ML Sept Oct 2012

Contents
8COVER STORY
Optimizing Oil Change Intervals in Heavy-Duty Vehicles
Whether through driving patterns, oil analysis, algorithms, onboard sensors or other methods, optimizing the oil
drain interval in heavy-duty vehicles is not only possible but practical.
September - October 2012
2AS I SEE IT
Why You Should Inspect Bearing Grease Discharge
The routine inspection and analysis of grease discharge should be a
30 LUBRICATION PROGRAMS
Using Oil Analysis and Daily Inspections
to Improve Lubrication
part of the skill set of operators and technicians responsible for lubri- An effective lubrication-management system can help ensure that
cation, maintenance and machine reliability. machines are well-lubricated and, if a fault or abnormal situation is
6
detected, further analysis or a corrective action can be carried out.
36
FROM THE FIELD
Inhibiting Rust and Corrosion OIL ANALYSIS
to Prevent Machine Failures Vibration and Oil Analysis Techniques
Corrosion is detrimental to a reliability program and should always Reveal Root Cause and Severity
be fought at its root causes. When evaluating mechanical defects in roller elements and gears,
16
there are several techniques that can reveal root cause and severity.
48
VIEWPOINT
How Particle Ingression Impacts CERTIFICATION NEWS
Equipment Reliability Laboratory-Based Technician Skills
Learn to recognize the effects of particle ingression and what you can to be Standardized
do to reduce or eliminate it. ICML assists in the development of a standard to be used by labora-
20
tories worldwide for assessing the skills of technicians and analysts.
52
HYDRAULICS AT WORK
How to Manage Complex Hydraulic Problems IN THE TRENCHES
Maintenance professionals of the 21st century not only must be Understanding the Differences in Base Oil Groups
competent problem-solvers, but they also must be able to wrestle Almost every lubricant started off as just a base oil. Discover how
with complexity and win. to distinguish between base oils in the ve different categories.
242012 SALARY SURVEY

Lubrication Professionals Seeing Bigger Paychecks
When Machinery Lubrication asked its audience of lubrication profes-
54 BACK PAGE BASICS
The Importance of Dirt-Holding
Capacity in Oil Filters
sionals about their occupation, the responses revealed evidence of an Understand the factors that contribute to how well lters hold the
economic recovery and growing optimism. contaminants they catch.
More Editorial Features

40 GET TO KNOW
Departments
22 PRODUCT NEWS
42 TEST YOUR KNOWLEDGE
44 PRODUCT SUPERMARKET
46 NOW ON MACHINERYLUBRICATION.COM 28 CROSSWORD PUZZLER 58 BOOKSTORE
Bearing Lubrication
AS I SEE IT JIM FITCH NORIA CORPORATION
Why You SHOULD

