Archive | March/April

175

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March 1, 2008
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LMT News

News of people and events important to the Lubrication Management community

ALEITHE NAMED VP & GM ABB LOW VOLTAGE DRIVES BIZ
Aaron Aleithe has been named vice president and general manager of Low-Voltage Drives at ABB Inc., Automation Products. He fills the position Rick Hepperla held before his recent promotion to division manager for Automation Products in North America. In his new role, Aleithe will be responsible for the continued growth and strategic business development of low voltage drives in the U.S. market. He also will serve as a member of both the ABB Global LV Drives Business Unit team member and the North America Automation Products Division management team and work closely with the Power & Control sales and channel management teams in the U.S., to ensure continued growth in the industrial market, while extending ABB’s position in the HVAC market segment.

ATS APPOINTS JOE PYCZ AS NEW VP OF OPERATIONS
Advanced Technology Services, Inc., (ATS), a leader in managed services for equipment maintenance, IT infrastructure support and industrial parts repair, has announced the appointment of Joseph A. Pycz as vice president of Operations. Pycz brings 30+ years experience in operations and management to ATS, including having served the past 12 as president and CEO of ThyssenKrupp Crankshaft, LLC. During that time, he led and managed the company’s growth from two plants with annual revenues of $35 million to four locations with annual revenues near $350 million. Prior to that, he had been plant manager at Wyman-Gordon Company.

TIMKEN IN ALADON NETWORK & IVARA EXP PARTNER PROGRAM
Ivara Corporation has announced that The Timken Company has joined The Aladon Network and the Ivara EXP Enterprise Implementation Partner Program. The Aladon Network is Ivara’s global network of reliability experts and certified practitioners of Ivara RCM2™ and Ivara Maintenance Task Analysis (MTA), advanced methodologies for team-based approaches to developing a reliability strategy for all assets in an organization. As an Aladon Network Member, Timken is certified to deliver training and consulting services for Ivara RCM2 and MTA. In addition, the company now is an authorized reseller of Ivara EXP Professional asset reliability strategy development software. As an EXP Enterprise Implementation Partner, Timken will be able to deliver implementation consulting for Ivara EXP Enterprise asset performance management software. EXP Enterprise provides a cohesive and integrated platform to develop, implement and manage a living equipment reliability program.

Speaking of Timken, building on its extensive line of industrial lubricants, the company has announced the addition of several quality lubricant-delivery products, including grease guns, pumps and kits. These products are being introduced in the United States in March and in Canada during the second quarter of 2008. According to a company spokesperson, its new lubricant-delivery product line complements Timken’s ability to go beyond bearing technology and provide friction management solutions that meet maintenance needs.

BALDOR DODGE RELIANCE GOES ON THE ROAD AGAIN WITH MOTION
The latest Baldor Dodge Reliance “rolling road show” wraps up in March after a successful three-month tour. The centerpiece, a special trailer carrying the value message of Baldor Dodge Reliance products directly to end-users, has been traveling the country since January. As with previous road shows targeting the Poultry and Mining industries, Baldor again partnered with Motion Industries to produce the event, this time outfitting the trailer with products for the Energy and Power Gen industry.

Brought on site to customer locations, the trailer is supported by an area’s local sales team and other representatives of Motion, Baldor Dodge (mechanical products) and Baldor Reliance (electrical products). Inside the airconditioned unit, visitors can walk through a display of Baldor Dodge Reliance offerings, including motors, variable speed drives, gear products, shaft couplings and bearings, then access a touch-screen plasma TV to review specific industry process flow charts. Touching a particular area of the screen produces a dropdown window showing which Baldor products are used at a given point in the process. The customer then can pull up datasheets, drawings and performance data for the product. Actual product demonstrations, Q&As, etc. are conducted outside the trailer where lunch typically is grilled and served for visitors. According to Dave Felt, Baldor’s manager of Channel Development, at the close of its latest three-month, cross-country gig, the trailer will have set up at approximately 30 sites and hosted close to 700 end-user visitors. More “rolling road shows” focusing on other industry markets, he notes, are on tap for the future.

INTEGRATED POWER SERVICES BUYS ELECTRO-MEC OPERATIONS 
Integrated Power Services (IPS), a national leader in the service and repair of electric motors and mechanical power transmission components, has acquired Electro-Mec. Electro-Mec, a third-generation, family-owned power services company based in Indiana, PA, offers motor and mechanical repair, new product sales, field services and precision machined products. Terms were not disclosed. IPS is the former Power Services unit of Reliance Electric and Dodge. Headquartered in Greenville, SC, it now has 12 regional service centers across the country, offering coast-to-coast, 24/7 support to over 1400 customers across a wide range of capital-intensive industries.

