47.9 175.1 16.2 9.6
Limit
Table 3. An example of how a few data 28,417 843,817 Max. 8 1 75 484 34 29
points can skew the results PPM Per
1,000 0.4 0.0 2.2 2.2 0.5 0.3
per million over five years of data. However, Miles
if you look at the iron wear in detail, a
great storyline develops. When the oil was Table 4. A macro-analysis example from a V-8 diesel engine
run longer, the iron went up and very
predictably. In 2007, the average oil sample those who leave it in for longer periods are
not hurting the engine. MILES 3,500 7,500 11,500
was taken at 4,500 miles, and the iron
The oil analysis results from this Iron
average was 10.2 ppm. Five years later, the PPM Per
average oil sample was taken at 8,100 example showed that engine wear was 3.0 2.3 2.0
1,000
miles, and the iron average was at 18.1 generally unaffected by operational condi- Miles
ppm. An 80-percent increase in mileage tions and oil change intervals. It was also
was mirrored in a resultant 80-percent concluded that the filtration selection, oil
Table 5. An example of using three sub-
increase in iron. That is a very predictable brand and grade, as well as various service
groups to determine how the oil’s life
response curve; the wear is consistent. factors did not have much of an influence cycle affected wear rates
When oil is changed frequently, a higher on the results. For this engine, it didn’t
iron wear metal count will be seen in the oil make much difference what oil was used
deemed “normal.” While 41 samples may
analysis results. There are two reasonable or how it was driven.
seem like a large amount of data to remove,
explanations for this phenomenon — The next set of data in Table 4 is from a
they represent only 7.7 percent of the total
residual oil and tribo-chemical interaction. V-8 diesel engine. These oil analysis
samples represent fairly high-mileage vehi- population, and yet their removal resulted
Studies have shown that elevated wear
cles, with 179 of the 527 samples from in nearly a 79-percent drop in the “average”
levels after an oil change can be directly
vehicles with more than 100,000 miles and copper magnitude (from 16 to 3.4 ppm).
linked to chemical reactions of fresh addi-
many others from vehicles with more than To determine how the oil’s life cycle
tive packages. In addition, when you change
oil, no matter how much you drip into the 250,000 miles. affected wear rates, three sub-groups were
catch basin, there is always a moderate Once again, there is a need to manipu- examined: 3,500 miles, 7,500 miles and
amount left in the engine. It is estimated late the data to remove abnormalities. 11,500 miles. Again, higher iron wear rates
that up to 20 percent of the old oil remains, Forty-one samples had ultra-high copper were revealed toward the front of the oil
depending on the piece of equipment. So (Cu) counts, with many readings more than change interval (see Table 5).
when you begin your new oil change 100 ppm and some more than 300 ppm. In no way does this mean that an engine
interval, you are not starting at zero ppm. Therefore, a separate “copper prime” is being harmed, but it directly contradicts
While the wear rate is not greatly esca- column was created to root out the high the mantra that more is better (“more”
lated at the front end of the oil change flyers. Although some might decry the being more frequent oil changes and
interval, it certainly is not lessened by removal of data, you can clearly see how “better” being less wear). At some point
frequent oil changes either. Changing your these spikes can adversely affect what is the iron wear rate will begin an ascent and
oil early does not reduce wear rates,
presuming you did not allow the sump load AL CR FE CU PB
to become compromised. When you have
Truck A (synthetic
reasonably healthy oil, the wear rate slope oil and bypass 2 1 15 4 1
is generally flat. Only after the oil becomes filtration)
compromised in some manner would you Truck B (conven-
see a statistical shift in wear rates. Thus, 2 0 14 3 5
tional oil and filter)
higher wear at the front of an oil change Standard Deviation 1.2 0.5 10.5 4.3 2.5
interval is plausible, but the claim of lesser Upper Limit 6.4 1.8 47.9 16.2 9.6
wear with fresh oil is most certainly false.
Those who change oil frequently at 3,000 Table 6. Oil analysis results for two diesel-engine trucks that were driven in similar
miles are not helping their engine, and circumstances but with different engine oils and filters
www.machinerylubrication.com | January - February 2016 | 29

OIL ANALYSIS
probably become parabolic, but that is farther down the road manifest into uniquely different results. When viewed within an engine
than most people think. What is clear is that you can change your family, if engine A is compared and contrasted to engine B, and the two
oil early, but it will not reduce your wear rate. You can also put off engines used different oils but resulted in similar wear metal counts and
your oil change for a long time (at least to 12,000 miles), and it rates, you can conclude that neither oil was better than the other. When
generally will not affect your wear rate. the results are within one standard deviation, the proof is conclusive
that neither product had an advantage over the other. Essentially,
Defining What is Normal under these conditions, you cannot say that either choice is better, but
Table 6 illustrates how macro-analysis can be used to determine you can say that neither is better.
what is normal in separate cases. Two diesel-engine trucks were Keep in mind that standard deviation data can be large or small,
driven in very similar circumstances for the same length of time. depending on your definition of large and small. For a frame of refer-
Both trucks pulled heavy recreational vehicles into the mountains ence, when the standard deviation is more than 50 percent of the
for roughly 6,500 miles and experienced heat and cold patterns average magnitude, many consider this to be large. However, this does
that were comparable to each other. However, there was a signifi- not preclude it from being “normal,” as defined by happening with
cant difference: one vehicle was run on premium synthetic 15W-40 great regularity and having no adverse successive effects.
engine oil and utilized bypass filtration, while the other truck used
conventional 10W-30 engine oil with a normal filter. Below are the Conclusion
oil analysis results in regard to wear for both trucks. In conclusion, used oil analysis is a great tool, but you must
Did either truck perform better than the other? Without true understand how to properly manipulate the data and interpret the
micro-analysis, you could not make such a determination. Iron is results. You must know not only the averages but also if there are
the greatest indicator of cumulative wear, and these samples were any abnormalities embedded in those averages and how large the
right at average levels. At face value, one might claim the synthetic standard deviation is. Unfortunately, you’ll never know how many
oil did better because the lead value was lower in truck A and higher abnormalities are present, nor if they have been pre-screened for
in truck B, but they are both well within the typical variance. Ironi- you, because most oil analysis services do not perform this extra
cally, the chromium, iron and copper levels were higher in the truck filtering. You can take solace in the fact that if your results are near
using synthetic oil and bypass filtration, but again these amounts or less than “universal average,” you’re probably in good shape. You
were well within the normal variation. are, in essence, “normal.”
It can be expected that wear metal counts will bounce up and
down from one sample to the next. It is also normal for metals to
vary in mass populations and in individual units. However, when
you can see a single sample well within mass population
“normalcy,” you can deduce that it is performing no better or
worse than any other unit using any other fluid/filter combination.
The slight variation that occurred was the expected normal vari-
ation due any engine in this family. Two vastly different inputs
(lubes and filters) did not result in any significant difference under
nearly identical operating conditions at the same duration expo-
sure. So in these two examples with very similar operational
circumstances and conditional limitations, there was no tangible
benefit whatsoever to using the high-end products.
Contrasting Micro-analysis and Macro-analysis

Unlike micro-analysis, macro-analysis does not allow for any
conclusion to be drawn as to what product(s) might be better or worse
than any other in the grouping. When a sample is within one or two
standard deviations of average, thereby defining itself as normal, you
can only conclude that the events and products that led to that unique
data stream were also normal. Any variance is not due to one partic-
ular product or condition but the natural variation of macro-inputs.
Therefore, you cannot say that brand X was better than brand Y or
brand Z because typical variation is in play. Only with micro-analysis,
using long, well-detailed controlled studies, can you make specific
determinations as to what might be better or best for an application.
With macro-analysis, if two separate samples are both within the
standard deviation, the separate conditions and products did not
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PRODUCT NEWS FLUID INVENTORY CONTROL SYSTEMS
The new RFC and RFC Plus fluid inventory control systems
from Alemite are designed to accurately track dispensed
fluids for vehicle maintenance applications. The systems pro-
vide wireless communication between the keypad and dis-
pense valve with no hard wiring required. Both systems can
control portable fluid tanks and dispense in pints, quarts,
gallons or liters. The RFC manages up to eight fluids and 30
simultaneous dispensing meters, while the RFC Plus manages
up to 16 fluids and 99 simultaneous dispensing locations.
Alemite
www.alemite.com
800-822-4579
ANTI-SEIZE COMPOUND
Bel-Ray’s new anti-seize compound is specially formulated for use in a wide
range of heavy industrial applications, including steel mills, power generation,
refineries and petrochemical processing. The Nickel Anti-Seize Compound is
an aluminum-complex grease that features high contents of nickel and graph-
ite powders. It is free of any copper or soft reactive metals, making it ideal for
use on stainless-steel fasteners and fittings. With a simple brush-on applica-
tion, the nickel compound coats metal threads and components to prevent
damage caused by galling, fretting and seizing.
Bel-Ray
www.belray.com
732-938-2421
WIRE ROPE GREASE

The Earthwise EAL Wire Rope Grease (3353)
from Lubrication Engineers is specifically for-
mulated to be earth-friendly while still meeting GREASE SAMPLING KIT
the performance demands of industrial appli-
cations. The soft, semifluid grease is designed MRG Labs’ new sampling kit can be used to analyze
to coat wire rope as well as moving chain and the condition of grease-lubricated robots commonly
cable parts to ensure long life and smooth, quiet employed in the automotive and manufacturing
operation. A certi- industries. Each kit enables sampling without robot
fied environmentally disassembly or grease purging, thus allowing for
acceptable lubricant, periodic grease sampling while the robot is in service.
it is readily biode- Serving essentially as a “blood test” for robots, the
gradable with semi- kits utilize the Grease Thief sampling tools outlined in
tacky, water-resistant ASTM D7718 and analysis methods listed in the new
characteristics that ASTM D7918 standard for in-service grease testing.
enable it to adhere MRG Labs
to the application, mrgcorp.com
seal out moisture, 717-843-8884
protect against rust
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against acid attack.
Lubrication Engineers
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800-537-7683

ENVIRONMENTALLY ACCEPTABLE LUBRICANTS
The new BioMax line of environmentally acceptable lubricants (EAL) from Royal
Purple are engineered to deliver protection in the most corrosive environments.
BioMax lubricants are formulated with the Synerlec additive technology, which
creates an ionic bond that adheres to metal parts and forms a tough, slippery
synthetic film on all metal surfaces, improving lubrication and maintaining
longer-lasting results. It also displaces moisture and protects metals from rust,
corrosion and the detrimental effects of heat.
Royal Purple
www.RoyalPurpleIndustrial.com
888-382-6300
METALWORKING FLUID
The new hybrid semi-synthetic metalworking fluid from Cimcool was cre-
ated for heavy-duty machining of non-ferrous and ferrous metals, includ-
ing 6000 and 7000 series aluminum, stainless steels, titanium and other
exotic alloys. Cimperial 861 with InSol Technology can be used for grinding
and is formulated to deliver extended sump life. The metalworking fluid
is intended to increase tool life and provide lubricity while remaining low
foaming for high-pressure applications. It also has low chemical odor and
is mild to the skin.
Cimcool Fluid Technology
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IN-LINE FILTER
The new LC50 in-line filter from Schroeder Industries is a high-pressure
filter capable of handling 9 gallons per minute at 150 Saybolt univer-
sal seconds (SUS). The compact design allows for in-line installation
on hose reels and is also suitable for a wide variety of other applica-
tions with operation pressures of up to 5,000 pounds per square inch.
The high-quality, high-collapse synthetic elements come standard in a
non-bypassing housing to ensure all fluid is filtered.
Schroeder Industries
www.schroederindustries.com
724-318-1100
MOTORCYCLE OIL
Shell’s new Advance Ultra motorcycle oil is intended to provide protection and per-
formance for all modern four-stroke motorcycles, regardless of their engine size. Made
from natural gas using proprietary gas-to-liquid (GTL) technology, the premium oil
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Shell Advance Ultra is available in 10W-40 and 15W-50 viscosity grades.
Shell
www.shell.com
713-241-6161

GET to KNOW
Lebel Takes Lubrication Name
Program to Next Level

Stephane (Steph) Lebel
Age
47
Stephane Lebel became interested in machinery lubrication while studying equipment reli- Job Title
ability for his bachelor’s degree in mechanical engineering. He developed a greater interest Maintenance Supervisor
in lubrication when he was promoted to maintenance supervisor at LD Commodities in Company
Portland, Oregon. In 2013, Lebel attended his first Reliable Plant Conference and found it LD Commodities
to be an eye-opener. He decided to take advantage of the free training offered and completed
a course on machinery lubrication. This soon led to him becoming the first person at his Location
company to be certified as a Level I Machine Lubrication Technician (MLT). Portland, Oregon
Length of Service
9 years
Q: What’s a normal work day like program as well as semi-annual

for you? oil testing/analysis.
A: A normal work day can be pretty hectic,
as I get our reliability program going while Q: On what lubrication-related
projects are you currently working?
addressing immediate maintenance needs.
A: I’m currently working on installing
Thankfully, I have the help of another
sample ports on our hydraulic units. I’m
recently certified MLT Level I individual. We
also planning on using condition-based
both monitor equipment health and direct
lubrication in the near future utilizing ultra-
the four to six maintenance technicians in sound technology. We are currently
our department. metering the amount of grease we put in
each bearing based on the calculated relu-
Q: Are you planning to obtain
brication period, so that is the next step.
additional training or achieve
higher certifications? Q: What have been some of the
A: I would like to take more training in oil biggest project successes in which
analysis so I can better understand the you’ve played a part?
reports. I could then take the test to become A: I would like to think that I took our lubri-
certified as a Level I Machine Lubricant cation program to the next level. We used to
Analyst (MLA). grease the bearings on an inconsistent
schedule with undetermined amounts of
Q: What is the amount and range grease. Nobody except for me and the main-
of equipment that you help tenance supervisor knew which oil went into
service through lubrication/oil which equipment. By using color-coded fill
analysis tasks? ports, fittings and tags, even the newest
A: I work in a grain terminal where every employees now know which oil to use when-
piece of equipment has at least two bear- ever they check the equipment. We also have
ings. We have belt conveyors, bucket many shaft-mounted gearboxes that used to
elevators, grain cleaners, fans and blowers be overfilled due to a lack of training. We
that all have bearings, motors and/or gear- installed bull’s-eye sight glasses on every
boxes. We have a quarterly lubrication gearbox so oil levels can be monitored.
Q: How does your company view machinery lubrication?
machinery lubrication in terms A: We just nominated a reliability engi-
of importance and overall neer for our North American facilities a
business strategy? few months ago. The company is pushing
A: I was the first to take the training and for more reliable plants, and I believe
become certified as a Level I MLT. My that proper machinery lubrication offers
colleague became certified about a month the most bang for your buck in the quest
ago, and the company just invited all other for reliability.
maintenance personnel to train in
machinery lubrication and take the Level I
MLT certification test. Be Featured in the Next
Q: What do you see as some of the
‘Get to Know’ Section
more important trends taking place in WOULD YOU LIKE TO BE
the lubrication and oil analysis field? FEATURED IN THE NEXT
A: I see consolidation. No plant should “GET TO KNOW” section or
have to carry the same grade or type of oil know someone who should be
from two different manufacturers. I also profiled in an upcoming issue of
see a push to use biodegradable oils instead Machinery Lubrication magazine?
Nominate yourself or fellow lubri-
of the conventional oils.
cation professionals by emailing a
photo and contact information to
Q: What has made your company editor@noria.com.
decide to put more emphasis on
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sis - FFT Vibration plus shock pulse, Caddy Pro has the ability to measure, containers, test tubes, needle valves,
IR temperature, laser tachometer, data log and trend the amount of lubri- cap and probe samplers, tubing,
electronic stethoscope, voice record- cant used in order to optimize lubrica- vacuum pumps, custom packaging,
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software. Leonova Diamond and and boxes.
UE Systems, Inc.
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End greasing frustration with the LE’s Full Torque Diesel Fuel
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Let Noria help you solve tough lubrication
problems and discover the root cause of
equipment and lubrication failures. noria.com
For more information, contact Dymian Kritikos at 800-597-5460, ext. 241 or email dkritikos@noria.com
THE “LUBE-TIPS” SECTION OF MACHINERY LUBRICATION
MAGAZINE FEATURES INNOVATIVE ideas submitted by our readers.
Additional tips can be found in our Lube-Tips email newsletter. If you have a
tip to share, email it to editor@noria.com. To receive the Lube-Tips newsletter,
subscribe now at www.MachineryLubrication.com/page/subscriptions.
Oil Sampling Tips How to Estimate Reservoir Capacity