INSPECT BEARING
Grease DISCHARGE
35%
There are three opportunities to What can be Learned
inspect the state of in-service
grease. One is by disassembly (such as by from Purge Discharge
removing the bearing cap), the second is by The discharge from bearings and other
sampling the grease using a probe (ASTM machine components is basically a sample of
D7718), and the third is by examining the the grease condition as it exits (its terminal
of lubrication professionals state). It carries out a historical account of the
purge discharge. The purge discharge is the never inspect the grease
grease thats extruded from exhaust ports, bearings. This includes debris from the
discharge from bearings and other
seals and other openings during relubrica- machine components at their bearing, contaminants the bearing was
tion or machine operation. plant, based on a recent survey exposed to and degradation byproducts from
at machinerylubrication.com the grease. The state of the discharge corre-
Not all grease-lubricated machines have
a purge stream, but many do. Machines lates to the quality and state of lubrication
Some blower/fan bearings
(mostly bearings) that purge grease provide and ultimately the reliability of the bearing.
Some grease-lubricated gearbox bearings So what questions might the purge
a valuable opportunity for inspection. The
Mechanical couplings stream be able to answer? Take a look at the
opportunity is significant because of the
following list for examples:
frequency and simplicity of the inspection. Some process pump bearings Wrong or Mixed Grease A wrong or
Machines that purge are generally total
Some compressor bearings mixed grease color can be observed in the
loss systems, meaning the grease is not
discharge. An incorrect grease consistency
recovered for reuse but instead is discharged Hinge pins and some journal bearings might also be detected.
to a catch-pan, trap, grease thief, exterior Degraded Grease Evidence of oxida-
Agitator bearings
surface or straight to the floor (Figure 1). tion (tar-like), thermal distress and/or dry,
Following are examples of machines that Some extruder bearings
caky grease (oil loss) may be visible.
commonly have a purge stream: Some calender roll bearings Contaminated Grease Signs of water,
Electric motor bearings corrosion, dirt or other impurities can be seen.
In many cases, purging grease through a
Pillow-block bearings (conveyors, etc.) bearing is not recommended, although it is
commonly practiced. The decision to purge There is a story to tell
or not to purge should not be trivialized. To
understand this better, see the sidebar on from the condition
page 4 about purge versus volume control and state of grease
methods for lubricating bearings.
Too often the opportunity to inspect
discharge.
grease discharge is dismissed largely due to
ignorance. In fact, there is a story to tell from Inadequate Grease Volume or Frequency
the condition and state of grease discharge. This is shown from prematurely degraded
This relates both to the state of lubrication and/or contaminated grease.
and the health of the machine. There is also Excessive Grease Volume or Frequency
information to be learned about the applica- Large piles of grease discharge reveal problems
Figure 1. In total loss systems, grease is tion of the grease, the relube frequency and (Figure 2).
discharged to a catch-pan (left), exterior
surface (right) or straight to the floor. the relube volume that can be assessed by Cake-lock Conditions The telltale
Source: OilDoc inspecting grease discharge. sign of this condition is when the catch-pan
2 | September - October 2012 | www.machinerylubrication.com
Machinery
Lubrication
PUBLISHER
Mike Ramsey - mramsey@noria.com
GROUP PUBLISHER
Brett OKelley - bretto@noria.com
Using a Grease Discharge Trap EDITOR-IN-CHIEF
Jason Sowards - jsowards@noria.com
A grease discharge trap (GDT) is a perfect inspec-
tion device. One version of the GDT uses a simple barb SENIOR EDITOR
Jim Fitch - jfitch@noria.com
fitting that is installed in the purge port (also known as
a drain port, vent port or exhaust port). A 1-inch zip- TECHNICAL WRITERS
lock plastic bag (of various lengths) is positioned on the Jeremy Wright - jwright@noria.com
Pete Oviedo - poviedo@noria.com
barb side of the fitting using an O-ring (see photos on the
Josh Pickle - jpickle@noria.com
right). Grease that purges out of the fitting goes straight Wes Cash - wcash@noria.com
into the bag for easy inspection, disposal and sampling.
CREATIVE DIRECTOR
Reasons for Using the GDT Ryan Kiker - rkiker@noria.com
Cleanliness Purged grease is contained in the GRAPHIC ARTISTS
bag and not dispensed to the ground, floor or side Steve Kolker - skolker@noria.com
of the machine. Julia Backus - jbackus@noria.com
Disposal Once the bag is full, it can be removed, Terry Kellam - tkellam@noria.com
sealed (using the zip-lock) and discarded. It is replaced ADVERTISING SALES
with a new bag. Tim Davidson - tdavidson@noria.com
Contamination Control The machine is protected 800-597-5460, ext. 224
from contamination ingestion through the purge MEDIA PRODUCTION MANAGER
port during normal thermal air exchange and wash- Rhonda Johnson - rjohnson@noria.com
down sprays.
CORRESPONDENCE
Unobstructed Purge Path During machine opera-
You may address articles, case studies,
tion, grease can freely purge to the trap to avoid excessive special requests and other correspondence to:
grease volume buildup in the bearing (heat generation Editor-in-chief
and premature bearing failure). MACHINERY LUBRICATION
Inspection of Grease Discharge Volume The Noria Corporation
trap enables easy inspection of the amount of grease 1328 E. 43rd Court Tulsa, Oklahoma 74105
Phone: 918-749-1400 Fax: 918-746-0925
discharge (too much or too little) from auto-lubers and E-mail address: jsowards@noria.com
manual lubrication practices.
Inspection of Grease Condition Look at the color of the grease
including mixed colors (cross-contamination). Touch the grease through
the bag to inspect for solids, grit and grease consistency. Slide a strong
magnet on the outside of the bag to attract large wear particles. MACHINERY LUBRICATION Volume 12 - Issue 5 September-October
Grease Sample Remove the bag with the grease discharge sample. 2012 (USPS 021-695) is published bimonthly by Noria Corporation,
1328 E. 43rd Court, Tulsa, OK 74105-4124. Periodicals postage paid at
Zip it tight, place in a sample bottle and send to a lab for analysis. Tulsa, OK and additional mailing offices. POSTMASTER: Send
address changes and form 3579 to MACHINERY LUBRICATION, P.O.
BOX 47702, Plymouth, MN 55447-0401. Canada Post International
Publications Mail Product (Canadian Distribution) Publications Mail
Agreement #40612608. Send returns (Canada) to BleuChip Interna-
tional, P.O. Box 25542, London, Ontario, N6C 6B2.
only has oil. This means the thickener is binding Obstructed or Diverted Purge Path The SUBSCRIBER SERVICES: The publisher reserves the right to accept or
up in the bearing. normal amount of grease discharge is not reject any subscription. Send subscription orders, change of address and
all subscription related correspondence to: Noria Corporation, P.O. Box
Abnormal Wear Conditions Visible observed, meaning that grease is being diverted 47702, Plymouth, MN 55447. 800-869-6882 or Fax: 866-658-6156.
evidence of wear debris is seen. Use a magnet to to another purge path. Copyright 2012 Noria Corporation. Noria, Machinery Lubrication
and associated logos are trademarks of Noria Corporation. All rights
extract larger wear particles. Solvents can also Auto-Lube Malfunction or Neglected reserved. Reproduction in whole or in part in any form or medium
be used to separate particles from the grease. Grease Gun Relubrication The normal
without express written permission of Noria Corporation is prohibited.
Machinery Lubrication is an independently produced publication of
Noria Corporation. Noria Corporation reserves the right, with respect to
amount of grease discharge is not seen, resulting submissions, to revise, republish and authorize its readers to use the tips
and articles submitted for personal and commercial use. The opinions
in a potential starvation condition. of those interviewed and those who write articles for this magazine are
not necessarily shared by Noria Corporation.
How to Inspect the Discharge CONTENT NOTICE: The recommendations and information provided in
A quick, daily visual inspection is sometimes Machinery Lubrication and its related information properties do not
purport to address all of the safety concerns that may exist. It is the respon-
adequate. Look for abnormal grease discharge, sibility of the user to follow appropriate safety and health practices. Further,
Noria does not make any representations, warranties, express or implied,
color, consistency and location. Clean away the regarding the accuracy, completeness or suitability, of the information or
recommendations provided herewith. Noria shall not be liable for any inju-
discharge so the amount of new discharge (since ries, loss of profits, business, goodwill, data, interruption of business, nor
for incidental or consequential merchantability or fitness of purpose, or
the last inspection) is easily recognized for damages related to the use of information or recommendations provided.
inspection. Alternatively, use a simple grease
discharge trap (see sidebar above). A discharge
Figure 2. This is an example trap is a plastic bag, grease thief or bellows
of excessive lubrication. device connected to the purge port (Figure 3).
September - October 2012 |3
AS I SEE IT
Fourier transform infrared (FTIR) spectroscopy, Karl Fischer, oil