SCHNEIDER DONATES $500K TO IEEE & NFPA ARC FLASH RESEARCH 
In keeping with its commitment to improving electrical standards and protecting worker safety, Schneider Electric’s North American Operating Division has contributed $500,000 to the Institute of Electrical and Electronic Engineers (IEEE) and the National Fire Protection Association (NFPA) Arc Flash Collaborative Research Project. The results of this collaborative project will provide information to improve electrical safety standards, predict hazards associated with arcing faults and accompanying arc blasts and provide practical safeguards for employees in the workplace. The multiyear project is estimated to cost $6.5 million. With its donation, Schneider becomes a Platinum Level sponsor of the project. OPC

FOUNDATION OPENS ITS FIRST CERTIFICATION LAB
The OPC (open connectivity) Foundation has announced the opening of its first Independent Certification Test Lab to validate and certify OPC products. The laboratory is located at the premier facility of Ascolab in Erlangen, Germany. OPC Foundation president and executive director Tom Burke notes that Ascolab staff members have been designers and developers of OPC Certification tools since the Foundation’s earliest days. “They are widely acknowledged as ‘the experts’ in OPC Certification and they provide a solid foundation on which to build our certification program.” According to Burke, companies that purchase OPC-compliant products expect secure, reliable interoperability in a highly plug-and-play fashion. Thus, all products that are newly-certified by the Test Lab will carry a new ‘OPC Foundation Certified’ logo that provides endusers with an assurance of excellence. “This Certification program,” he says, “means that users can expect reduced system installation costs and products that will perform reliably in multi-vendor installations.”

ASSOCIATION NEWS

ACEEE PROFILES EXEMPLARY ENERGY EFFICIENCY PROGRAMS
The American Council for an Energy-Efficient Economy (ACEEE) has just released a report entitled “Compendium of Champions: Chronicling Exemplary Energy Efficiency Programs from Across the U.S.,” that profiles 90 of America’s most successful and effective energy efficiency programs. Together, these profiles are a vivid demonstration of how energy efficiency is America’s cheapest, fastest and cleanest new energy resource. Selected from a large set of nominations received during a national search, the 90 initiatives cover 20 different categories, ranging from industrial processes to residential lighting.

This new report is reflective of ACEEE’s second national review and selection of exemplary programs. As with the association’s first such review in 2003, this one not only recognizes outstanding energy efficiency efforts, it also honors the people and organizations responsible for their successes. (ACEEE publicly recognized these “exemplary programs” in an awards ceremony at the 4th National Conference on Energy Efficiency as a Resource, in Berkeley, CA, last October.) In addition to describing each honored program, the report also makes a number of overall observations on the factors that make them stand out.

The “Compendium of Champions” report, including brief summary profiles of each of the 90 honored programs, is available for free at http://aceee.org/pubs/u081.htm. It also can be purchased through ACEEE Publications, by e-mailing: aceee_publications@aceee.org.

ASHRAE & BOMA SIGN MOU
ASHRAE (www.ashrae.org) and BOMA, the Building Owners and Managers Association International (www. boma.org), have signed a Memo of Understanding recognizing shared technical interests in fostering superior building performance. Among other things, the groups will work together to identify opportunities and achieve goals associated with shared services, collaboration on product/ service development and support and participation in standard development, initially centering around ASHRAE standards 62.1, 90.1, 180P and 189.1P.

“ASHRAE and BOMA are on the forefront of developing standards that significantly impact building owners and managers, and we look forward to working more closely with them on these matters,” says BOMA’s international chairman and CEO Brenna S. Walraven. ASHRAE president Kent Peterson, P.E., agrees. “We are all working toward optimal performance of both new and existing buildings. This partnership will be beneficial for both ASHRAE and BOMA members.”

SEND MT NEWS ITEMS TO: jalexander@atpnetwork.com

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2095

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March 1, 2008
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Part II of II…Screw Compressors: Operating Principles & Sealing

0408_compressors_1Part I of this two-part series (LUBRICATION MANAGEMENT & TECHNOLOGY, Jan./Feb. 2008) emphasized the application ranges and volume control options of twin-screw compressors. It explained the general features of these dual-shaft rotary machines, which operate on the principle of positive displacement combined with internal compression. Operation of oil-free (dry) vs. liquid flooded (wet) rotary screw compressors and available seal design options are the primary focus of this concluding installment.

Operation
Regardless of whether a screw compressor is executed for oil-free (“dry”) compression or oil or water injection (the “wet” method), the gas is compressed in chambers that progressively decrease in size. These progressive chambers are formed by the intermeshing action of the two helical rotors and by the surrounding housing wall. Dry machines, however, incorporate timing gears that keep the two counter-rotating screws in the exact relationship to each other. Oil-injected (sometimes called “oil-flooded”) compressors do not incorporate timing gears and the driven male rotor interacts directly with the female rotor. The oil that is injected into the compressor cavity provides intensive lubrication and a large portion of the compression heat is absorbed. At the same time, the clearances between rotors and cylinder (casing) walls also are filled with oil. This prevents the reverse flow of compressed gas and increases the overall compression efficiency.

After leaving the compressor discharge flange, gas and oil exit through a check valve to the oil reservoir where most of the oil is separated from the gas. In oil-flooded compressors, the remaining oil is removed in a downstream separator, and only residual oil amounts of typically five parts per million (ppm) continue to remain in the gas stream. Even this oil carryover can be further lowered by downstream cooling and final moisture separation. The oil separation unit has to be properly maintained and the pressure drop across the separator cartridges taken into account to determine the overall performance of the compressor package. It should also be recognized that the efficiency of oil separation changes as the separator elements become progressively more contaminated.