for Critical Equipment To estimate the capacity in a rectangular oil reservoir, measure
For critical gearboxes, consider the length, width and height (from the tank bottom to the oil level)
taking a reference sample of in inches. Multiply these dimensions together to get the cubic inches
clean oil when performing of oil. Divide this number by 231 for gallons. Now label the tank with
an oil change and mark it the capacity so you won’t have to do this calculation again.
with the equipment iden-
tification, lubricant Why You Should Inspect Rebuilt Electric Motors
information and the date
of the oil change. After the
gearbox has been drained,
flushed (if necessary) and
charged with lubricant, run
the unit for a period of time to
allow for thorough mixing of the
lubricant. Then a reference
sample of the actual gearbox oil can
be taken and marked with the same information.
When the next oil change occurs, the sample of the old lubri-
cant, the clean reference sample and the mixed reference sample
can be sent to the laboratory together. This gives the analyst a
basis for comparison of the clean oil, the actual initial charge and
the final sample, eliminating erroneous trends caused by partial When receiving electric motors that have been rebuilt, inspect the
or incomplete flushing or change-out. It costs a little more, but grease tube to the bearings to ensure that contamination is not present
for critical equipment, it is worth the expense to track gearbox (metal shavings, dirt, etc.) and to verify that the grease path to the
conditions and prevent unscheduled outages. bearings is full of grease. If the grease path is empty, it could take two
to three years before any grease reaches the bearing, since regreasing
Writing Better Lubrication Procedures amounts are typically very small (0.3 to 0.7 ounces per year).
When writing preventive maintenance (PM) procedures that
require multiple grease guns to be taken up ladders and stairs, add Stop Turbine Oil from Cooking in Outages
a stop point in the PM that states, for example, “Before ascending If you have an outage in a turbine and your lube oil pumps are
these stairs, make sure you have guns A, C and D.” This prevents locked out, be sure to turn off the tank heaters. Most heaters and
technicians from having to carry too much equipment up flights of resistance thermometers are located in two different places that
stairs or ladders, which is a safety benefit. It also keeps them from heat and read flowing oil. This can result in overcooking the oil in
reaching the top of the stairs with the incorrect guns and mixing the non-flowing/heated area.
grease in the equipment, which can lead to premature failures.
How Filter Changes Can Disrupt Particle Counts
Bearing Installation Advice for Optimal Lubrication Have you ever seen a sudden spike in the particle count for a
Spherical roller bearings with a lubrication groove and three stable circulating oil system where no oil has been added or lost?
lubrication holes in the outer ring should be oriented correctly Check to see if the oil filter was changed just prior to the oil sample
when mounting inside the machine. This helps to ensure that date. It is not uncommon to see a spike in the particle count after
there is an adequate amount of lubricant in the outer ring raceway changing oil filters due to the “disturbance” to the system. There-
of the bearing. Make sure the lubrication hole is not located at the fore, don’t be too zealous in changing filter elements purely on a
6 o’clock position. Otherwise, the lubricant will drain out from calendar basis. Take full advantage of the operating life of your
the bearing and reduce the lubricant level inside. This tip is very elements and only change them when they have reached their load
important for bearing lubrication with grease, oil spray or oil capacity or have been in the system up to their manufacturer’s
drop lubrication. recommended service life.

BOOKSTORE
WELCOME TO MACHINERY LUBRICATION’S For descriptions, complete table of contents and excerpts from
BOOKSTORE, designed to spotlight lubrication these and other lubrication-related books, and to order online,
related books. For a complete listing of books of visit: store.noria.com or call 1-800-597-5460, ext. 204
interest to lubrication professionals, check out the
Bookstore at store.noria.com.
Oil Analysis Basics – Handbook of Lubrication and Tribology

Second Edition – Volume II: Theory and Design –
Publisher: Noria Corporation Second Edition
The new second edition includes Author: Robert W. Bruce
more detailed information on oil Sponsored by the Society of
sampling, filtration and contam- Tribologists and Lubrication Engi-
inant removal, base oils and neers, this handbook incorporates
additives, water-in-oil contamina- up-to-date, peer-reviewed infor-
tion and removal, ASTM standards, mation for tackling tribological
glycol testing, flash point tests, and problems and improving lubri-
14 additional oil analysis tests. cants and tribological systems. It
demonstrates how the principles
Lubrication Fundamentals — of tribology can address cost
Second Edition savings, energy conservation and
Authors: D.M. Pirro and A.A. Wessol environmental protection.
This newly revised and expanded
reference book emphasizes the Lubrication Awareness Poster Set
need for lubrication and careful Publisher: Noria Corporation
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.
Lubrication Basics for Machinery This set of five posters effectively uses humorous illustrations
Operators Training Video and bulleted tips and pointers to communicate critical lubrica-
Format: DVD tion advice. Posters included in the set are Home Sweet Home,
Publisher: Noria Corporation Keep Our Machines Clean, Overgreasing Doesn’t Pay, Use The
Correct Oil and Watch Your Aim.
Train your team on the
basics of lubrication
Automotive Lubricants and Testing
and how to recognize
Authors: Simon C. Tung and George E. Totten
early signs of lubrica-
This book provides a compre-
tion-related problems
hensive overview of various
with this convenient
lubrication aspects of a typical
video training DVD.
powertrain system, including the
Your operators will engine, transmission, driveline
learn the basics of and other components. It also
operator-based lubri- covers lubrication fundamentals
cation inspections and and lubricant testing methods
gain the knowledge to that are influenced by lubricant
ensure that routine inspections and top-offs are performed with additive formulation and engine
precision and accuracy. hardware changes.
NOW ON MACHINERYLUBRICATION.COM
FIND MORE GREAT ARTICLES AND CONTENT FROM Machinery Lubrication magazine
online. From Web exclusives and industry news to videos, white papers, buyer’s guides and more,
everything that relates to machinery lubrication is available now on www.MachineryLubrication.com.
Are Higher-priced Possible Causes and why it is important to match the oil
and the additives to the application.
Lubricants Better? of Gearbox Overheating
The cost of Gearbox overheating can be linked to Why an Oil’s
equipment, many different root causes. To perform a Base Number Drops
machine failures proper investigation into why a gearbox
and maintenance may be experiencing overheating, an As oil is used in service, it becomes
is considerably in-depth list of data must be collected. contaminated with acids,
more than the causing the base number to
price of a lubri- drop over time. The rate of
cant. While some the drop is determined by
instances may the amount of acids intro-
call for premium duced to the system. Read
lubricants, you must first consider this article on the ML site
the various operating conditions and to understand how you can
machine factors to determine the type of track the base number of
lubricant to use. Check out this article your oil and determine how
on the ML site to see which key elements much life is remaining.
you should take into account before
looking at the price of the lubricant.
Discover which clues can help you diag-
3 Simple Ways to Improve nose an overheating problem by reading
this article on the ML site. FEATURED WHITE PAPERS
Fluid Cleanliness
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MachineryLubrication.com

TEST YOUR KNOWLEDGE
THIS MONTH, MACHINERY LUBRICATION CONTINUES
ITS “TEST YOUR KNOWLEDGE” SECTION in which we Stay Connected With Noria
focus on a group of questions from Noria’s Practice Exam for
Level I Machine Lubrication Technician and Machine Lubricant
Analyst. The answers are located at the bottom of this page. The
complete 126-question practice test with expanded answers is
available at store.noria.com.
1. The Pareto Principle (80/20 Rule) states:

A) The largest beneficial effect is obtained from a critical few maintenance tasks
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B) The largest beneficial effect is obtained from the (random) many
maintenance tasks https://twitter.com/NoriaCorp
C) All machines die sometime
D) All bearings live forever
E) 80 percent of the people do 20 percent of the work
2. Polyalkylene glycol (PAG) synthetic oils:

A) Offer the best additive solubility
B) Are the prime choice for fire-resistant fluids
C) Are a copy of the best structure found in mineral oils
D) Are incompatible with mineral oils Like us on Facebook
E) Offer the very best high-temperature stability http://www.facebook.com/noriacorp
3. The amount of additives in a finished oil can range from:

A) 0.1 to 30 percent
B) 0 to only 10 percent
C) 10 to 50 percent
D) 1 to only 10 percent
E) 10 to 30 percent
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dispersants, anti-wear additives, etc.
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/noria-corporation
oils, which include antioxidants, anti-foam agents, corrosion inhibitors, detergents,
inhibitors. However, the percentage may reach 30 percent in the case of engine
which mainly represent antioxidants, anti-foam agents, demulsifiers and corrosion
example, steam turbine and compressor oils contain 0.5 to 5 percent additives,
The correct range is from 0.1 to 30 percent. It differs based on the application. For
3. A
than PAG. PAG oils also are incompatible with mineral oil, so the correct answer is D.
perature option. For instance, ester-based fluids have higher temperature stability
than mineral oil. It offers high-temperature stability, but it is not the best high-tem-
phate ester is the prime fire-resistant choice.) PAG has a totally different structure
with water (water-glycol), it is not the prime choice for fire-resistant fluids. (Phos-
PAG oil offers marginal additive solubility. While it is fire-resistant when combined
2. D
the effects come from 20 percent of the causes, so the correct answer is A.
In general, the Pareto Principle states that, for many events, roughly 80 percent of Continue learning with us on YouTube
http://www.youtube.com/user/noriacorp
1. A
Answers

Gear Lubrication
B ennett F itch | N oria C orporation
THE RIGHT WAYto

Lubricate WORM GEARS
O f all the different types of

gear configurations, worm
gear systems are consid-
ered some of the most problematic because
they present unique lubrication challenges
veloping), single-throated (single-enveloping)
and double-throated (double-enveloping
or globoidal).
Non-throated or non-enveloping is the
most basic design in which the worm and
due to their distinct design. To overcome worm wheel are both cylindrical in shape. This
these challenges, you must understand not allows for simplistic manufacturing, but the
only the complexities of worm gears but limited contact zone of a single point on one
also which qualities to take into account or two gear teeth can become problematic.
when choosing a worm gear lubricant. In single-throated or single-enveloping
designs, one of the gear elements (most Figure 1. Non-throated
Worm Gear Designs commonly the worm wheel) has concave (non-enveloping)
A worm gear is a non-parallel, non-inter- helical teeth for contour or envelopment of

secting axis design consisting primarily of two the gear teeth onto the worm. This enables
gear elements: the worm, which is the driving the contacting zone to increase to a line.
gear in the shape of a spiral or screw, and the Double-throated (double-enveloping)
worm gear or worm wheel, which is the driven or globoidal designs not only have concave
gear in the shape of a common spur gear. helical teeth on the worm wheel, but the
Technically, the entire worm gear system worm is also shaped like an hourglass so
should be called a worm drive or worm the two gear elements wrap around each
gearset to avoid confusion. The worm always other during motion. This results in nearly
drives the worm wheel. This design character- eight times more contact area (in the shape
istic is due to the extreme helical angle, which of a radial band) with three or more teeth Figure 2. Single-throated
is nearly 90 degrees. The worm drive resem- (single-enveloping)
in contact.
bles the design of the crossed helical gear As the contact surface area increases, the
configuration, except the gear teeth on the torque capacity, load-holding ability (shock
worm of a worm drive will circle around the load resistance) and durability are improved.
circumference of the worm at least once. Enveloping gear designs also have a lower
Since the worm may have as little as one tooth anticipated wear rate as a result of the load
that spirals radially around the helix, the distribution. Worm drive manufacturers
number of teeth on the worm is more appro- attempt to optimize this contact relation-
priately identified by the number of starts ship between the two gear elements for
or threads. improved reliability.
There are three categories of worm drive Other notable advantages of worm
designs that describe the degree to which the drives over potential gear system alterna-
gears mesh together: non-throated (non-en- tives include: Figure 3. Double-throated
(double-enveloping)
Non-throated (cylindrical) worm
Three starts (threads)
Side view
Input Throated (enveloped)

worm wheel
Worm wheel
Figure 4. Single-throated (single-enveloping) worm drive
•• A worm drive can be designed with a This is crucial in certain applications entirely sliding. This poses a significant
gear ratio of more than 200-to-1, in such as robotics. challenge because the lubricant is continu-
comparison to that of a helical gear, •• Low noise and vibration results from ally scraped aside. The sliding friction
which may be limited to 10-to-1 on a minimal moving components in worm losses result in elevated temperatures and
single reduction. The gear ratio for drives in comparison to alternative inadequate hydrodynamic pressure devel-
worm drives is the number of teeth on gear designs. opment. Consequently, wear debris
the worm wheel to the number of generation can increase. In many cases, the
threads (or starts) on the worm. higher temperatures will be the limiting
Lubrication Challenges factor on the worm drive before the loading
•• The high gear ratio and configuration
Worm drive designs have one major limitations are reached. The load distribu-
of the two gear elements allow for a
drawback: the relative motion between the tion of enveloping gear designs can lessen
compact design, making the worm
mating teeth of the two elements is almost this problem, but the challenge still persists.
drive a great option for space-limited
areas. In addition, the number of
160
moving parts is reduced along with the
opportunities for failure. However, this 150
may be partially offset by a loss in effi-
140
ciency from large increases in torque.
Sump Temperature (°C)
•• Due to the extreme helical angle, 130

polyglycol
switching the direction of power is 120
nearly impossible. The worm wheel
cannot easily be rotated independently 110
to force movement on the worm. This 100
self-locking ability eliminates the need
for a backstop, which may be required 90
in alternative gear systems. mineral oil
80
•• With the precise movement of worm
drives, particularly in double-envel- 70
300 500 1,000 5,000 10,000 30,000
oping designs, backlash (play between Oil Change Interval (hours)
gear teeth) can be greatly minimized. Figure 5. A comparison of lubricant life and oil change intervals for mineral oil,
PAOs and PAGs over a range of oil sump temperatures

PAGs do have some drawbacks, most

ADVANTAGE OF A SYNTHETIC GEAR OIL OVER notably their higher costs. They also are not
TYPES OF WORM DRIVE EFFECTS A MINERAL OIL
compatible with some seal materials, plas-
Reduction of total losses 30% or more tics and paint coatings, so always confirm
Improved efficiency 15% or more compatibility when switching to PAGs.
Reduction of operating temperature 20˚C or more
The Right Additives
Figure 6. Advantages of synthetic gear oil over mineral oil
One of the most important jobs of a
Also, because of the sliding nature of the The energy transmission efficiency of the gear oil additive is to form a protective or
worm drive, metals with a low coefficient of gear system’s input and output can be sacrificial barrier between contacting
friction are generally used. The worm wheel significantly influenced by the lubricant surfaces when the conditions exceed that of
typically contains yellow metals, while the the bulk oil’s film strength. An additive
selected. Figure 6 specifies the improved
worm is usually made of steel. This results package for a lubricant in a worm drive
efficiency when choosing a synthetic over a
in more favorable wear characteristics, must be selected with care, since the yellow
mineral oil, particularly PAGs, which have
better loading ability and less heat genera- metals often contained within worm wheels
an inherently low coefficient of friction. can be adversely affected by corrosion from
tion not found in other metal combinations.
Yellow metals like bronze that are used on PAGs are also known to reduce operating the activated sulfur within the extreme-pres-
the worm wheel can present unique lubrica- temperatures and total losses. Additional sure (EP) additive, particularly in the
tion challenges when selecting a compatible comparisons between mineral and PAG presence of heat. Nevertheless, advance-
additive package. With this metallurgical base oils are seen in Figure 7. ments in additive formation with
combination, it is also expected that the
worm wheel act sacrificially in comparison 1500 ol
glyc
to the worm due to the relative effort and oly
Torque Limit Nm
P
costs in worm drive rebuilds.
1000
Lubrication Solutions il
Mineral O
Gearing designs and materials have been 500
modernized through the years to achieve
better load-carrying capability, higher
torque conversions and improved longevity.
Sophisticated testing platforms and 50 100 150 200 250 300 350 400 450
computerized methods have provided a Viscosity @40°C
better understanding of common worm 1.6 ISO
ISO 150
drive failure modes and offered clues for 1.4 220 ISO
Power Loss P.
optimizing the solutions. Lubricants are no Oil ol 220

1.2 al yc
r ygl
exception to these enhancements for worm ne Pol
drives. Generally speaking, a high-quality 1.0 Mi
worm drive lubricant will have low friction, 0.8
high oxidation resistance, good anti-wear 0.6
protection and high viscosity index.
The Right Base Oil 40 60 80 100 120 140 160
While using lubricants formulated with Torque T, (daNm)
Temperature at Meshing Height °C
110
mineral oil is quite common within worm
100
drives, employing synthetic base oils gener-
ol
ally results in improved gear efficiency and 90 glyc
Oi l Poly
eral
lower operating temperatures. Figure 5 illus- 80 Min
trates lubricant life and oil change interval 70
expectations for polyalphaolefins (PAOs),
60
polyalkylene glycols (PAGs) and mineral oils
over a range of oil sump temperatures. This 50
is supported by the Arrhenius Rate Rule,
which states that for every increase of 10 400 600 800 1000 1200 1400
degrees C in the average oil temperature, the Torque T, (daNm)
chemical reactions double. Figure 7. Polyalkylene glycol vs. mineral oil

tion of approximately 80 degrees C before
ISO VISCOSITY GRADES
oxidation rates rapidly increase, resulting in
PITCHLINE VELOCITY OF FINAL
A Ambient temperature (°C) acidic products that can attack cupric
REDUCTION STAGE
worm wheel materials.
-40 to -10 -10 to 10 10 to 55
Less than 2.25 m/s 220 460 680 The Right Viscosity
More than 2.25 m/s 220 460 460 Aside from the ambient and operating
NOTES: Worm gear applications involving temperatures outside the limits shown above temperature, the correct viscosity will
or speeds exceeding 2,400 rpm or 10 m/s sliding velocity should be addressed by the depend on several variables of the final
manufacturer. In general, for higher speeds, a pressurized lubrication system is required worm wheel, including the pitchline velocity,
along with adjustments in the recommended viscosity grade. center distance and revolutions per minute.
This table applies to lubricants with a viscosity index of 100 or less. For lubricants with
Figures 8 and 9 provide recommendations
a viscosity index greater than 100, wider temperature ranges may apply. Consult the
lubricant supplier. for the ISO viscosity grade selection on
cylindrical and double-enveloped worm
Figure 8. ISO viscosity grade guidelines for enclosed cylindrical drives according to the American Gear
worm gear drives Manufacturers Association (AGMA) 9005-
E02 standard.
WORM ISO VISCOSITY GRADES
CENTER DIS- As these recommendations and the oil
SPEED
TANCE OF FINAL A Ambient temperature (°C) change interval chart show, temperature
OF FINAL
REDUCTION has a significant impact on effective lubri-
REDUCTION -40 to -10 -10 to 10 10 to 35 35 to 55
STAGE cation. Not only are the lubricant and
STAGE (RPM)
machine longevity negatively affected by
<300 460 680 1000 1500 higher temperatures, but worm drives in
Up to 305 mm 300-700 320 460 680 1000 particular have trouble with temperature
spikes. As a result, if higher temperatures
>700 220 320 460 680 are expected, more effective alternatives for
<300 460 680 1000 1500 base oils and additives should be selected.
More than Synthetic oils such as PAOs and PAGs
305 mm to 300-500 320 460 680 1000 perform better than mineral oils due to
610 mm
>500 220 320 460 680 their naturally higher resistance to thermal
degradation. Nevertheless, an increase of
<300 460 680 1000 1500 32 degrees C above the ambient tempera-
More than ture in single-throated worm drives (37
300-600 320 460 680 1000
610 mm degrees C for double-throated worm drives)
>600 220 320 460 680 is not considered excessive for the oper-
NOTES: Worm gear applications involving temperatures outside the limits shown above ating conditions.
or speeds exceeding 2,400 rpm or 10 m/s sliding velocity should be addressed by the
manufacturer. In general, for higher speeds, a pressurized lubrication system is required The Right Oil Level
along with adjustments in the recommended viscosity grade. As with most splash-lubricated gear
This table applies to lubricants with a viscosity index of 100 or less. For lubricants with systems, the oil level in a worm drive is essen-
a viscosity index greater than 100, wider temperature ranges may apply. Consult the tial to maintain accuracy. Depending on the
lubricant supplier.
position of the worm relative to the worm
Figure 9. ISO viscosity grade guidelines for enclosed
globoidal worm gear drives
wheel, a small drop in oil level could be the
difference between ideal lubrication and no
deactivated sulfur have helped to reduce or tallow as the compounding agent along lubrication. When monitoring the oil level in
eliminate these corrosive attacks. with rust and oxidation inhibitors and the three most common worm drive positions
Worm drives can present a unique other additives. This results in improved (Figure 10), adhere to the manufacturer’s
recommendations, which will often be in line
boundary lubrication challenge, with the lubricity, reduced friction and decreased
with the standards for depth of oil immersion.
focus more on friction reduction than on sliding wear.
When the pitchline velocity of the worm
the effects of wear. In these applications, a EP oils are still commonly used in worm elements exceeds 10 meters per second,
specific type of mineral-based lubricant drive applications where they are formu- particularly with double-enveloping worm
known as a compounded oil can be used. lated with yellow metal compatibility. drives, a force-feed lubrication system is
This lubricant is formulated with up to 10 However, both compounded oils and EP recommended to spray the entire face of
percent fatty acid (natural oil) or acidless gear oils have a working temperature limita- the worm.

Photos courtesy Agnee Transmissions
Worm-under Worm-over Vertical

POSITION (worm on the bottom) (worm on the top) (worm on the side)
Wheel immersed at approximately Wheel immersed to approximately the Half the wheel immersed to at least
OIL LEVEL one-third of its diameter center of the meshing zone worm height
Figure 10. The three most common worm drive positions (Ref: The Lubrication Engineers Manual)
The Right Visual Inspections glass is extended out from the gear housing potential consequences of failure. Fortu-
Besides monitoring the oil level, a sight so light can be passed through it, as in the nately, improving lubrication practices for
sight glass shown on the left. worm drives should not be costly and may
glass should be regarded as a window into
If possible, a bottom sediment and be as simple as confirming that the lubri-
the oil’s condition. This may include visual
water bowl should also be used. This will cant meets the minimum requirements
checks for unusual oil darkening (a sign of while performing visual inspections and
help capture any solid particles or liquids
oxidation), visible sludge, solid particles even oil analysis for effective condition
that are heavier than the oil and provide a
and moisture. These inspections can be monitoring. Just as worm drives are some of
daily visual inspection point.
performed more efficiently when the sight the most simplistic and beneficial gear
The Right Choice designs, the lubrication practices that they
The goal of any chosen lubricant should require are equally unique and essential.
be to protect the worm drive from undesir-
About the Author
able levels of friction, the dangerous effects
Bennett Fitch is a technical consultant with
of corrosion and inefficient operation.
Noria Corporation. He is a mechanical engi-
Assessing and achieving the optimum refer- neer who holds a Machine Lubricant Analyst
ence state for every style of worm drive in (MLA) Level III certification and a Machine
accordance with its operating and environ- Lubrication Technician (MLT) Level II certi-
mental conditions will come down to one fication through the International Council
thing: justifying the costs of improved lubri- for Machinery Lubrication (ICML). Contact
cation practices to minimize the risk and Bennett at bfitch@noria.com.

Lubrication Programs
PERSPECTIVE
B y A lejandro M eza | N oria C orporation
Selecting
LUBRICANTS
Based onSPECIFICATIONS
E ffective lubricant selection must strike a balance

between quality, application and affordability. In
order to achieve and maintain this balance, lubricant
specifications should be created to serve as a guideline
for what to purchase and how to use it. This article will discuss
the necessary steps for creating lubricant specifications and how
Physical and Chemical Properties
These are the intrinsic physical and chemical properties of
the lubricant. Here it is important to identify not only the
testing parameters used but also the expected test results. An
ASTM or appropriate test method should also be referenced.
Examples include ISO viscosity grades (ASTM D2422), minimum
they can lead to sustained machine reliability. viscosity index (ASTM D2270), aniline point (ASTM D611),
flash point (ASTM D92) and thickener type.
What Are Lubricant Specifications?
Performance Properties
Lubricant specifications are internal documents that
contain the technical standards, performance requirements These refer to bench and laboratory tests that the lubricant
and industry approvals for every lubricant used in the facility formula should pass at a minimum level. Examples include copper
or fleet. They may include information on product safety, corrosion protection (ASTM D130), demulsibility (ASTM D1401)
proper disposal or alternative products available on the and dropping point (ASTM D2265).
market. Among the lubricants typically found in these speci- Product Compatibility
fications are gear oils, turbine oils, hydraulic fluids, This describes the concerns or characteristics of the product’s
compressor oils, greases, solid lubricants, multi-purpose compatibility with other lubricants as well as with synthetic mate-
bearing oils, engine oils, cutting fluids, total-loss lubricants rials existing in machine lubrication systems, such as seals and
and others. gaskets. This section may have added importance when the stan-
For small facilities or fleets, creating lubricant specifica- dard refers to synthetic lubricants or special formulas, since they
tions can be a relatively simple exercise. However, the may require specific procedures when switching to other lubricants.
complexity often increases according to the facility’s equip- For example, this product is manufactured with polyalkylene glycol
ment diversity or the number of sites involved. The more (polyglycol) base stock, which is not compatible with mineral oils
complex the facilities or the higher the number of sites and other synthetics such as polyalphaolephins.
involved, the greater the value of creating specifications.
Product Approvals
Elements of Lubricant Specifications These are the lubricant approvals or endorsements required by
Depending on the needs of the plant or fleet, lubricant specifica- the specific machine(s) in which the product is intended to be used.
tions may consist of the following elements:
Scope of Application
This defines the lubricant’s general function or purpose as Lubricant specifications are
well as the material type. It also describes specific applications
within the facility. For example, the lubricant defined by this
effective guidelines for selecting
specification is an API Group II mineral gear oil containing and using the right lubricants in
extreme-pressure additives. It is intended for use in gearboxes
operating at temperatures up to 160 degrees F and which are the right applications.
lubricated by bath or circulation systems.

PERSPECTIVE
BOOKSTORE
They may come from original equipment manufacturers (OEMs) or relating to product quality. For example, the supplier should be ISO
other industry organizations, such as the American Gear Manufac- 9000-certified, or every batch of lubricant should be sent with a
turers Association (AGMA), the National Lubricating Grease certificate of analysis. The lubricant supplier approval process can
Institute (NLGI), etc. Please note that some lubricants may claim a provide more detailed information about the supplier.
certification or approval for certain technical standards or OEM
Lubricant Disposal
specifications, while others may only “comply with” the standard or
This element provides general or specific requirements for lubri-
requirement but are not necessarily approved or certified. This may
cant disposal based on the product type, formula, contaminants
be particularly significant when complying with equipment
and lubricant volumes. These requirements should be defined
warranty requirements.
according to local regulations and corporate policies.
Potential Restrictions and Hazards
Supporting Information
This section describes any undesired ingredients or product
This information supplements the specifications’ technical
properties as well as toxicological or safety aspects to be consid-
descriptions. It may include a glossary of terms, ISO viscosity
ered when buying or handling the lubricant. For example, the
grades, NLGI classifications and ASTM standards.
Creating Lubricant Specifications

The process of creating lubricant specifications should first begin
by developing or updating the database of machines, lubrication
points and lubricants in the plant or fleet. Product recommenda-
tions will come primarily from OEMs, lubricant suppliers, consulting
companies or internal experience. Other technical references may
also be consulted, such as the AGMA, ISO, NLGI and others. For
critical machines, additional validation may be needed to ensure the
selected lubricant fulfills the lubrication requirements based on the
product must not have mutagenic or carcinogenic compounds. equipment’s current operating conditions.
Once the database of lubricants and lubrication points has
Lubricant Identification System been completed, it is time to consider product consolidation. The
Every lubricant to be used in the plant should have a unique goal is to minimize the number of lubricants used in the plant
identification code to prevent mislabeling or misapplication. The while still maintaining appropriate lubrication of all machines.
classification should be independent of the brand name. In a The consolidation process should help identify products that are
proper identification system, every product will have unique visual equivalent, lubricants that have similar specifications, machines
and written codes. For example, a hydraulic oil may have a square that can utilize multi-purpose lubricants and when it is practical
lube identification tag, while a grease may have a round tag. to use a higher quality lubricant.
Quality Control at Reception At this point, a consolidated list of lubricants can be generated,
including all equipment applications for each product. The next step
This element specifies the tests to be conducted on lubricants
is to create specifications for every lubricant or lubricant family.
entering the facility in order to verify product quality. Here it is
Whenever possible, the information should be categorized by product
necessary to define laboratory or field tests as well as the accept-
family, i.e., all lubricants that have similar properties but differ only by
able results or limits. ASTM methods, test equipment, field test kits
viscosity grade. If there is a single lubricant with special properties for
and product inspections may be referenced. See the example below.
a specific application, a lubricant specification document should be
Supplier Requirements produced just for it.
53%
This section identifies the requirements for the lubricant supplier Creating these specifications
may involve several different
INCOMING LUBRICANT QUALITY TEST - HYDRAULIC OIL ISO VG 68
departments such as engi-
TEST OR PROPERTY BASE MIN. MAX. neering, maintenance and
Viscosity at Field purchasing. Lubrication know
170 200 ledge will be required as well as
20°C (cSt) viscometer
Acid number access to equipment manuals of lubrication professionals
Field test kit 1.1 1.4 and lubricant requirements. say their plant has created
(mg KOH/g of oil)
Particle counter Expert outsourcing support can lubricant specifications to
Particle count --- 19/16/13 be employed when internal aid in the lubricant selection
/ ISO 4406:99
resources are limited. process, according to a
Moisture Calcium recent poll at
--- 500 Keep in mind that the specifi-
analysis (ppm) hydride kit
cations as well as the database MachineryLubrication.com