0408_compressors_fig1_2

On small rotary screw compressors, the housing is vertically parted on the suction side. Cylinder (generally called “casing”) and discharge side plate are frequently combined in a single housing. The housings of larger machines usually are parted horizontally for easy assembly. Rotors and shafts are milled out of one piece of either forged or stainless steel. Some manufacturers provide rotors with non-metallic coatings. In severe service, where loss of coating occurs on the rotor edges, a rapid drop in compressor efficiency could be encountered.

Process gas machines typically are designed with the direction of flow from the top to the bottom. This facilitates liquid removal from the compression space whenever liquid is injected into the rotor chamber for cooling, or for cleaning during operation. On-stream cleaning is highly advantageous in services where gases are contaminated or tend to polymerize. The sealing area is equipped with connections for sealing medium supply and relief. In principle, it is possible to apply a cooling medium to the cylinder wall, but non-cooled cylinder housings (or casings) can be used as well. Part 1 illustrated typical rotor combinations, including an asymmetrical rotor profile. The profile combination 4+6 means that the male rotor has four teeth and the female rotor, six. Due to this profile combination, the diameter of the rotor core is relatively thick. This allows for operation with large differential pressures.

Bearing concerns… 
Although air machines often are equipped with rolling element bearings, the majority of dry and wet process gas compressors are furnished with journal bearings and thrust bearings of the type commonly found in centrifugal process gas compressors. The service life of these bearings is practically unlimited as long as proper lubricating and operating procedures are in force. Rolling element bearings are acceptable for (relatively) light loads and where oil cleanliness is assured. Needless to say, selecting a separate closed-loop bearing oil circuit is a powerful step in the direction of maintaining a clean bearing environment.

If a vendor offers a wet screw machine with a single “same oil serves all” support system, the purchaser-owner may be taking a big risk—unless prepared to run up operating and maintenance costs by planning very frequent oil changes, or major investment in oil purification equipment. If that’s not in your plans, make sure you specify twin-screw compressors with separate oil circuits. In other words, do not buy wet screw machines where the oil introduced into the compression space also flows to the bearings. Separate circuits are used in the 5200 kW coke gas compressors illustrated in Fig. 1 and Fig. 2. However, instead of oil, water is being used in these coke gas services.

Seals 
In many oil-free rotary screw compressor applications, it is best to provide a sealing barrier between the process gas and the bearings. A number of different seal types are feasible (see Figs. 3, A-G). Included are:

  • Carbon ring seals (3A)
  • Carbon ring and ejector-inductor porting (3B)
  • Carbon rings, ejector-inductor and purge gas porting (3C)
  • Combined floating rings and mechanical seals (3D)
  • Mechanical seals and carbon rings (3E)
  • Water as the sealing liquid (3F)
  • Water in small quantities as the sealing liquid (3G)
0408_compressors_fig3a_d
0408_compressors_fig3e_g

At the compressor input shaft, manufacturers often opt for either labyrinth seals, or double-acting mechanical seals with rotating springs.

Carbon ring seals, with connections for the injection and education of inert, clean gases, are used in cases where leakage gas, even in connection with sealing gas, may enter into the bearing areas or into the atmosphere. The gas pressure is relieved across floating carbon rings at the edge of the seal chamber.

Not to be forgotten are barrier water floating ring seals and double-acting mechanical seals with stationary springs. On barrier water floating ring seals, barrier water enters the seal chamber and a small amount of water reaches the compression space. Most of the water is returned to the barrier water system for cooling, filtration and re-use. Barrier water seals are able to fully prevent gas leakage and can provide valuable cooling and scrubbing duties. A double-acting stationary spring mechanical seal and a combination mechanical and floating ring seal are primarily used for compression with high differential pressures.

0408_compressors_fig4

The principle of oil separation and much other worthwhile information can be obtained from Fig. 4 and the various references [Refs. 1, 2 and 3].

Contributing editor Heinz Bloch is the author of 17 comprehensive textbooks and over 340 other publications on machinery reliability and lubrication. He can be contacted at:hpbloch@ mchsi.com

References: 
1. Bloch, Heinz P., A Practical Guide to Compressor Technology, (2nd Edition, 2006) John Wiley & Sons, (ISBN 0-471-727930-8), [See also 1st Spanish Edition, (1998), McGraw-Hill, New York and Mexico City, ISBN 970-10- 1825-7].

2. Bloch, H.P., and Pierre Noack, “Recent Experience With Large Liquid-Injected Rotary Screw Process Gas Compressors”, (1991, Proceedings of 20th Turbomachinery Symposium, Texas A & M University, Dallas, TX).

3. Bloch, Heinz P., and Claire Soares, Process Plant Machinery, 2nd Edition, 1998, Elsevier Publishing, London-New York-Amsterdam, ISBN 0-7506-7081-9.

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March 1, 2008
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When it comes to ball bearings…What Keeps Customers Rolling? “Five Factors of Excellence”

Providing unfailing operation from ball bearing failure requires looking at the subject the way experts do—with a cold eye on the factors leading to success and failure. Ignore them and the result could be production interruptions that cost your company time, money and reputation. Embrace them and you can look forward to a number of benefits, including fast product delivery and fatter profit margins.

When Goodrich Aerospace (GA) of Vermont opened the door to The Five Factors formula, good things rushed in. According to senior buyer Ross Lowery, long lead times for product delivery vanished, even “troublesome” parts were always in stock and the mind-bending exercise of price comparisons for various quantities of parts came to an end. GA thus expanded its contract with the formula originator, Intercontinental Bearing Supply Company (IBSCO). This Houstonbased supplier of ball bearings and services defines and utilizes The Five Factors for its clients as follows:

Factor One: Traceability… 
Goodrich Aerospace is a Prime Contractor and OEM for the Federal government. Accurate and complete traceability is requisite, especially for bearings. Thus, if there’s a failure in the field, IBSCO’s ball bearing experts will be able to isolate those failures to a given stock number and then take necessary precautions. If it is shown to be a factory defect, IBSCO can do a recall of the specific bearing and minimize the impact. For example, a ball bearing in a piece of handheld equipment used in brain surgery heated up so much that doctors couldn’t handle the device. Diagnosis: a lubrication overfill from bearings acquired through a distributor. Traceability made it possible to pinpoint each of the bearing lots that went into the surgical tool for that particular customer.

On the other hand, ruling out a bearing malfunction can help lead to the real cause of a problem. For example, a client reported that a ball bearing was corroding fast. When a review of the suspect bearing lots showed no prior history of problems, the client shifted focus and discovered the culprit to be its own process that allowed etching fluid into the bearing housing assembly.

As industry relies more on high technology, these days, such situations are not isolated incidents. A problem in a manufacturer’s process creates a domino effect that can cause long-lasting harm to business relationships. Every part received and delivered by your bearing supplier should be accompanied with a Manufacturer’s Certification and lot number or traceability identifier. By providing the Manufacturer’s Certification, it makes the distributor 100% accountable for each bearing—from the point of entry to point of delivery. You ought to know what you are getting, whether you’re buying a $2 bearing or a $10 bearing.

Factor Two: Delivery… 
Suppliers that “out-think” the customer are a step ahead. By being prepared, they can significantly reduce lead-times for delivery. This is critical given the fact that in today’s economic climate, delivery time can stretch from 30 to 55 weeks. With IBSCO’s help, Goodrich Aerospace has reduced its delivery time to days—or a few weeks at most—by obeying one rule: Managing inventory well is the key to managing delivery time.

IBSCO manages Goodrich Aerospace’s inventory. In doing so, GA’s needs are evaluated on a weekly basis with the help of a complex computer matrix and extensive data about sales cycles. As a result, short-term trend changes can be accommodated, such as those occasions when product is required sooner or later than anticipated.

That type of flexibility helped Goodrich Aerospace pause in its delivery of a braking system. Components needed to move forward on the project were delayed, forcing GA to hold back its own production. The change was accommodated without harm to the outcome. There have been other instances where replacement parts for military aircraft, for example, came in sooner than expected. Again, communication about what’s in the pipeline and safety stock for unique situations provided the solution.

Also, remember delivery is not just related to time. Procurement and Quality Control requirements are a significant issue. The U.S. government enforces the Defense Federal Acquisition Register Schedule (DFARS). This means all government-contract parts must be manufactured, purchased and built with raw materials from the United States market or a North Atlantic Treaty Organization (NATO) country. If DFARS compliance is required, all raw material and product components must be made from U.S. steel that can be traced back to the milling process. This has grown more difficult as the domestic steel industry has eroded, even as demand and manufacturing costs have increased.

Factor Three: Re-lubrication… 
The ability to re-lubricate bearings serves a dual purpose. First, it restores the shelf life for product with expired use dates. The ability to re-lubricate expired bearings is essential to the aircraft and aerospace industry.

But the primary purpose is producing a custom lubricated bearing. This means while product specific to client needs is stocked, the commonly used sizes are onhand and available for lubing as needed.

Also, buying basic ball bearing stock at bargain prices allowed a medical firm to improve gross sales, even as the value of the U.S. dollar dropped. How? The currency imbalance meant overseas customers would eventually want to buy more American-made products because when the dollar value dropped so did the price. By stocking up on basic parts, the medical firm was well prepared when overseas demand for its equipment increased.

Factor Four: Custom Lubrication… 
Goodrich Aerospace benefits when its provider buys large quantities of “vanilla” stock on its behalf—stock that later can be custom-lubed to GA specs. When incorporated in this type of purchase, OEMs like Goodrich Aerospace may get a better price than they would get from the factory they normally buy from.

Also, as technologies change, adjustments to lube specs may be required. Sometimes re-lubes are needed because the design specs change due to improvements in technology. Dental tools, for example, pose a particular challenge. They require lubricants that can withstand hot-steam cleansings after each use, yet are not so heavy that they promote heat build-up during operation.