ML
of lubricants and lubrication points must be

updated whenever there is an equipment
change or new product option. An overall
Lubricant review of the system should also be
conducted on a yearly basis. This system may
Specifications be part of an overall lubricant selection
initiative as illustrated on the left.
In conclusion, lubricant specifications are
Product Database of effective guidelines for selecting and using
Environmental Lubricants and the right lubricants in the right applications.
Health and Lubricant Lubrication These documents not only can help ensure
quality products are acquired at the best
Safety Selection Points possible price, but they can also provide
Strategy guidance to lubricant suppliers, simplify

lubricant handling and application, improve
lubricant management, and reduce costs at
different levels of your organization.
Lubricant About the Author

Lubricant
Approval Supplier Alejandro Meza is a senior technical consultant
with Noria Corporation. He has more than 20 years
Procedure Approval of experience in the lubricant industry, technical
Process services, quality assurance, training, consulting and
development in the United States, Brazil, Mexico
and the Americas region. Contact Alejandro at
ameza@noria.com to learn how Noria can help you
select the proper lubricants for your machinery.
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TRAINING AND CERTIFICATION Lubrication Programs
How to
ADDRESS the
Skilled Worker SHORTAGE
B y Caitlin Schudalla, Noria Corporation

The “skills gap” or skilled worker shortage is a hot topic of effective autonomous maintenance or a sense of empowerment
in industrial workplaces, but why and how bad is it? A in their work and will likely develop frustration and resentment.
recent Tooling U-SME study of more than 850 U.S. Productivity and financial setbacks are also significant, as
manufacturing companies revealed that 64 percent of respondents numerous breakdowns translate into frequent repair costs, addi-
reported significant setbacks due to a shortage of skilled laborers. tional labor and lost yield opportunity. Even brief stoppages or
The U.S. Bureau of Labor Statistics and the Boston Consulting slower equipment operation (due to unreliable machines) can add
Group estimate that roughly 264,000 machinists will be needed in up quickly with devastating results. Tooling U projected one manu-
the next five years. Meanwhile, research and consulting firm facturer would experience an 11-percent loss of annual earnings
Deloitte has predicted that a staggering 2 million U.S. manufac- — $4.6 million — just from not having appropriately trained
turing jobs will be vacant by 2025. personnel in the right plant positions.
The studies all seem to agree that the demand for skilled workers
is increasing and this demand is not being met for a variety of Short-term Solutions
reasons. Unfortunately, they also conclude that the resulting Employers have several options, but perhaps the most immediate
shortage will likely persist or even get worse. and impactful involve competency modeling, succession planning
and training. A 2013 study by Manpower Group indicated that 53
Far-reaching Effects percent of skilled trade workers in the United States were 45 years
Plants that are short-staffed, particularly those needing skilled old or older, and at least one-fifth of them were between 55 and 64
workers, stand to suffer serious losses that extend far beyond daily years of age. In spite of this, a troubling tendency to overlook or
challenges. On a day-to-day basis, these facilities may experience underestimate this growing problem seems to prevail. Approxi-
strain on existing staff members and increased limits in machine avail- mately 54 percent of Tooling U’s respondents reported that no
ability. Plant personnel will need to work extra hours and take on company-wide plan was in place for addressing the aging workforce
added responsibilities for which they aren’t trained. As a result, or existing gaps. Deloitte found similar results. Respondents indi-
repairs and maintenance may be performed incorrectly or not at all, cated that they had methods for developing talent within the existing
and machines may break down, prompting expensive repairs, reduced workforce, but they were informal and therefore impossible to track
productivity and investment loss. or measure for effectiveness. Only 31 percent even had a formal
According to Deloitte’s survey, 60 percent of respondents said career-development program in place.
they rely heavily on overtime to meet demand, and almost half of Managers must begin by establishing a competency model with
them reported using third-party labor contractors to compensate clear-cut expectations for employees’ knowledge, skills and abilities.
for unfilled skilled positions in the workplace. These methods may This strategy is woefully underutilized. Only 17 of Deloitte’s respon-
get the job done, but this comes at a high cost to the company’s dents reported using competency model tools. By utilizing
financial and human capital. data-driven information on where a workforce is lacking and pairing
Respected efficiency models like Six Sigma and lean manufac- this with clearly defined expectations, standards and goals,
turing emphasize the importance of autonomous maintenance, managers can gauge which areas to target in terms of training and
employee ownership and empowerment. A staff burdened by unre- career development. The end results will vary based on the work-
alistic expectations or too many responsibilities will not be capable place, but the most essential step is to implement an analytical

Skilled Technicians and
a Lubrication Program.
Noria Workforce Solutions (NWS) is the answer
to the complex problem of filling skilled reliability
positions. When you have NWS, you get Noria
lubrication technicians, a Noria lubrication program
and Noria expert support. Our lubrication technicians,
embedded full-time at your facility, work with Noria
experts to build and run a world-class lubrication
program. This includes:
• Every machine getting the right lubricant, in the
right amount at the right time.
• Documented best-practice procedures for every
lubrication task - from receiving lubricants to
environmental disposal.
• A comprehensive oil analysis program and more.
Get It All... in One Solution.
Receive a complimentary consultation by

calling 800-597-5460 x200 or learn more
at noria.com/workforce-solutions.
1328 East 43rd Court Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
approach. Informal workplace training, unreported stoppages and zation in Tooling U’s survey adopted mandatory training of 50
vague information on personnel skills and job requirements only hours each year for all employees and collaborated with local high
facilitate confusion and mask the source of recurring problems. schools and colleges to create a strong recruitment plan. As a
As part of a competency model, managers can make note of the result, the company has an employee turnover rate of only 5 percent,
age and impending retirement of senior employees and plan for compared to the industry average of between 23 and 30 percent.
them to train younger staff members before they leave. This is an The company also has a thriving intern program and has signifi-
extremely valuable and cost-effective strategy for preserving the cantly lowered workers’ compensation claims.
experienced workers’ knowledge base, particularly because these In conjunction with educational collaborations, organizations
individuals can offer insight specific to the machines and condi- must also consider branding themselves as excellent employers that
tions in their workplace. offer young people gainful opportunities and meaningful careers.
For many short-staffed plants, competency modeling and Higher education and four-year degrees have long been favored as
training may be far too demanding in the face of daily operations the most cost-effective decision for high-school students, but this is
challenges. Consulting groups like Noria exist to help companies in rapidly diminishing as tuition costs skyrocket and collegiate-level
these types of circumstances. Consultants can provide expertise jobs are not as guaranteed as they once were. Technical schools and
and effective solutions without consuming the limited time and faster gainful employment in companies that need skilled labor can
energy of overworked personnel. Once competency models have be a very attractive option for students if presented well.
been created, managers can then make informed decisions on how
and where to train their staff. Determining Your Solutions
Studies show that manufacturers who are at or near world-class It is important to note that any effective skills-gap solution
levels of continuous improvement and workforce development also requires substantial investments of time, money or both. Given the
exhibit world-class manufacturing status. For example, 72 percent costly nature of both the shortage and its prospective solutions, it
of world-class facilities met 91 to 100 percent of their production is wise to consider outsourcing certain steps to companies that
goals. Eighty-two percent had at least 80 percent machine avail- specialize in data gathering, engineering solutions, recruitment,
ability, while 85 percent generated at least a 10-percent gross profit. etc. Accurate company statistics — the first element in making an
Considering this relationship between consistent workforce devel- informed selection — are particularly crucial and can serve to posi-
opment and high performance, the growing skills shortage makes tively impact problems that extend beyond staffing.
training a necessity for any business wishing to stay competitive. Regardless of the industry or individual circumstances, any plant
will benefit from an accurate, well-conducted needs assessment. A
Long-term Solutions great first step for employers looking to address their skills gap is to
Finding a skilled workforce in an era of aging workers, scarce obtain a third-party assessment and then use the results to pinpoint
new talent and higher demand will be extremely difficult. However, exactly what they need in a new hire. Third-party consultation can
accomplishing this will be critical for growth and sustained success. also be helpful or even necessary in other phases, such as workforce
Outdated recruiting methods continue to be a major problem. development and recruitment. The more urgent or time-sensitive
Traditional recruitment assumes that qualified workers are out the problem, the more beneficial third-party outsourcing becomes.
there waiting to be discovered, but this is increasingly untrue. All possibilities aside, employers should make informed deci-
Creating a talent pipeline with local vocational or higher educa- sion-making their greatest priority. Investing time and money in an
tion institutions is an excellent long-term strategy for companies accurate understanding of their unique circumstances and needs will
anticipating a gradual, steady decline in skilled labor. One organi- guarantee selection of the best available options at every juncture.
“The information from this course could save
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CERTIFICATION NEWS
RECENT RECIPIENTS OF ICML CERTIFICATIONS
THE INTERNATIONAL COUNCIL FOR MACHINERY LUBRICATION (ICML) CONTINUES
TO PROVIDE SKILL CERTIFICATION testing for professionals in the areas of oil analysis and
machinery lubrication. The organization offers three certifications: Machine Lubricant Analyst
(MLA), Machine Lubrication Technician (MLT) and Laboratory Lubricant Analyst (LLA). ICML
congratulates the following individuals who recently achieved certified status in one of the three
certification areas.
Advanced Technology Cargill Inc. Erik Javier Silva Lara, MLT I Edward Baker, MLT I
Services Michael Cromer, MLT I George Harron, MLT I
Covestro
Herman Woods, MLT I Jonah Henry, MLT I
Carpenter Technology Dilip Venigalla, MLT I
James Holliday, MLT I Michael Wheat, MLT I
Kenneth Reisch Jr., MLA I
Matthew Tarver, MLT I CTM Salto Grande Mohammed Nabulsi, MLT I
William Gainey, MLT I
William Bench, MLT I Cristian David Barboza, MLT I Peter Peekhaus, MLT I
Cascade Pacific Pulp David Geisenblosen, MLT I Rich Mullikin, MLT I
Albemarle Corp.
Andrew Norris, MLT I Travar Cheatham, MLT I
Need to take Francisco Ramirez, MLT I
Basil Cummins, MLT I
Dilmar Oil Co.
Jeremy Erikson, MLT I William Willis, MLT I
Oscar Hernandez, MLT I
an exam? Cementos Avellaneda John Erikson, MLT I Germanauto Parts
Altpros Eric Ivan Lastra, MLT I
ICML regularly holds exam Domtar Lothar Ranft, MLA I
Gregorio Magariños, MLT I Juan Martin Bahl, MLT I
sessions throughout the Chris Lewis, MLA I Graphic Packaging
United States and the American Refining Group Cemex George Tallon, MLA I International
world. Upcoming dates Peter Parker, MLA I Hunter Bishop, MLT I Marc Lefebvre, MLA I Andrew Temples, MLT I
and locations for ICML Analysts Inc. James Kordsmeier, MLT I Perry Laderoute, MLA I
exams can be found at Zach Temple, MLT I Toby Swan, MLA I GSB Lubrication Services
Grant Dawson, MLA II
www.lubecouncil.org. Vince Sweeney, MLA I Ben Tomkinson, MLA I
Anglo American Centralia College Nathan Lazarevski, MLA I
Edney Alessandro Gabriel, Jacob Fay, MLT I Duke Energy
Emilio Villanueva, MLA I Gwinnett County Water
MLT I Chevron
Kathleen Alexandridis, MLA I Resources
Hugo Freitas, MLT I Gregory Fernandez, MLT I Byron Adkisson, MLT I
Pinkie Dlamini, MLA I EDF Energy
CITGO Petroleum Charles Treiber, MLT I
Antapaccay Mining Co. Felice Gallucci, MLA II Daniel Hill, MLT I
Brian Frieh, MLT I
Jack Teves, MLA II Gary Stacey, MLA II David Osborne, MLT I
Garrett Glinski, MLT I
ICML Certifications Martin Orozco, MLA I Eldorado Brasil Jeremy Cagle, MLT I
Archer Daniels Midland Co.
Michael Arena, MLT I Leandro Bastos, MLT I Jeremy Lucas, MLT I
Jeremy Stevenson, MLT I
LLA I Peter Gerstenkorn, MLT I Moises Santos, MLA II Jonathon Philbeck, MLT I
L aboratory Lubricant Archrock Rebecca Miller, MLT I William Santos, MLT I Leon Nance, MLT I
A nalyst Level I Brad Curtis, MLA III Mark Pirkle, MLT I
City of Largo Esco Products Walter Clark, MLT I
Ascend Performance Cody Bergen, MLT I Christopher Haught, MLT I
MLA I Materials Harley Davidson Motor Co.
Coy Christoffel, MLT I
M achine Lubricant Robert Markham, MLT I Clearwater Paper Louis Evanitus, MLT I
A nalyst Level I Brian Robirts, MLT I Euxinio Industrial Michael Davila, MLT I
Axiall Corp. Lavern Payton, MLT I Martin Heriberto Garcia William Scott, MLA I
MLA II David Leveque, MLT II Nancey McDonald, MLT I Sotelo, MLT I
M achine Lubricant Rick Lundvall, MLT I Hartford City Paper
Bruce Power Exelon Corp.
A nalyst Level II Steve Garrett, MLT I Robert Hurst, MLA I
Bradley Dietrich, MLA I & II Carl Swienton, MLA II
Ed Keuken, MLA I & II Thomas French, MLA I Hollingsworth & Vose
Phil Gernenz, MLA I
MLA III Greg Schmidt, MLA I & II Doña Inés de Collahuasi Fiber Co.
M achine Lubricant Jamie Brown, MLA I General Engineering Ben Mendenhall, MLT I
Mining Co.
Services
A nalyst Level III Marcel Timmons, MLA I David Patricio Garrido Joel Wheeler, MLT I
Nauman Rana, MLA I
Nova Bordynuik, MLA I & II Castillo, MLT I Josh Kolling, MLT I
MLT I Sergiy Protasenko, MLA I Floridor Juan Araya Tola, General Mills Keenan Christensen, MLT I
M achine Lubrication Butler Machinery
MLT I Cody Fogle, MLT I Paul Hamlet Jr., MLT I
Technician Level I Maikel Antonio Peralta David Zweigenbaum, MLT I
Mathew Berogan, MLA II Honeywell
Casanova, MLT I Robert Walker, MLT I
Andrew Thompson, MLT I
MLT II BW Offshore Osvaldo Octavio Martinez
Georgia Pacific
M achine Lubrication Andre Lewis, MLA II Rocha, MLT I Hyrax Oil
Ashish Sharma, MLT I
Technician Level II Shiva Gowda, MLA II Salvador Esteban Coluccio Zaini Yaakub, MLA II
Bradley Montalbano, MLT I
Thura Lwin, MLA II Fumey, MLT I
Christopher Claar, MLT I IIasa Cat
Calumet Specialty Products Conauto Dale Allen, MLT I Nelson Jacinto Pluas
James Erickson, MLA I David Andres Castro David Cloutier, MLT I Cedeno, MLT I
Erik Greenway, MLA II Sánchez, MLT I David Turner, MLT I