Goodrich Aerospace chose IBSCO because of its expertise in custom lubrication blends, fill amounts and understanding the specific needs of the customer.

Factor Five: Certification… 
A factory certification is essential because it includes lot numbers that allow the material to be traced all the way back to the smelting factory. Certification ensures that you’re getting the legitimate part you ordered. You need paperwork to make sure there’s a pedigree.

Lubricants, as well as ball bearings, must be documented. The original factory certification papers must include a lot number and where it was made. Substantial time can be saved if your supplier is factory authorized to do re-lubes. Without this authorization, manufacturers can expect to wait 30 weeks for delivery of a full-warranty product. You need certification detailing what work was done before it was shipped to you. Also, it is essential that the factory scrutinize the processes of the distributor that has been authorized to do full-warranty work—twice a year.

When it comes to ball bearings, those who pay attention to these Five Factors of Excellence should have no trouble rolling along.

Jack O’Donnell has spent 37 years in the bearing business. He has served as president of IBSCO since 1998. IBSCO is a distributor of NHBB, NMB, IJK, Barden and Timken products. Telephone: (800) 231-6480; e-mail: jack.odonnell@ibsco.com

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March 1, 2008
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Taking it to the extreme…Lubes For Severe Environments

0408_techupdateThe places where lubrication is needed aren’t always made to order. Too often, lubricants are required to stand up (and perform without a hitch) under some of the most severe conditions imaginable—extremely hot and cold environments, hazardous surroundings, contaminated areas, etc. The following list reflects companies and products that take care of the critical equipment and processes that must stay up and running in these types of challenging, often remote, situations.

Royal Purple
Most severe-service equipment reliability problems are caused by heat, contamination and/or load. The severity of these conditions impacts lubricant’s ability to adequately lubricate and protect equipment, resulting in premature failure and reduced operating efficiency. Conventional, low-film strength R & O (rust and oxidation inhibited) oils rely almost solely on their viscosity to protect equipment against wear. A new generation of lubricants offers improved oxidation stability to withstand heat and dramatically increased film strength to withstand severe load. Synfilm, from Royal Purple, has become increasingly popular in severe service applications. Synfilm is a long life, high film strength, synthetic lubricant that’s proven to significantly increase the reliability and life of equipment operating in severe conditions.

Royal Purple 
Porter, TX 
www.royal-purple-industrial.com

The Timken Company 
Timken’s Mill Grease is formulated with high VI paraffinic mineral oil, resulting in better oxidation stability than competitor formulas that use low VI naphtenicbase oil. Use this grease when resistance to water washout and performance under broad operating temperatures are absolutely necessary. Design attributes include superior protection against rust and corrosion, including salt spray, and excellent high-temperature properties, including conditions from -40 F to 400 F. The lubricant contains no heavy metals or other environmentally undesirable additives. Timken’s Mill Grease is applicable for steel mills, paper mills, aluminum mills, foundries, cement plants, power generation, off-road applications, mineral processing, offshore rigs and marine applications.

The Timken Company 
Canton, OH
www.timken.com

CITGO Petroleum Corporation 
According to CITGO, its range of synthetics provides exceptional protection for compressors in remote locations, where maintenance and parts replacement demand premium products. CompressorGard PAOs offer superior oxidation and thermal stability for use in rotary vane, rotary screw and centrifugal compressors. The CompressorGard PAGs are recommended for highpressure reciprocating compressors pumping natural gas, hydrogen, helium, CO2 and other polar gases. DE synthetics combine premium diester base stocks with advanced additives for better low-temperature fluidity and thermal conductivity. Compared to conventional lubes, the low vapor pressure of the CompressorGard SS helps reduce oil carryover in a compressed gas stream, and inhibits H2S corrosion. CompressorGard IPG 100 provides increased viscosity at high temperatures, oxidation resistance and good water separation.

CITGO Petroleum Corporation 
Houston, TX
www.citgo.com

Mobil Industrial Lubricants
Mobilgear 600 XP Gear Oil Series is engineered to deliver exceptional, long-lasting wear and corrosion protection for gearboxes, and can help companies become more competitive by raising their productivity. Surpassing the industry’s most demanding specifications, such as Flender BA Table 7300 A, DIN 51517 Part 3 and AGMA 9005 E02, Mobilgear 600 XP helps control micropitting and is designed to significantly reduce the formation of oil degradation by-products that often lead to frequent oil changes.

Mobil Industrial Lubricants 
Fairfax, VA
www.mobilindustrial.com

CRC Industries
CRC’s Extreme Duty Open Gear & Chain Lube is a heavy duty, extreme pressure lubricant recommended for reducing friction and wear in harsh environments. The formula is specially prepared to penetrate pores in metal, with exceptional “stay-put” characteristics. It assures a smooth, long-lasting, economical and effective coating that will not wash or wear off because of harsh weather and will not break down after repeated use. The lube contains Moly and Graphite, providing lubrication and shock protection, preventing scoring and welding of gear teeth. Its black color guides proper coverage, allowing easy touchup. Use CRC Extreme Duty Open Gear & Chain Lube to lubricate open gears, chains, cables or wire ropes. It is ideal for use on quarry and mining equipment, leaf springs, drive chains, screw threads and flexible couplings. It can also be used on racks and pinions, ball and rod mills, trunions, roller gears and winches.