Ilim Group Bruce Hausinger, MLT I OCI Beaumont PUSPEKA U.S. Army Corps
Aleksandr Pliusnin, MLT I Darrell Vetor, MLT I Wayne White, MLT I Chek Chang Jie, MLA II of Engineers
& MLA I Doug Johnson, MLT I Mohd Shahrul Nizam Bin Catherine Campbell, MLT I
Oman ORPIC
Andrey Balaganskiy, MLA I Elliott Allen, MLT I Mohd Hedzir, MLA II
Amr Gadalla, MLA I Vale Malaysia Minerals
Anna Trapeznikova, MLT I Jeffrey Bautista, MLT I
Roseburg Forest Products Danny Shin Yeong Liew,
& MLA I Jeffrey Cowie, MLT I O’Rourke Petroleum
Dave Dolan, MLT I MLA II
Dmitrii Korobeinikov, MLT I Joseph Tarongoy, MLT I David Day, MLT I
& MLA I Matthew Werzyn, MLT I Fred Finch, MLT I Sappi Vale Oman
Dmitriy Nikolaev, MLT I & Olivier Raffray, MLT I Gail Saltz, MLT I Benjamin Clukey, MLT I Pradeep Shamba Gaonkar,
MLA I Ralph Leblanc, MLT I Scott Field, MLT I MLA I
SAT Services
Evgeniy Protopopov, MLT I Warren Hall, MLT I Owens Corning Suchint Vishnupant
Dean Harvy, MLA I
& MLA I Andrew Williamson, MLT I Rajhansa, MLA I
Lubrecon Services
Irina Smirnova, MLT I & Seacoast Supply
Cynthia Moblo, MLT I Derrek Pace, MLT I Verso Paper
MLA I Gregory Campo, MLT I
Douglas Gates, MLT I Daniel Peterson, MLT I
Kseniya Krasnoluckaya, LubriCenter
Joseph Coots, MLT I SemCams
MLT I Martin Ivan Cevallos Gomez, Darrell Trzebiatowski, MLT I
Joshua Morris, MLT I David Burkin, MLA II
Sergey Maltsev, MLT I & MLT I David Richard Slaga, MLT I
MLA I Pall Corporation Seneca Sustainable Garren Beauchamp, MLT I
Lubrival
Valerii Cherkasov, MLT I & Sean Bailey, MLA I Energy Glenn Friday, MLT I
José Luis Ventura Chancay,
MLA I Wayne Ragan, MLT I Jim Hiltunen, MLT I
MLA I Parker Drilling Co
Vladimir Isachenko, MLT I Daniel Colby, MLA II Shell John Cretens, MLT I
& MLA I Luminant Kevin Brooks, MLT I
Alan Hok Thiam Yeik, MLA II
Samuel Jones, MLA I Paul Murray Oil Co. Kevin Huiras, MLT I
Imperial Sugar Co. Nadiah Binti Amir, MLA II
Allan Gieger Jr., MLT I Laura Lynaugh, MLT I
Bernard Grant, MLT I Marathon Ashland Quek Teck Meng, MLA II
Jeff Murray, MLT I Patrick Hanneman, MLT I
Emory Cox, MLT I Petroleum Vishnuvarman A/L Aruganan,
Joe Tellez, MLT I Jorge Rojas, MLA I PDV Ecuador MLA II Paul Mroz, MLT I
Sujay Soman, MLA I Hugo Fabricio Pinargote Paul Schlaefer, MLA I &
Mars Inc. SKF
William Horton, MLT I Castro, MLT I
Tom Wallace-Hodgkin, MLA I Ajith Weerakoon, MLA I
MLT I Rick Robinette, MLT I
Industrial Oils Unlimited Khashayar Hajiahmad, MLA
Metex EP Jose Ricardo Palacios Scott Beauchamp, MLT I
Jerry Ray, MLT I I & II
Jan Viljoen, MLA I Miranda, Scott Smith, MLT I
Intercement MLA I Specialty Granules Steven Montag, MLT I
Mosaic Co.
Sergio Vila, MLT I Duane Thurston, MLT I Tim O’Day, MLT I
Ashley Semeniuk, MLT I Port of Portland
Brad Young, MLT I Severn Durand, MLT I Sugar Australia Tony Wanta, MLT I
International Paper
Richard Dupret, MLT I Brayden Olafson, MLA I Rick Gualano, MLA I Victor Boldon, MLT I
Port Waratah Coal Services
Tracy Olson, MLT I Brent Heppner, MLA I Terence Thorpe, MLA I William Rae Jr., MLT I
Saiful Kabir, MLA I
Jamie Mitchell Holodniuk, Wausau Paper Co.
Intertek Testing Suralco
MLT I Portland General Electric
Yeow Ming, MLA II Pancham Selweyn, MLT I William LeTourneau Jr.,
Justis Dorma, MLA I Codey Meissel, MLT I
MLA II
Intrepid Potash Logan Totchek, MLA I Derrick Mauritson, MLT I Talen Energy
Ray Koch, MLA I Michael Lawrence, MLT I Duane Davis, MLT I Peter Phillips, MLA II WearCheck Canada
Noelle Lailey, MLA I Ellis Langley, MLT I Gloria Gonzalez, MLT I
Invista Tamko Building Products
Gary Potter, MLT I
Eric Jones, MLT I Motiva Enterprises Gregory Colburn, MLA II WearCheck Ghana
Jason Schacher, MLA II
Kirton Neipp, MLT I Scott Thibodeaux, MLA I Nathan Lancaster, MLA I Daniel Kwame Boakye,
Jeff Tice, MLT I
TestOil MLA II
Kleenoil South Africa National Oilwell Varco Juan Orozco, MLT I
Max Sizwesakho Ngwenya, Lloyd Massey, MLA I Leanna Whitaker, MLT I Sara Stirling, LLA I Weyerhaeuser
MLT I Nate Garcia, MLT I Stephen Brezovsky, LLA I Anthony Huffman, MLT I
National Police of Colombia
Robert Kilbourne, MLT I Turner Industries Group Chris Brokopp, MLT I
Kohler Jorge Eduardo Cabezas,
Russ Scholl, MLT I Eric Mogridge, MLT I
Cody Gadzinski, MLT I & MLA II Joshua Pulido, MLT I
MLA I Prairie State Robert Suchowski, MLT I Jeffrey Young, MLT I
National Reliability Warren Casteel, MLT I
Generating Co.
Lake Utopia Paper Services Tyree Oil
Kenneth Landolt, MLT I Wilcox and Flegel
Devin Shannon, MLT II Rily Hargreaves, MLT I Brian Otto, MLT I
Patrick Knox, MLT II Robert Beckett, MLT I Pronaca Greg Agee, MLT I Patrick Rall, MLA I & MLT I
Carlos Andres Recalde Trent Tyree, MLT I Yellow Technical Services
Louis Dreyfus Nucleoelectrica Argentina
Simancas, MLT I Rofhiwa Eddy Tshikovhi,
Commodities Alberto Augusto Cattaneo, U.S. Army
Julio Andrade, MLT I
Adam Hoffman, MLT I MLT I Charlie Starling, LLA I MLA I
Andrew Jensen, MLT I Guillermo Galarza, MLT I Proviso Systems Rodney McWhorter, LLA I Tswelopele Rodney
Brett Reeves, MLT I Christopher Deakin, MLA II Steven Cephus, LLA I Ledwaba, MLA I

ASK the EXPERTS
“How can you find the root cause of increasing water

contamination in a coal mill gearbox?”
Water can find its way into a
machine by a variety of ways.
The first place to start is by
testing the new or stored lubricant that will
be going into the gearbox. Studies have
shown that new oils are not clean and
sometimes not dry. By testing new oils or
oils that have been stored for an extended
amount of time, you can obtain an accu-
rate baseline not only for water content but
also for a particle count to determine water can migrate into the oil that it can sion. There are several areas where water
overall cleanliness. begin to displace the volume of oil and can enter a machine. If it is operating in a
Oil storage should be addressed as well. push it out of the top of the drum. humid environment, a desiccant breather
Testing lubricants upon delivery can Drums and totes “breathe” throughout should be installed to dry the air entering
provide information on their initial proper- the day and night, and when they are stored the gearbox during the inhalation process.
ties and contamination levels, but then you outside, this process is more dramatic. Any In addition, check seals and replace
must store them in a manner that is condu- rain water or moisture will be drawn into any that are worn or leaking. Also, inspect
cive to maintaining or improving their the oil during the inhaling process. Once in
for steam leaks that may be blowing on
condition. This includes decontaminating the oil, the water coalesces and sinks to the
the gearbox. If the gearbox has a lube-
the oil with the use of a filter cart or some bottom of the drum. It then begins
cooling system that uses water, it should
other means of circulation through a filter. displacing the oil as mentioned above.
You also need to ensure that the storage be checked for leaks in the piping or the
Oil has the tendency to be hygroscopic,
area is clean and dry. Water ingression which means it absorbs moisture from the heat exchanger.
often occurs when oil drums and totes are ambient environment. Simply leaving oil While there are many ways water could
stored uncapped and outdoors. Water drums unsealed or open to the atmosphere be entering the gearbox, only by doing a
from rain, sleet, melting snow or simply can increase the water content due to the thorough inspection of the machine, its
high humidity can find its way into the oil natural affinity of oils for moisture. surroundings and the new oil can you
and begin increasing the water content of Don’t forget to consider the machine as begin to determine the reason behind the
the storage device. In some cases, enough well. Look for any areas of possible ingres- high water content.
“We have 18 large pulverizer gearboxes that hold nearly

175 gallons of oil. The gearbox manufacturer recommends
a 40-micron filter, but we use a 20-micron filter.
“We previously tried a 10-micron filter but had filtration and having cleaner oil. From a surface area. The most popular would be to
problems with higher oil differential across the design standpoint, if you would like to add additional filter housings to the system
filter and were very close to bypassing. What would move to finer filtration without increasing parallel to the current housing. Another
be your recommendation for an appropriate filter the pressure differential across the filter to would be to simply procure a larger filter
micron size?” the point of bypass, a few changes should housing (if it fits the application). The last
Pulverizer gearboxes are very be made in order to achieve additional and often forgotten solution is to change
robust pieces of equipment, but surface area and a lower flow rate. the filter media type itself. Materials such as
they still benefit from additional There are multiple ways to get more synthetic fiberglass have a much smaller
fiber than wood cellulose, and by default, the
fiber consumes less space on the media face.
This gives the fiberglass media more pores per
unit area, inherently increasing the perceived
surface area.
In addition, if it is possible to reduce the flow
rate of the pump, finer filtration can be used
without an increase in differential pressure.
If you want to be considered “world class,”
the cleanliness level of your pulverizer gear-
boxes should be ISO 17/15/12. Depending on
the flow rate, a B6=100 filter or multiple
parallel filters should enable you to achieve and
maintain this level in a 175-gallon sump.
If you have a question for one of Noria’s experts,
email it to editor@noria.com.
ML
Global Training Calendar

March 2016 MACHINERY LUBRICATION I OIL ANALYSIS 2
Kuala Lumpur, Malaysia • March 14 – 16, 2016 Bangkok, Thailand • March 22 – 25, 2016
MACHINERY LUBRICATION I (4-DAY)
Johannesburg , South Africa • March 7 – 10, 2016 LUBRICACION DE MAQUINARIA I FUNDAMENTALS OF MACHINERY LUBRICATION
ANÁLISIS DE ACEITE III – CURSO AVANZADO DE San Jose, Costa Rica • March 15 – 17, 2016 Daegu, South Korea • March 28 – 30, 2016
ANÁLISIS DE LUBRICANTES
PRACTICAL OIL ANALYSIS LUBRICACIÓN DE MAQUINARIA I – FUNDAMENTOS
México • March 8 – 10, 2016
St. Petersburg, Russia • March 15 – 17, 2016 DE LA LUBRICACIÓN DE MAQUINARIA
FUNDAMENTALS OF MACHINERY LUBRICATION
MACHINERY LUBRICATION I Ecuador • March 29 – 31, 2016
Odense SV, Denmark • March 8 – 10, 2016
Quebec, Canada • March 15 – 17, 2016 LUBRICACIÓN DE MAQUINARIA I – FUNDAMENTOS
ANÁLISIS DE ACEITE III – CURSO AVANZADO DE
ANÁLISIS DE LUBRICANTES FUNDAMENTALS OF MACHINERY LUBRICATION DE LA LUBRICACIÓN DE MAQUINARIA
Monterrey, México • March 8 – 10, 2016 Florence, Italy • March 16 – 17, 2016 Quito, Ecuador • March 29 – 31, 2016
ICML certification testing is available for most of the courses listed.

Visit www.lubecouncil.org for certification information and test dates.

Contamination Control
BACK PAGE BASICS

G arrett B app | N oria C orporation
The
IMPORTANCE of Lip Seals
in Controlling CONTAMINATION
A nyone in the mainte-

nance field who has
repaired a pump or
gearbox knows the one
component that always seems to get
replaced during a rebuild is the lip seal. It
usually is damaged when being extracted
or during disassembly. Perhaps the lip
seal is the reason the piece of equipment
was pulled from service due to leakage.
Regardless, the fact remains that lip seals
are vital machine components. They keep
oil or grease in and help keep contami-
nants out. Lip seals seem to be on almost
every piece of plant equipment, so why
not take the time to learn how to
correctly select and install them.
Selecting a Lip Seal Other seal materials that can be used
Purpose of Lip Seals Maintaining functional lip seals begins
with petroleum oils include Aflas, Simiriz,
carboxilated nitrile, fluorosilicone, highly
The primary purpose of a lip seal is to with the selection process. When choosing
saturated nitrile (HSN), polyurethane,
exclude contaminants while retaining lubri- a material, you must consider the operating
polyacrylate, FEP and silicone. All of these
cants. By nature, lip seals function by temperature, the lubricant in use and the
materials have specific applications and
maintaining friction. They can be used in a application. The most common lip seal
material is nitrile (Buna-N). This material precise temperature ranges. Be sure to
variety of applications from slow-moving
equipment to high-speed rotation and in functions well at temperatures of minus 40 take into account the process and environ-
temperatures from below freezing to more degrees F up to 275 degrees F. Nitrile lip ment before selecting a seal material or
than 500 degrees F. seals cover most applications in industry making a switch, as the correct material
To be effective, a lip seal must maintain from new equipment to replacement seals. can prevent a costly failure.
proper contact with its rotating counter- They have excellent resistance to petroleum
part. This will be influenced by proper oils, water and hydraulic oils, but what Lip Seal Construction
selection, installation and care of the seal really sets these seals apart is their low cost. Once the seal material has been selected,
once it is installed. I’ve often seen a new lip Another affordable option is Viton. Its the next step is to consider the seal’s
seal start to leak as soon as it was put into temperature range is minus 40 degrees F to construction. In the past, a simple lip seal
service. This typically is due to improper 400 degrees F, depending on the specific consisted of a leather strap on a wheel axle.
installation. Other seals will leak initially compound. Viton seals provide good resis- Today’s lip seals have multiple parts that
but then stop leaking once the seal material tance to petroleum oils and can be employed affect how the seal performs. There are
has seated to the shaft. with gasoline and transmission fluid. various contacting patterns as well as

non-spring and spring-loaded seals. A
non-spring seal generally will be less expen- Lip Seal Installation Checklist
sive and be able to retain viscous materials
The elastomer is not damaged (no nicks, scratches, cuts, etc.)
like grease at slow shaft speeds. Typical
applications include conveyors, vehicle The case is not damaged (no nicks, cuts, dents, etc.)
wheels and greased components. Spring- The garter spring is properly placed (if used)
loaded seals are typically used with oils and Wipe the seal and shaft of any debris
can be found on a wide range of equipment. The assembly lube is compatible with the lubricant in operation
The case is of the proper specification
Installation The elastomer is of the proper specification
After the seal material and construction The lip seal is pointing in the correct direction
have been chosen, the lip seal must be
The shaft is free of defects (no nicks, scratches, grooves, etc.)
installed correctly for it to perform. There
The bore is free of defects (no nicks, debris, roundness, etc.)
are a number of products on the market
dedicated to this single task. Most look like There is adequate ventilation of equipment when stored or in operation
a socket set that will position the seal Proper installation tools are used to avoid damaging seals
squarely into its bore. These tools can work Equal pressure is applied during installation to ensure the seal is not cocked
well if selected carefully, but most off-the-
shelf versions aren’t as effective, especially the inner metal ring that attaches to the lip was placed. You should never set the
when a shaft is already installed. For these seal material. Just be sure to set the seal in contact patch to a previous contact point.
instances, I prefer to use a pipe that is large straight and at the correct depth. Failure to If this is unavoidable, there are products
enough to slip over the shaft and makes properly set the seal perpendicular to the that you can slip over the shaft to help with
good contact with the lip seal’s outer shell. shaft can cause immediate leakage. the damaged surfaces. This is usually
If you can find something that catches the If you have a used shaft, it likely has quicker and more cost effective than
outer casing, you can prevent damaging developed a wear ring where the old lip seal replacing a shaft. Keep in mind that the lip
BACK PAGE BASICS
How to Inspect a Lip Seal