CRC Industries 
Warminster, PA
www.crcindustries.com

ConocoPhillips 
The use of synthetic lubricants has become more widespread in automotive and industrial machinery, partly because of the severe demands imposed on the lubricants by downsizing of oil sumps, generating more power and the more stringent performance requirements established by the OEMs. ConocoPhillips Syncon® & Syndustrial ® synthetic lubricants are commonly used in industrial machinery such as air & gas compressors, aero-derivative turbines, underground mining equipment and gearboxes operating in very cold weather or very high temperature environment. They offer significant advantages over conventional lubricants in terms of low temperature pump ability and easier starts in cold weather, as well as energy savings, superior high temperature protection and longer service intervals.

ConocoPhillips Lubricants 
Houston, TX 
www.conocolubricants.com
www.76lubricants.com
www.phillips66lubricants.com

DuPont 
Designed specifically to perform under harsh conditions and critical chemical service, DuPont™ Krytox® NRT & XHT oils and greases offer an ideal solution to extend equipment life, improve safety and reduce the potential for explosions and fire. Krytox NRT inert lubricants deliver safe, non-reactive, non-flammable lubrication for systems containing LOX, GOX, chlorine and other reactive gasses while extending equipment life. Krytox XHT Extreme High Temperature lubricants perform up to 752 F. From gearboxes, bearings and chains—to seals, actuators, valves, and more—DuPont Krytox NRT & XHT provide unparalleled performance with everyday reliability.

DuPont Performance Lubricants 
Wilmington, DE
www.dupont.com

JET-LUBE, Inc.
JET-LUBE’s industrial 769 Lubricant®, first introduced in 1969, is still delivering high performance in harsh environments. Salt water and salt spray, in particular, are no match for this product. It’s economical, environmentally safe and non-flammable, and it doesn’t evaporate or harden. It contains ashless extreme pressure additives and highly refined lubricating oils that provide superior lubricating protection and anti-wear properties. Additionally, 769 lifts and displaces moisture, while also preventing rust and corrosion. The product is available in a variety of sizes, ranging from 12-oz. aerosol containers to 50-gal. drums.

JET-LUBE, Inc. 
Houston, TX 
www.jetlube.com

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Onboard Pump Intelligence Gives A Timely Heads Up

Kiss unexpected ANSI pump failures good-bye. This industry first is the type of intuitive and efficient early warning system you’ve been wishing for.

0408_solutionspot_2

We all know it. With so few people and so little time to manage and maintain your equipment and processes, your plant’s ANSI pumps simply may not get as much love and attention as your turbines, compressors and higher-ticket pumping equipment. That’s all about to change!

The new i-FRAME from ITT Goulds provides operations personnel, maintenance managers, reliability engineers and technicians—anyone responsible for monitoring and repairing rotating equipment on a 24/7 basis—with early warning of impending trouble so that changes to the process or machine can be made before failure occurs. The unit’s stainless-steel condition monitor (see inset) is nested securely atop the power end to measure critical vibration and temperature readings. Variations that exceed preset parameters will activate the early warning system by displaying flashing red lights—things that are easily recognized during routine walk-arounds.

Great has gotten better 
According to Patrick Prayne, product manager of ITT Goulds ANSI Process Pumps, the company’s Model 3196 is acknowledged to be the most popular process pump in the world. “Now,” he says, “we’ve made it even better. This increased reliability and condition monitoring intelligence gets to the heart of our most important customer requirement—reduced downtime and equipment life cycle cost.”

In addition to the condition monitor built into the pump, the patent-pending i-FRAME incorporates a number of other standard features designed to increase reliability and the life of the pump, including:

  • Premium severe duty thrust bearings that increase fatigue life by 2 to 5 times that of standard bearings.
  • Dual stainless-steel, bronze bearing isolators for improved corrosion resistance and contaminant exclusion.
  • An optimized sump design to improve heat transfer and collect and concentrate contaminants away from the bearings, resulting in longer bearing life.

Model 3196 units with i-Frame power ends also carry a whopping 5-Year Warranty as standard.

Availability
Recognized as a true workhorse in chemical, oil & gas, petrochemical, pulp & paper, and other industrial operations around the globe, the Goulds 3196 comes in 29 different sizes offering a wide range of features for handling challenging applications. According to the manufacturer, its new i-Frame units will be available this April.

ITT Goulds
Seneca Falls, NY

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March 1, 2008
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Compact, durable, lightweight, economical… This New Speed Reducer Takes On Your Toughest Jobs

0408_solutionspotBaldor has introduced the Dodge MagnaGear XTR, an extra-tough speed reducer that has been engineered to offer maximum reliability and superior performance in especially challenging, high-torque applications. According to the manufacturer, the MagnaGear XTR is ideal for bulk material handling in dirty, dusty, harsh environments. That means mining, aggregate, cement, wood products and grain industries, where these robust new products are well suited for a wide range of applications, including conveyors, bucket elevators, feeders, mills and crushers/breakers.

Putting proven technology to work 
Engineered with proven planetary and helical gear technology, the new MagnaGear XTR line covers a full range of horsepowers, up to 2000 HP. Designed as a global product, the reducers are offered with parallel shaft or right-angle configurations, a solid or hollow shaft output and will initially offer torque capacities up to 920,000 lbin. Incorporating a modular design that allows for multiple mounting configurations, they can be used with a variety of soft-start mechanisms.

Developed to meet or exceed AGMA and international standards, heavy-duty, cast iron units feature carburized, hardened and precision-ground gearing. Tandem HBNR lip seals are standard for extra protection. All bearings exceed AGMA standards for L10 life. All components are power matched for optimum performance at a lower installed cost.

A complete line of engineered accessories are available for MagnaGear XTR, including internal lift-off style backstops, cooling systems, rigid couplings, torque arms, swing base mounts, tunnel housings and baseplates.

Baldor Electric Company 
Fort Smith, AR

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6:00 am
March 1, 2008
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Problem Solvers

0408_probsolver_cameraCompact IR Technology

Infrared Cameras’ new compact ICI 7320 is roughly the size of a business card. Offering high image sensitivity and clarity for a 320 x 240 radiometric imager, it operates on a single watt of power using a USB connection. IRFlash software sends real-time radiometric data directly to a hard drive or portable device. Available enclosures provide harsh weather and/or environment protection while meeting all meeting NEMA 4-NEMA 9 specifications.

Infrared Cameras, Inc. 
Beaumont, TX

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Lockout/Tagout Compliance

Brady’s new 16- page “Complete LOTO Solutions” handbook lays out a straightforward “4-Steps to Compliance” plan for creating an effective energy control program. Each step includes an explanation of OSHA’s basic requirements, and provides information on the related resources Brady has available for successful implementation of your lockout/tagout program.

Brady Corporation 
Milwaukee, WI

Interactive Tool Helps Manage Energy Costs

Dow Corning has launched an interactive Molykote® Energy Savings Calculator. The online tools helps manage rising energy prices and carbon dioxide emissions by identifying energy and cost savings available through lubrication best practices. Users enter the number of motors, gearboxes, pumps, compressors and fans, the kilowatts needed to run them, their efficiency, the hours per day and days per year into the calculator. They are shown potential reductions in kilowatt hours, CO2 emissions and the associated cost savings.

Dow Corning
Midland, MI

0408_probsolver_shaftShaft Seals For Dry Bulk Processing

According to Woodex Bearing, its custom-engineered MECO shaft seals can increase MTBF by a factor of 4 or more over packed glands in dry bulk process equipment. Rotating on a plane perpendicular to a shaft means there is no relative motion between the shaft and seal, and, thus, no shaft abrasion damage. Seal faces are soft, faulttolerant and almost impossible to break. Like all MECO seals, these robust products are available fully-split for quick installation and rebuilds. Accommodating 6mm or more total shaft runout/misalignment, shock loads and thermal shaft growth, they also contain no internal springs to loosen, corrode or break.

Woodex Bearing Company
Georgetown, ME

0408_probsolver_trampCompact Tramp Oil Separator

Master Chemical’s Master Coalescer Jr.™ is a compact and affordable processor of machine tool coolants. Designed for use with water-miscible coolants and parts-washing fluids that reject tramp oils, it is available in both wheeled and stationary models. Requiring minimal maintenance, these units allow for maximum removal of tramp oil, even while they are running.

Master Chemical Corporation 
Perrysburg, OH

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Tank & Vessel Level Measurement

The Gladiator Smart Admittance Level Switch from Hawk is designed to detect the level of liquid, slurry or powder in a tank or vessel. Designed to operate in tough environments, it measures the capacitance between a probe and the wall of the container. The Gladiator is simple to set up and calibrate, and has excellent temperature stability. Several probe types are available to meet specific application requirements, and all types are resistant to product build-up.

Hawk Measurement Systems 
Melbourne, Australia

0408_probsolvers_bearingsSelf-Lubricating Bearings For Dry & Submerged Jobs

Metallized Carbon Corporation offers Metcar grades M-161 and M-162 mechanical materials, unique carbon/graphite Babbit impregnated products designed to operate where conventional lubricating methods can’t. At temperatures up to 350 F, they are well suited for lubricating in submerged low viscosity fluids such as water and fuels. For dry environments, they provide oil-free lubrication at high temperatures. According to the manufacturer, because these materials are completely homogenous and provide continuous lubrication for their long service life, they are ideal for use in bearings, bearing assemblies and mechanical components operating at elevated temperatures. Bearings made from Metcar are self-lubricating, non-galling, dimensionally stable and have high compressive strength.