Lip Seal Inspection Checklist Among the things to look for when
Check for cracked or deteriorated elastomer inspecting lip seals include deteriorated or
Check for case damage cracked elastomer. This is a telltale sign that
Check to see if the breather is plugged heat is an issue. Also, verify that the lip seal is
Check equipment for excessive temperatures
still in place. I’ve seen a few pumps that had
the wrong seal installed. Upon startup, the
Check for oil leaks around the lip seal
vibration and movement caused the seal to
come out of the bore and spin on the shaft.
seal will need to be resized for the added sleeve. exclude contaminants than to try to remove Any oil leaks around the seal should be a
When installing lip seals, make certain the them. Too tight of a fit between the lip seal red flag to investigate further. Worn seals can
job is done correctly. I’ve seen guys install and the shaft can also create a groove. cause leakage, plugged breathers or damaged
seals with a punch so they wouldn’t have to Excessive temperature is the leading cause bearings that allow radial motion.
take the extra time to locate the right tool. of seal failures. As temperatures rise, the When analyzing any lip seal failure, look at
One wrong thump from a hammer can tear lubricating film becomes thinner, resulting in the seal, shaft and bore. While inspecting the
sealing material, puncture the seal casing or dry running conditions. Elevated tempera- shaft, you typically will see a contact or wear
push the seal through the housing. Always tures can also lead to the elastomer cracking zone where the lip seal was riding. This will
take time when installing lip seals, and lubri- or blistering. Nitrile seal life decreases by a appear as a black scuffmark where the elas-
cate the shaft and seal adequately to prevent factor of two for every increase in tempera- tomer has transferred to the shaft.
tearing or sticking. Also, verify that the lip seal ture of 57 degrees F.
is the correct size. There must be an interfer-
The oil level can be another factor in a lip
ence fit in the bore and on the shaft. Not
having the proper size can result in the seal
seal’s lifespan if it is too low. In this situa- Lip seals are vital
tion, the seal will eventually become hard
rotating on the shaft or becoming dislodged
and not be able to follow the shaft, resulting machine components.
from the equipment.
in leakage. They keep oil or grease
Maintaining Lip Seals Cold temperatures can cause seal
in and help keep
embrittlement. Selecting the proper lubri-
To help your lip seals stay as healthy as
cant and seal material can help in these
possible, you must keep your oil clean, cool and
colder environments.
contaminants out.
dry. Any contamination in the oil will get into
Seals may also fail due to shaft runout.
the contact patch and deteriorate the shaft
and elastomer. Likewise, the hotter the oil This can be caused by misalignment, shaft
imbalance and manufacturing inaccuracies, Remember, in order to keep your lip seals
becomes, the more wear and tear will be
to name a few. Different elastomers will in good operating order, you must maintain
exerted on the seal. Lip seals should also be
kept as clean as possible. Painting over a seal or tolerate varying amounts of runout. Adding a the sump. Cover all seals before painting,
having dirt built up around it can create exces- garter spring will help with any runout that keep the oil at the proper level, make sure
sive heat and quickly degrade the elastomer. can be measured. oil coolers are functioning correctly, and
Excessive pressure is another potential select the right seal design and material. If
Failure Causes cause of lip seal failure. If you’ve ever walked you are proactive in your approach to
past a pump or gearbox and noticed oil rebuilding and installing equipment, you
If you’ve ever pulled out a lip seal and seen
leaking out the seal, the sump has somehow can give your lip seals and machinery a
a groove cut into your shaft, this is probably
due to particle contamination. Without good overpressurized and leaked to the point of fighting chance at survival.
breathers, all the dust and dirt that gets into least resistance. This can be attributed to About the Author
your equipment can destroy not only your clogged breathers or non-vented sumps. Garrett Bapp is a technical consultant with
bearings and gears but also your shafts and Applications with higher pressures should Noria Corporation, focusing on machinery lubri-
lip seals. Of course, it is always better to employ a special seal design. cation and maintenance in support of Noria’s
70%
Lubrication Program Development (LPD). He is a
certified lubrication specialist through the Society
of lubrication professionals say their of Tribologists and Lubrication Engineers (STLE)
plant uses lip seals to control contam- and holds a Machine Lubrication Technician
inant ingression, based on a recent (MLT) Level I certification through the Interna-
survey at MachineryLubrication.com tional Council for Machinery Lubrication (ICML).
Contact Garrett at gbapp@noria.com.

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ATTEND. LEARN. APPLY. APRIL 5-7
At the 17th annual Reliable Plant Conference & Exhibition
in Louisville, Kentucky, you can expect to gain the tools, strategies and
support you need to achieve and maintain a serious competitive edge.
2016
LOUISVILLE
“...a wealth of products

and knowledge
all in one place...”
- JACOB WILCOX, ROQUETTE AMERICA INC.
NEW FOR 2016

75 + Sessions 20 + Case Studies 7 + Networking Events Jim Beam Distillery Tour
90 + Exhibitors New Certificate Programs 6 Workshops Professional Certification Exams
For more information visit Conference.ReliablePlant.com

SCHEDULE
AT-A-GLANCE
Monday, April 4
• Onsite Registration Opening
• Pre-conference Workshops
Tuesday, April 5
Beautiful Louisville! • Opening Keynote
• Exhibit Hall Grand Opening
• Conference Sessions
2
0 • Meet and Greet Reception
1
6 Wednesday, April 6
• Prayer Breakfast
CON F ER E NC E & E XH I BI T I O N
WHY THIS EXPERIENCE IS FOR YOU • Exhibit Hall Open

• Networking Reception
• Jim Beam Distillery Tour
The Reliable Plant Conference & Exhibition is designed to help you find the solutions your
machines, staff and leaders need. Thursday, April 7
Over three days, you’ll meet industry leaders, exhibitors and fellow attendees as you discuss • Giveaways in Exhibit Hall
case studies and sessions, sample products in the exhibit hall and forge new business • Post-conference Workshops
relationships. You’ll learn key aspects of reliability that are new to you or applied in innovative
ways. You’ll see leadership and implementation strategies for making lasting changes.
Once the conference ends, you’ll return to your workplace, but Reliable Plant is hardly over.
You’ll apply what you’ve learned, perhaps implement a new product you sampled and
start seeing results. Within three months of attending Reliable Plant, 76% of surveyed 2015
attendees said they were able to make changes like these in their workplace. One-third of
them were already seeing results.
It all starts with something – or a few things – someone learned at Reliable Plant. Be that
person for your plant. Turn three days into years of continued improvement and thousands,
even millions, in savings.
100
percent GUARANTEE
SATISFACTION
!
WHY ATTEND? “As a maintenance supervisor, I’m in
Reliable Plant covers every facet of reliability, industrial lubrication and oil analysis in one charge of our lubrication program. This
!
three-day event. Realize immediate bottom-line results by obtaining real-world information show has really opened my eyes to a lot of
SATISFACTION
and processes that you can put into practice as soon as you get home.
100 GUARANTEE
opportunities I can implement immediately
at our facility.”
percent
1 Improve your plant’s reliability – learn about real-world deployment processes to
sustain your plant’s reliability program
– MARK BOWEN, ABBOTT NUTRITION
2 Develop powerful connections – exchange ideas with peers, share best practices
and expand professional relationships
3 SATISFACTION
!
Stay up-to-date on new technologies – make your job easier
4 Become more valuable to your company – learn processes to reduce downtime

and control costs
100
percent GUARANTEE
5 Discover solutions that you can implement right away – address specific issues
SATISFACTION GUARANTEE
6 Save money by deducting conference expenses on your taxes – yes, this is a
valid reason to attend!
Noria proudly stands behind Reliable
Plant 2016. If you’re not satisfied with
7
the information and insights you gain
Find new customers, suppliers and resources – generate leads and develop partnerships
at this event, we’ll refund 100% of
your paid registration fee.
8 Attend specialized half-day workshops – offered before AND after the conference
9 Share what you learn with co-workers – technical papers and presentations
provided to you on CD
10 Invest in your company – capture information and apply what you’ve learned on
the job
98% indicated that Reliable
Plant met or exceeded their 98%
overall expectations.
WHO ATTENDS? 100% of attendees at last year’s show

As a professional in machinery lubrication, oil analysis and reliability, you value best practices to said they learned something new
100%
ensure bottom-line results. Whether you’re entry-level or a seasoned member of your plant’s among all the products and services
management team, you’ll benefit from the comprehensive schedule of sessions, case studies in the exhibit hall.
and peer interactions. Make plans now to attend Reliable Plant 2016 to network with and gather
information from the following attendees:
Asset Care Planners Lube Analysts Project Leaders

CBM Coordinators and Specialists Lubrication Technicians & Specialists Quality Managers
Chief Engineers Machinery Engineers Reliability Coordinators
Design Engineers Maintenance Engineers & Managers Reliability Engineers
Engineers & Engineering Managers Maintenance Planners Reliability Team Leaders
Facility Managers Managers of Maintenance and Reliability Reliability Technicians
Hydraulic Specialists Mechanical Engineers Safety Managers and Directors
Industrial Maintenance Supervisors Operations Managers Senior Reliability Engineers
Industrial Mechanics PdM Analysts and Specialists TPM Coordinators and Facilitators
Infrared/Vibration Technicians Planners and Schedulers ….and more
Lab Managers Plant Managers & Engineers
KEYNOTE DETAILS
Catch Dan Rockwell’s speech on
Tuesday, April 5th, 8:00–9:30 a.m.
in the Cascade C Ballroom.
Dan Rockwell is a Leadership Freak.
OPENING GENERAL SESSION

NON-DENOMINATIONAL
FEATURED KEYNOTE – Dan Rockwell PRAYER BREAKFAST
Dan Rockwell is a sought-after leadership coach, trainer and presenter who is best known Wednesday, April 6th, 2016
for his highly recognized blog, Leadership Freak, which he began writing in 2010. Millions of 7:00 a.m. – 7:50 a.m.
leaders in every country on the globe gain encouragement and insight from his daily articles.
• Hyatt Regency – directly
Leadership Freak has been recognized by the Center for Management & Organizational across from the Kentucky
Convention Center
Excellence as the most socially shared leadership blog in the world for three years running.
More than 350,000 subscribers have opted into Dan’s social media channels. • Full, hot buffet breakfast,
coffee, juices
Rockwell’s keynote entitled “Finding Fire” describes how one individual in a small community • Opening remarks and prayer
turned his desire to make a difference into a global organization that changed the world.
• Inspirational keynote speaker
Exploring how this leader overcame obstacles, built the right team and pursued excellence,
Rockwell will illustrate to his audience that five powerful principles have the potential to • Closing ceremony
invigorate leaders and transform organizations: • No cost, but registration
• How to eliminate the deadly behavior that • Reconnect with purpose and strength is required.*
quenches vitality. to fuel vibrancy. *Add to your conference registration
• One unexpected word that provides lifelong • Uncover the path that one lumber-yard
SPONSORED BY
challenge and opportunity to any leader. clerk took toward leadership and
• A simple five-step conversation that global impact.
initiates forward momentum.

SPONSORED BY PENTAIR
$75 per guest Includes:
5:30 p.m.- 9 p.m. Wednesday, April 6 • Round-trip transportation
Be one of 50 registrants to enjoy a private, after-hours • Bourbon-infused BBQ meal
guided tour through the Jim Beam distillery, plant and
• Commemorative Jim Beam gift
facilities. Bourbon tasting and dinner are included.
Limited to 50 seats (first come, first served). Make your reservation when you register.
ATTEND RELIABLE PLANT AND YOU COULD
WIN A SIX-DAY TRIP FOR TWO TO HAWAII!
Prize Includes:
• Round-trip airfare for two adults
• Five nights in a two-bedroom condo at the Aston Waikiki Sunset Resort
• Arrival and departure ground transportation between airport and hotel
• Admission for two adults to the Ali’i Luau Polynesian Cultural Center
• A self-guided tour of six villages representing Tonga, Tahiti, Fiji,
Aotearoa (Maori New Zealand), Samoa and Rapa Nui (Easter Island)
• Canoe pageant
• “Hawaiian Journey” film
• Ali’i luau dinner buffet and performance
• Reserved seating at evening show, “Ha: Breath of Life” featuring
traditional music and fire dancing
For more information visit Conference.ReliablePlant.com