Metallized Carbon Corp.
Ossining, NY

0408_probsolvers_lanceNew Jet Lance

Lightweight and ergonomic, the NCG40-286 water jet lance from NLB Corp. offers a 40,000 psi and 60- second cartridge change. A one-finger latch prevents accidental actuation and its patented trigger design allows the operator to immediately dump pressure by simply pushing the trigger forward. The lance also can be used with the company’s Viper 40™ self-rotating head, producing rotating water jet action without compressed air.

NLB Corp. 
Wixom, MI

0408_probsolvers_oilmistCalling All Safety-Conscious Oil Mist Users

Inpro/Seal’s OM 32 oil mist seal contains no ferrous materials that could generate sparking conditions by sealing faces or magnets upon wear and eventual component d e g r a d a t i o n . Made of 100% non-sparking bronze, it does not contain any contact surfaces to heat up due to the combustion of volatile materials. Plus, it puts an end to mist condensation on surrounding structures. If the rolling element, primary bearing fails, the OM 32 acts as an emergency sleeve bearing to prevent shaft-to-housing contact. Improvements to the original design include the ability to work with low base lubricant viscosities and the addition of VBXX™, a proprietary technology that eliminates the ingress of contamination.

Inpro/Seal Company 
Rock Island, IL

0408_probsolvers_airUpgraded Air Management Equipment

F or storage, handling and unloading of commodities, AIRLANCO offers the AIRAUGER™ unloading system for storage, handling and unloading of commodities. It safely and efficiently empties commodities from storage facilities utilizing both pitched flooring and air—without bin entry. Capable of being installed in new or existing storage units, all mechanical equipment is situated outside the bin for added safety and ease of service. The system also provides bin aeration of the stored commodity with the same ductwork and fans used during unloading operations.

AIRLANCO 
Falls City, NE

0408_probsolvers_loggerMulti-Tasking Data Logger

Omega’s battery-powered, 3-axis OM-CP-ULTRASHOCK101- 50-EB shock recorder measures and records temperature, pressure and humidity at the selected reading rates, while recording shock at peak acceleration rates. Compact and portable, features include CE compliance, 60-day battery life and data retrieval via a COM or USB port.

OMEGA Engineering, Inc.
Stamford, CT

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6:00 am
March 1, 2008
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Our Perspective: Changing Of The Guard

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Ken Bannister, Contributing Editor

Unless you have been in hibernation these past months, you likely have been riveted to unfolding events in what may be one of the most exciting election seasons in United States political history. I am, of course, referring to the race for the Democratic Party’s nomination for President. For the first time, the Democrats will offer the American public either a woman or an African-American as their candidate for the highest office in the land.

As the campaign for President progresses, the candidates for both the Democratic and Republican parties will be offering platforms based on varying degrees of change (i.e. subtle to sweeping changes) to the current administration’s way of doing business. Later, voters will exercise their choice by casting ballots for their preferred platform. That’s how many political systems work—but that’s not how business works. Although politics and business are inherently tied together, business differs greatly when it comes to changes in management.

The first indication most of us receive about a new corporate ownership or the hiring/promotion of a new manager is on the actual day new management takes over. Unlike politics, employees rarely get to influence management change through a democratic questioning and voting process. In and of itself, the changing of the guard is often a good thing in that change must occur if we are to break the status quo and progress. In politics, we can prepare ourselves for change by getting to know the candidates and their platforms prior to voting. In business, we typically aren’t afforded such luxury.

New management/new managers, eager to introduce their version of how the company or department should be managed, often move too quickly and don’t provide their staff adequate time to prepare a business case to showcase any current program excellence. Instead, many first-class programs may be defended poorly and replaced— through ignorance—with inferior approaches.

Over the past decades, I have worked with many corporations that have endured a changing of the guard, in which instantaneous sweeping change frequently has thrown the “baby out with the bath water.” Ironically, in my experience, the program that offers the most for the least expenditure— a lubrication management program—is almost always the first thing on the chopping block. Pending automation of lubrication systems is cancelled in favor of good old grease nipples. Structured lubrication PM tasks are discarded in favor of the good old “lubricate as necessary” approach. Predictive oil sampling is cancelled immediately. It’s all done in the name of costsaving. Thus, small short-term gains are achieved at the expense of large long-term losses.

New management should question their new staff, asking not about what they would get rid of, but rather, what program or part of a program they would keep—and why. If we are not questioned in such a way, we must defend excellence and worthwhile programs by producing the original Return On Investment (ROI) statement, or audit/review that will have documented the original findings creating a need for a program’s introduction. These documents must be presented to the new management along with current success stories, backed up with tangible performance indicators that will include uptime, overall equipment effectiveness (OEE), mean time between failure (MTBF), decreased lubrication-related failures, etc. A good presentation also should include suggestions for making incremental change(s) needed to improve upon the current program.

Defending excellence ensures that good program investment is not lost. This not only makes you look good, it also gives the new management team solid ground from which to manage a successful “changing of the guard.”

Are you ready to defend your lubrication or management program? Good Luck!

Ken Bannister is lead partner and principal consultant for Engtech Industries, Inc. Telephone: (519) 469-9173; e-mail: kbannister@engtechindustries.com

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