NEW FOR 2016:
LEADERSHIP & FUNDAMENTALS
CERTIFICATE PROGRAMS
Whatever your expectations for Reliable LEADERSHIP FUNDAMENTALS
Plant, you are guaranteed to learn CERTIFICATE PROGRAM CERTIFICATE PROGRAM
something new - 100 percent of our 2015
attendees did. Why not make the most of Reliable Plant’s leadership program will put you If you’re new in the field or feel your
in key sessions that will explain how to tackle understanding could use some updating, Reliable
your experience by enrolling in one of our
problem areas and identify solutions so you can Plant’s fundamentals program will cover the
two new certificate programs? Enrollment
build a world-class lubrication/reliability program. basics of lubrication and reliability to put your
in either of the Leadership or Fundamentals career on the fast track.
programs will include:
Workshop Workshop
Full-conference registration Lubrication Excellence Essentials for Leaders The Essential Elements of Industrial
Jim Fitch, Noria Corporation Lubrication Fundamentals
Pre-conference workshop
Wes Cash, Noria Corporation
Session 1
Access to the VIP lounge
(Starting the Change Conversation) Session 1
Noria books bundle How to Implement a Global Reliability Program (Sampling and Field Testing)
Ron Reimer, Eli Lilly and Company 30 Years Without an Oil Change: A Case Study
Commemorative plaque Brian Thorp, Seminole Electric Coop
Session 2
Certificate of completion (Coaching Your Team) Session 2
Filling the Gap: Transferring Knowledge to (Grease Fundamentals)
the Younger Workforce How to Determine Grease Compatibility and
“This conference was worth the time to Dave Abecunas, Predictive Service Why It’s Important
attend. The sessions were outstanding. I Rich Wurzbach, MRG Labs
enjoyed the knowledge all the speakers Session 3
shared. It was valuable information. This (Setting Metrics) Session 3
was my first year to attend, and I have Metrics for Lubrication Program Success (Filtration, Flushing and Transfer)
enjoyed the conference.” Jeremy Wright, Noria Corporation Key Components of Effective Lubricant Storage
Terry Harris, Reliable Process Solutions
– JIMMIE HENRY, GE OIL AND GAS Session 4
(Creating Good Procedures) Session 4
Improving the Effectiveness of PMs (Conducting Effective Inspections)
Roger Borycki, Tronox 10 Hydraulic Reliability Checks You Probably
Aren’t Making
91% of attendees said the learning Hank Ayers, GPM Hydraulic Consulting
sessions’ content and topics were 91%
important to their company.
CONFERENCE
WORKSHOPS PRE-CONFERENCE WORKSHOPS – MONDAY, APRIL 4th
PRE-CONFERENCE PRE-CONFERENCE
Optimize your conference experience How to Diagnose Critical Success

by attending specialized pre- and Employee Factors and Benefits
post-conference workshops. Professional Performance Issues of Condition-based
development is critical in any line of work. Maintenance
Results show that participation in workshops Chris Christenson – Noria Corporation Jason Tranter, Mobius Institute
ensures an enhanced conference experience. Monday, April 4, 8:00 a.m. – 11:30 a.m. Monday, April 4, 8:00 a.m. – 11:30 a.m.
Jumpstart your learning and quantify your Accurately diagnosing an employee’s This workshop will discuss the key elements of a
investment by committing to one or more of performance can be difficult. Many times what condition-based maintenance program, including
our conference workshops. you observe is only part of the story. This how to establish a new program and optimize
workshop will reveal the critical factors, how they an existing program. Learn the most effective
influence an employee’s behavior and how you condition monitoring techniques and precision
maintenance activities.
should respond.
PRE-CONFERENCE PRE-CONFERENCE
The Essential Lubrication

Elements of Excellence Essentials
Industrial Lubrication for Leaders
Fundamentals
Wes Cash – Noria Corporation Jim Fitch – Noria Corporation
Monday, April 4, 1:00 p.m. – 4:30 p.m. Monday, April 4, 1:00 p.m. – 4:30 p.m.
This interactive workshop provides an Effective lubrication is an essential enabler to
introduction to optimal lubrication practices. machine reliability and can yield amazing results
Designed for those with little technical on the bottom line. This leadership workshop
background, it covers the common activities will show you how to take control of reliability by
of a lube technician in support of a lubrication reinventing your lubrication program.
excellence program.
POST-CONFERENCE WORKSHOPS — THURSDAY, APRIL 7TH

POST-CONFERENCE POST-CONFERENCE
How to Achieve Certified Reliability
Maintenance Leader Workshop
Planning Excellence
Doc Palmer, Richard Palmer & Associates Inc. Terrence O’Hanlon, Reliabilityweb.com
Thursday, April 7, 1:00 p.m. – 4:30 p.m. Thursday, April 7, 1:00 p.m. – 4:30 p.m.
Maintenance planning and scheduling can World-class organizations recognize that success
dramatically improve productivity. Join Doc is achieved through leadership. This is especially
Palmer, author of McGraw-Hill’s Maintenance true for reliability. Come get ideas and practical
Planning and Scheduling Handbook, as he covers tips to engage and empower every stakeholder in
not just theories and principles but the nuts and your organization as a reliability leader.
bolts of how planning and scheduling work.
LEARNING SESSIONS
SPONSORED BY ROYAL MANUFACTURING COMPANY
HERE’S A QUICK LOOK AT SOME OF OUR LEARNING SESSIONS:

There are more than 75 learning sessions and counting. New sessions are being added weekly.
Stay up-to-date by visiting Conference.ReliablePlant.com.
Case Studies Leadership Program Fundamentals Program
6 Key Elements for World-class Manufacturing Improving Fuel System Cleanliness to Meet
Paul Bokrossy, Zimmark New Emissions Regulations
Attend this session to learn why data-driven KPIs and maintenance Scott Shafer, Caterpillar Inc.
are powerful tools for boosting reliability, along with the six essential This session will outline the types of hard particle wear that
elements of world-class manufacturing that are borne out of commonly occur in high-performance fuel systems operating on dirty
excellent data and performance tracking. fuel and will detail an enhanced filtration solution to counteract these
problems. If dirty fuel is an unavoidable reality in your line of work,
Debunking the Most Common Hydraulic Myths and attend this presentation to learn how to limit impurities and damage
Misconceptions so you can get the most out of your engine.
Jaime Contreras, Ripipsa
This session will address the most common hydraulic misconceptions How the Industrial Internet is Changing
and the problems they produce. Learn how to spot poor pressure valve Asset Management
adjustment, differentiate directional valves, properly use hydraulic Matthew Wells, GE Intelligent Platforms
accumulators and interpret/utilize hydraulic symbols correctly. Today, more and more companies are connecting their machines in
order to collect and analyze data that will aid them in preventing
A Complete Guide to Using Root Cause Analysis breakdowns. This session will dive into the ways in which greater
Gary Helmink, Roxane
connectivity and the industrial Internet are enabling a new level of
Root cause analysis has a bad reputation as being difficult and asset monitoring and accurate failure prediction. Come learn how
time-consuming. This session will reveal why this is an incorrect you can harness this incredible power to drive transformative asset
assumption and how using root cause analysis guarantees far- management, efficiency and innovation.
reaching benefits in reliability. Discover how you can be confident the
solution you’ve enacted has truly solved the problem. Purchasing Equipment with Maintenance in Mind
Jay Zaffino, Burns & McDonnell
Understanding the True Cost of Improper Whether it is planned or unplanned, a time will come when machines
Lubrication must shut down for maintenance. This session will examine how to
Eric Rasmusson and Bill Correll, Generation Systems
purchase pumps with a planning mindset and reduce unplanned
If you think there’s not a direct relationship between lubrication and downtime significantly. You’ll learn the steps to take during the bid,
profitability – or you believe there is but can’t define it – this session purchasing, fabrication and installation stages to help machinery
is one you must attend. Drawing on findings from leading researchers maintenance go smoothly and efficiently – spelling more machine
and analysts, this presentation will clarify the key link between availability, productivity and profit.
lubrication and a company’s bottom line, and how misunderstanding
this link is extremely costly. How to Interpret Particle Count Results for
In-service Lubricants
Rüdiger Krethe, OilDoc
Sample preparation procedures can have a big influence on particle
“A ton of valuable information is packed
into a few days, presented by top-notch count results as well as related decisions and maintenance practices.
instructors. This conference is a tremendous This session will present a method of interpreting particle count
value, and my expectations were exceeded results based on three steps. You will leave knowing how to combine
in many ways!” information, get the most accurate picture of oil health and conduct
excellent maintenance.
- JOHN STACEY, METSO MINERALS
OIL ANALYSIS The Advantages of Choosing How to Avoid Lubrication-caused
Biodegradable Lubricants Failures
New Method for Detecting Glycol in Jim Pezoldt, BioBlend Renewable Resources Mike Gilliland, Whitlock Packaging
Used Engine Oil
Roland St. Germain, VHG Labs How to Choose a High-speed Grease Case Study: The Journey to
Wes Cash, Noria Corporation Lubrication Excellence
How to Determine Grease Compatibility Rodrigo Werneck, Samarco Mining
and Why It’s Important CONTAMINATION CONTROL
Rich Wurzbach, MRG Labs How to Implement an Effective
Moisture Contamination and Its Effect on Lubrication Program
How to Interpret Particle Count Results of the Remaining Useful Life of Bearings Alejandro Meza, Noria Corporation
In-service Lubricants Garrett Rowe, Arizona Instrument
Rüdiger Krethe, OilDoc Back to the Basics, Forward to Reliability
Improving Fuel System Cleanliness and World-class Lubrication
How to Determine Engine Oil Quality to Meet New Emissions Regulations Suzy Hitchcock, ICML
Tina Dasbach, Institute of Materials Scott Shafer, Caterpillar Inc.
Metrics for Lubrication Program Success
Using Linear Voltammetry to Analyze Combining Varnish-removal Technologies Jeremy Wright, Noria Corporation
In-service Lubricants for Better Turbine Lubrication
Dave Wooton, Wooton-Consulting Andy Sitton, Focuslab Understanding the True Cost of
Improper Lubrication
Identifying Contaminated and How to Keep Lubricants Clean Right Eric Rasmusson and Bill Correll,
Mislabeled Lubricants from the Start Generation Systems
Pat Maggi, Cannon Instrument Co. Jason Gerig, Chevron
The Benefits of Proactive Lubrication
How Oil Analysis Can Be Used for Controlling Water Contamination in Dale Jones, Allegheny Wah Chang
Lubrication Management Lubricants with Membrane Dehydrators
Bill Quesnel, WearCheck Canada Sudip Majumdar, Compact Secrets for Better Compressor Lubrication
Membrane Systems Wes Cash, Noria Corporation
LUBRICANT SELECTION
Embracing Precision Lubrication: A
When and How to Use LUBRICATION PROGRAM MANAGEMENT Case Study
High-performance Grease Case Study: How to Implement a Saul Cizek, Upper Occoquan Service Authority
Dr. Anoop Kumar, Royal Mfg. Plant-wide Lubrication Conversion Manual vs. Automatic Lubrication: Which
Best Practices for Selecting Lubricants Marian Hendrickson, Leprino Foods is Better?
Alejandro Meza, Noria Corporation How to Double the Life of Critical Jeffrey Boyles, Lubrication Engineers
The Future of Food-grade Lubricants Equipment Through Effective Lubrication

Tyler Housel, Inolex Jeremy Wright, Noria Corporation
“I thoroughly enjoyed myself and learned a
lot in the process. With a wealth of products Debunking the Most Common Hydraulic No Time for Maintenance? 12 Ways to Get
and knowledge all in one place, it is difficult Myths and Misconceptions It Done
not to find something to bring back and Jaime Contreras, Ripipsa Jeff Shiver, People and Processes
implement for improved plant reliability.”
Understanding the Requirements and RELIABILITY ENGINEERING
- JACOB WILCOX, ROQUETTE AMERICA INC. Classifications of Hydraulic Fluids
Doug Sackett, Total Lubricants How to Implement a Global
Reliability Program
4 Common Lubrication Problems and How 30 Years Without an Oil Change: Ron Reimer, Eli Lilly and Company
to Fix Them A Case Study
Joe Goecke, Petro-Canada Brian Thorp, Seminole Electric Coop The Impact of Green Technology on
Equipment Reliability
The Most Common Things That Destroy a Controlling Contamination in Larisa Gorodetsky, Ark Manufacturing
Lubrication Program Hydraulic Cylinders
Jorge Alarcon and Jesus Terradillos, Tekniker Tony Casassa, Aggressive Hydraulics How Technology Can Drive Reliability
Improvement
LUBRICANT STORAGE AND HANDLING The Real Reasons Why Hydraulic Tom Dabbs and Rick Zinkl, DXP Enterprises
Fluids Fail
The Importance of Proper Lubricant Doug Muennich, RelaDyne Reliability on a Budget: How One Person
Storage and Labeling: A Case Study Can Make a Difference
Gene Goetz and Fallon Schmidt, Sinclair Methods for Controlling Varnish in Christopher Haught, Esco
Wyoming Refining Co. Industrial Hydraulic Systems
Mrinal Mahapatro, Pall Corporation How to Develop a Corporate Reliability
Key Components of Effective Lubricant Strategy
Storage CONDITION MONITORING David Rosenthal, Reliability Strategy and
Terry Harris, Reliable Process Solutions Implementation Consultancy
Condition Monitoring Mobile
HYDRAULICS Fleet Assets Tactics to Sustain and Improve Your
John Hasson, Fulton Hogan Reliability Program
10 Hydraulic Reliability Checks You Vlad Bacalu, AECOM
Probably Aren’t Making, Identifying the Risks and Failure Modes of
Hank Ayers, GPM Hydraulic Consulting Electrical Systems Case Study: How to Increase the
Alan Ross, SD Myers, and Jakub Djielski, Reliability of a Lubrication System
Argonne National Laboratories Mario Rupf, Kinross Gold
Using Condition Monitoring Instruments to Preventing Machine Failures with

Get the Most from Your PdM Program Precision Alignment
Ken Piety, Azima DLI Pedro Casanova, Ludeca
Monitoring Slow-speed Bearings with Case Study: How to Start a Reliability

Ultrasound Improvement Program
Adrian Messer, UE Systems Ian Green, AV Terrace Bay
PLANNING AND SCHEDULING Using a Lean Approach for Greater

Machine Reliability
Establishing a Maintenance Planning and Paul Conley and Bryan Uncapher, SKF
Scheduling Program
Doc Palmer, Richard Palmer & Associates Inc.
Don’t miss insightful

case studies from these
industry leaders…
Case studies are marked.
MORE THAN 75 LEARNING SESSIONS AND COUNTING
MAINTENANCE MANAGEMENT How the Industrial Internet is Changing Using PdM Technologies to Achieve
Asset Management Greater Reliability
How to Develop a Life-cycle Asset Matthew Wells, GE Intelligent Platforms Nathan Southwell, Weyerhaeuser
Management Strategy
Timos Lolis, LafargeHolcim Purchasing Equipment with Training for PMs, PMs for Training
Maintenance in Mind Michael Mazur, Schwan’s Global Supply
Skills Assessment Testing and Remediation Jay Zaffino, Burns & McDonnell Chain
Jim Fitch, Noria Corporation
Filling the Gap: Transferring Knowledge to Improving Maintenance and Reliability
Case Study: How to Transition from the Younger Workforce for Wastewater Operations
Reactive to Condition-based Maintenance Dave Abecunas, Predictive Service David Tuccio, Monroe County Pure Waters
Jeffrey Ng, Kimberly Clark
Maintenance Metrics and KPIs You Should The Hidden Costs in Air Compressor
The Importance of Tactical be Measuring Operation
Maintenance Leadership Jay Ratliff, AssetPoint Matthew Kohosek, FS-Elliott
Abdul Alami, Alberta Government
Improving the Effectiveness of PMs
6 Key Elements for World-class Roger Borycki, Tronox ROOT CAUSE ANALYSIS
Manufacturing
Paul Bokrossy, Zimmark Strategies for Overcoming Asset A Complete Guide to Using Root Cause
Management Barriers Analysis
New Techniques to Fight the Mark Wolfgram, GenesisSolutions Gary Helmink, Roxane
Maintenance Crisis
Joel Leonard, SkillTV.net How to Update an Asset Management Using Root Cause Analysis to Break
Program: A Case Study Away from Reactive Maintenance
How to Use Effective Metrics for Better Tacoma Zach, Uberlytics, and Thomas Kurtz, Chris Eckert, Sologic, and Bill Lyons, Holcim
Asset Management Noria Corporation
Scott Kelley, GeoMetric Reliability
Optimizing Your PMR Program
Why Preventive Maintenance Will Not David Hull, Holcim
Solve Your Reliability Problems
Jason Tranter, Mobius Institute
GET A FREE NORIA

TRAINING COUPON
Valued at $1,295!*
Full-conference registration includes a $1,295 training coupon which
can be used toward Noria’s lubrication or oil analysis training courses
for up to one year. Use it yourself or give it to a co-worker. It’s like
attending the conference and getting Noria training for free!
*Terms and Conditions: Only one coupon issued per person. Coupon is transferable within your organization and must be presented when registering for the training. Coupon is valid for Noria public
training courses in the United States taking place between April 2016, and April 2017, or online courses purchased prior to April 2016. Coupons are given to full-conference (Tuesday-Thursday)
attendees who pay their conference registration fee and attend the conference. Speakers and exhibitors are not eligible unless paying full-conference registration fees. Coupons may not be
used for private onsite training.
OVER 150,000
SQUARE FEET OF EXHIBIT HALL SPACE
“I loved the format of learning
sessions mixed with exhibit hall time.
I found several products and vendors
on the exhibit hall floor that I never
knew existed. It is a great place to
Make your conference experience as valuable as possible. Wander learn firsthand who the leaders in the
the expansive exhibit hall and discover tools and solutions among EXPANSION
industry are.”
LUNCHEON
a comprehensive group of global suppliers representing various AREA
- KASEY DAVIS, NV ENERGY
disciplines of industrial lubrication and oil analysis.
With over 150,000 square feet of exhibit 131 332 431 432 531 532 631 832
hall space, attendees can meet with more
129 130 229 230 329 630 729 730 829 830
than 100 exhibitors highlighting innovative
products and services over the course of three 128 227 228 327 328 427 428 527 528 627 628 727 728 827
days. Unwind in the “Relaxation Station,” 125 126 225 626 725 726 825 826
network with colleagues during lunch breaks 124 223 224 323 624 723 724 823
and receptions, gather hands-on information 121 122 221 222 321 622 721 722 821 822
and generate ideas to address specific needs. 119 120 219 620 719 720 819 820
117 417 818
115 116 215 216 616 715 716 815 816
113 814
109 110 210 310 410 510 610 709 710 810
105 806
604 703 704 803
101 102 202 302 402 502 602 701 702 801 802
Air Sentry E + E Elektronik ENTRANCE

Lubrication Scientifics, LLC R&G Laboratories, Inc.
EXHIBITORS
Alemite Engineered Lubricants Lubrigard RelaDyne, Inc.

ALS Tribology Esco Products, Inc. Ludeca, Inc. Royal Mfg. Co.
American Chemical Technologies Fluid Technologies, Inc. Luneta, LLC Runningland
Analysts, Inc. Fluitec International Meggitt Sensing Systems SD Myers, Inc.
API Maintenance Systems FS-Elliot Company Midland Manufacturing Company, Inc. SDT North America, Inc.
Argo-Hytos Generation Systems Mighty Lube, USA SKF Lubrication
Arizona Instrument LLC Genesis Solutions Mobius Institute Society for Maintenance & Reliability
Azima DLI Gill Sensors and Controls MP Filtri USA Professionals (SMRP)
Beckman Coulter Life Sciences GTI Predictive Technology, Inc. MSC Filtration Technogies Specialty Manufacturing, Inc.
Beka Max of America, Inc. GUARDIAN Noria Corporation Spectro Scientific, Inc.
C.C. Jensen Hanil Lubtec Company Oil Filtration Systems, Inc. Spectronics Corporation
Cannon Instrument Company Harvard Corporation Oil Safe Spencer Strainer Systems
CheckFluid, Inc. Henek Fluid Purity Systems OilDoc GmbH SPM Instruments, Inc.
Chemsearch Reliable Lubrication HYDAC / Schroeder Industries Orion Engineered Seals Stauff Corporation
Solutions (RLS) Hy-Pro Filtration Pall Corporation Tannas Co.
*Sponsors shown in blue
Chemsearch Torrent Services IMI Sensors/PCB Piezotonics Panalytical TestOil

Closed Loop Recycling Indiana Bottle Company Parker Hannifin Corporation The Chemours Company
Compact Membrane Systems Inpro/Seal Company PdMA Corporation Total Specialties USA, Inc.
Computrac International Council for Machinery Pentair Filtration Solutions Tribologik Corporation
Connection Technology Center Lubrication (ICML) People and Processes, Inc. UE Systems, Inc.
Design Maintenance Systems, Inc. Intertek PerkinElmer Instruments Universal Flow Monitors, Inc.
Dexsil Corporation Lincoln Lubrication POLARIS Laboratories® VHG Labs/LGC Standards
Donaldson Company, Inc. Liquidynamics Projetech Inc. Whitmore Industrial
Dry Hydraulics, LLC Lubrication Engineers, Inc. Pruftechnik, Inc. Y2K Fluid Power, Inc.
HOST HOTEL
SPONSORED BY HENEK
Hyatt Regency Louisville
502-581-1234
TRAVEL 311 South 4th Street

Louisville, KY 40202
Reliable Plant 2016 will take place in the action at the Louisville Slugger Museum
Reserve Your Room by
beautiful city of Louisville, Kentucky. & Factory or the Louisville Glassworks to March 14, 2016
Conference sessions and exhibits will be see one of the largest privately owned hot
held at the Kentucky International glass studios in the U.S. Delve into history Single Occupancy: $169
Convention Center. Specially rated rooms for at the Frazier History Museum or learn Call the hotel at 502-581-1234
attendees are available at the Hyatt Regency about boxing legend Muhammad Ali at the
Be sure to provide the group code:
Louisville (located directly across from the Muhammad Ali Center. You can even cruise
Reliable Plant 2016
convention center). the Ohio River on the Belle of Louisville, a
paddle-wheel steamboat boasting on-deck Make all hotel reservation changes
Visitors will have access to the exciting dining and some of the best sightseeing in or cancellations directly with the
attractions that make Louisville a cultural the city. Hyatt Regency Louisville
linchpin of the American South, from a
Visit Conference.ReliablePlant.com
100-year-old, fully functioning steamboat These and many more opportunities await
for a shortcut to the hotel
to the Urban Bourbon trail featuring famous Reliable Plant attendees. Hotel availability is
registration site
bars and distilleries. Visit Museum Row on limited, so make your reservations today!
Main Street to witness craftsmanship in
GET TO KNOW LOUISVILLE

In Louisville, they have a saying that the question isn’t what to do, it’s what to do first. Whether you’re
looking for something to do downtown or in your downtime, here’s a list of our 10 favorite things to do in the Lou.
1 Sample some only-in-Louisville cuisine by eating a Hot Brown at

the Brown Hotel. 6 Savor some of the city’s best cuisine on “Restaurant Row” along
Bardstown Road.
2 Get your picture taken with a six-story-tall bat at the Louisville Slugger
Museum & Factory. 7 Take a swing at “The Champ” at the Muhammad Ali Center.
3 Sip a bourbon cocktail and get your passport stamped along the Urban
Bourbon Trail.
8 Do dinner and dancing at Fourth Street Live!, the city’s premier
entertainment and nightlife district.
4 Cruise down the Ohio River on the Belle of Louisville, the nation’s oldest
operating steamboat.
9 Make a bet and watch live racing at the historic Churchill Downs,
home to the Kentucky Derby.
5 Experience the Kentucky Derby everyday at the Kentucky Derby Musuem. 10 Get your picture taken with the Colonel at the Louisville Visitors Center.
Conference.ReliablePlant.com
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UNTIL MARCH 3, 2016
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INDIVIDUALS
+ CERTIFICATE $1,395 $1,595 WHAT’S INCLUDED?
PROGRAM SAVE $200 STANDARD RATE FULL-CONFERENCE REGISTRATION INCLUDES:
• Admission to all conference sessions
• Conference proceedings
GROUPS $795 $845 • Opening general session and keynote address
• Exhibition hall access
3-9 SAVE $50 STANDARD RATE • Daily breakfasts, refreshment and lunches
• Networking receptions
• FREE Noria training coupon, valued at $1,295
GROUPS $695 $745 WORKSHOP REGISTRATION INCLUDES:
10+ SAVE $50 STANDARD RATE • Course materials
• Refreshment breaks
• Opening general session (Tuesday only)
WORKSHOP
Additional with paid $225 $295 • Exhibition hall access (Tuesday only)
full registration WORKSHOP ONLY

BRINGING THE CREW?
GROUPS RECEIVE AN ADDITIONAL 30% DISCOUNT ON
ALL PRE- AND POST-CONFERENCE WORKSHOP FEES GROUP DISCOUNTS AVAILABLE
3 to 9 ATTENDEES:
It’s not too late to consider a sponsorship! Get three or more full-conference registrations for only $795 each,
plus a 30% discount on all pre- and post-conference workshop fees.
Sponsorship packages go fast and are sold on a first-come,
first-served basis. A few premier sponsorships remain – 10 or MORE ATTENDEES:
increase your visibility and put your marketing dollars to Get 10 or more full-conference registrations for only $695 each,
work for you by joining this prestigious group of 2016 plus a 30% discount on all pre- and post-conference workshop fees.
Reliable Plant sponsors.
HOW TO REGISTER
ONLINE: Conference.ReliablePlant.com
FAX: PHONE:
REGISTRATION FORM Fax your completed
registration form to:
Give us a call
Monday – Friday, 8 a.m. – 5 p.m. (CST)
2016 RELIABLE PLANT CONFERENCE & EXHIBITION 918-746-0925 918-392-5038
APRIL 5-7, 2016 | Louisville, Kentucky
KENTUCKY INTERNATIONAL CONVENTION CENTER
REGISTRANT INFORMATION PRE-CONFERENCE WORKSHOPS SAVE with Full

Registration
Please print your name clearly. Your name and company will appear on your  The Essential Elements of Industrial Lubrication Fundamentals. . . . . . . . $295 . . . . . . . $225
badge. PLEASE photocopy this form for an additional registrant.
 Lubrication Excellence Essentials for Leaders . . . . . . . . . . . . . . . . . . . . . . . $295 . . . . . . . $225
First Name _______________________________________________  How to Diagnose Employee Performance Issues. . . . . . . . . . . . . . . . . . . . . $295 . . . . . . . $225
 Critical Success Factors and Benefits of Condition-based Maintenance. . . . $295 . . . . . . . $225
Last Name _______________________________________________
Title ___________________________________________________ POST-CONFERENCE WORKSHOPS SAVE with Full

Registration
 How to Achieve Maintenance Planning Excellence. . . . . . . . . . . . . . . . . . . $295 . . . . . . . $225

Company _______________________________________________
 Certified Reliability Leader Workshop. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $295 . . . . . . . $225
Address 1 ________________________________________________
Address 2 _______________________________________________
 Wednesday, April 6, 2016 - 5:30 p.m. - 9:00 p.m.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . $75
City _____________________ State/Province ___________________
PRAYER BREAKFAST
Zip/Postal Code __________________ Country ___________________  Wednesday, April 6, 2016 - 7:00 a.m. - 7:50 a.m.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FREE
E-mail (required) __________________________________________

TOTAL PAYMENT DUE: $ _________________
Phone Number (required) ____________________________________
Payment due upon receipt of invoice and prior to conference. No registration materials will
be distributed without full payment. Customers outside the U.S.: We accept checks drawn
CATCH THE EARLY BIRD on U.S. banks in U.S. dollars.
CONFERENCE FEES REGISTER TODAY &
Individual Full Conference

SAVE $200 METHOD OF PAYMENT
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registration fees in the amount indicated on this form.
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BEST VALUE! Group Discounts Expiration Date ______ /_______
3 or more full-conference registrations for only $795 each (until March 3, 2016);
Name on Card __________________________________________________
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discount on pre- and post-conference workshop fees. Group registrations must Cardholder’s Signature ____________________________________________
be purchased at the same time. Call 918-392-5038 to take advantage of this offer.
 Bill Me/My Company - P.O. #_________________________________________
Cancellations must be in writing and postmarked by March 1, 2016. All cancellations received after this date are subject to a $75 administrative fee, but you will also receive a $75 coupon good for use
against the cost of a Noria training or conference. If you don’t cancel and you don’t attend, you will be charged the full registration fee. However, a company may substitute one attendee for another,
without penalty. Written notice prior to the event is required for substitute attendees.
0
2
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1328 East 43rd Court, Tulsa, OK 74105
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Registration Info Exhibitor Space Sales Attendee & Exhibitor Info YOU NEED
Elissa Ackerman Tim Davidson Gina Godfrey Find more details and the most
Toll Free: 1-800-597-5460 Toll Free: 1-800-597-5460 Toll Free: 1-800-597-5460 up-to-date information by visiting
or 1-918-392-5038 or 1-918-392-5052 or 1-918-392-5035 Conference.ReliablePlant.com
registrations@noria.com tdavidson@noria.com ggodfrey@noria.com
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Machinery Lubrication

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January-February 2016

This issue sponsored by:

H igh consumption of engine

2 January - February 2016 | www.machinerylubrication.com

Copyright © 2016 Noria Corporation. Noria, Machinery Lubrication

efficiency, increase blow-by and reduce oil

Oil Change Interval Effect

Oil Consumption Issues

4 | January - February 2016 | www.machinerylubrication.com

DON’T LET DIRT PARTICLES 4 MICRONS SMALL

6 | January - February 2016 | www.machinerylubrication.com

• 100% Synthetic Polyol Ester (POE)-Based, Compressor Fluids.

Synac Series 100% SYNTHETIC

• 100% Diester-Based Synthetic Air Compressor Fluids.

Syncool & Syncool FG ECO FRIENDLY

• 100% Synthetic, Polyglycolester-Based Fluids.

SFGO Ultra Series NSF H1 REGISTERED

• NSF H1 Registered, NSF/ISO 21469 Certified, Food Grade.

for 100 Years

FROM THE FIELD

8 January - February 2016 | www.machinerylubrication.com

seeking employment that allows them to

10 January - February 2016 | www.machinerylubrication.com

entering the manifold. Hoses can help

14 January - February 2016 | www.machinerylubrication.com

18 | January - February 2016 | www.machinerylubrication.com

Strainer alarms OK? Extra water on mill Possible Known

System extra dirty? Change in nozzle position

Too much pressure Bearing seal water deflec.

Bad mercoids Bearing seals bad

Regulator malfunction Loose seats on sleds System alarms

Too wide pres. fluct.

80" hot mill

An example of an Ishikawa diagram of lube oil system strainer basket failures

Surprising Findings from

Certified Reliability Leader

reliabilityleadership.com | 239.333.2500 | 888.575.1245 | crm@reliabilityweb.com

It is important to note that even when

26 | January - February 2016 | www.machinerylubrication.com

4.6L ENGINE OIL MILES VEHICLE MILES AL CR FE CU PB PB'

Table 2. A macro-analysis example from a V-8 gasoline engine

28 | January - February 2016 | www.machinerylubrication.com

AVERAGE STANDARD OIL VEHICLE CU

www.machinerylubrication.com | January - February 2016 | 29

Contrasting Micro-analysis and Macro-analysis

Learn How To Unlock The Full Potential Of

Enroll Today! Noria.com 800-597-5460

CON F ER E NC E & E XHI BIT I O N

ATTEND. LEARN. APPLY. HOW TO REGISTER

20 + CASE STUDIES FROM

See you in Louisville!

NEW FOR 2016

JIM BEAM DISTILLERY TOUR

Register Now to Reserve Your Spot at Conference.ReliablePlant.com

Dan Rockwell is a Leadership Freak. 1 Improve Plant Reliability – learn about

FEATURED KEYNOTE 2 Develop Powerful Connections – exchange ideas

have opted into Dan’s social media channels.

WIRE ROPE GREASE

34 January - February 2016 | www.machinerylubrication.com

www.machinerylubrication.com | January - February 2016 | 35

Lebel Takes Lubrication Name

Program to Next Level

Q: What’s a normal work day like program as well as semi-annual

Your single source supply for com-