content, analytical ferrography and others.
Artist Spatula/Light Table Inspection Use a common artists
spatula to spread grease across a smooth glass surface. Is the
grease soft, buttery, gummy, tar-like, crusty, cake-like, stringy or
inconsistent in color? Shining a strong light from below the glass
can help you identify clumps, wear debris, contaminants, etc.
Particle Inspection This can be done using solvents (e.g.,
toluene, mineral spirits, petroleum ether, etc.) to break down the
grease. Separate the particles for visual or microscopic inspec-
tion by employing a gold pan, patch test or ferrogram method.
Figure 3. A grease thief (left) and a bellows-type grease Ferrous Density Put some of the grease in a sample bottle
discharge trap (right) can be connected to a purge port.
along with solvents. Tape a strong magnet to the outside of the
bottle and then shake. Observe the ferrous debris collection
Grease exhaust is held by the trap for later inspection, sampling against the magnet. You can also place a magnet underneath a
and/or disposal. gold pan or glass bowl (Figure 4) and swirl.
If the conditions of the discharge merit further inspection,
consider the following:
Lab Analysis Many oil analysis labs can also analyze grease.
Common tests include ferrous density, elemental spectroscopy,
When to Stop Pumping

Grease into a Bearing
Bearings are often lubricated using a grease gun until a fresh grease
purge is observed. While there are many cases when this is best practice,
there are an equal number of cases when it is not.
Anyone who lubricates bearings with a grease gun should understand
the alternative methods and when each should be applied. Of course, the
machine or component manufacturer should always be consulted. Figure 4. A magnet placed under a gold pan or glass bowl can
Noria refers to the two options as the Fresh Grease Purge method enable you to observe ferrous debris in a grease sample.
and the Grease Purge and Volume method. These methods and target
applications are described below: Oil Content Load some of the grease sample in a small
Fresh Grease Purge (FGP) Method bushing the size of a thick wedding ring. Place this on blotter
The bearing is lubricated until fresh grease emerges from the purge paper and examine the amount of oil that wicks out into the
port (vent) or shaft/seal interface, or back-pressure is encountered. paper over a couple of hours. The damp zone relates to oil
When to use the FGP method: content. Try this with new grease first.
Low speed-factor bearings (DNs less than 50,000) with a suitable
purge path (purge port or shaft/seal interface) The routine inspection and analysis of grease discharge should
Bearings specifically designed for purge lubrication such as hinge be a part of the skill set of operators and technicians responsible
pins, bushings, open bearings and some bearings with labyrinth seals for lubrication, maintenance and machine reliability. The discharge
Bearings exposed to high environmental contamination with a
carries bits and pieces of potentially valuable information. This
purge path (purge port or shaft/seal interface)
could range from a clean bill of health to the remnants of a building
Grease Purge and Volume (GPV) Method internal machine graveyard.
The bearing is lubricated until a pre-established maximum volume
of grease has been introduced, fresh grease emerges from the purge
port (vent) or shaft/seal interface, or back-pressure is encountered. About the Author
When to use the GPV method: Jim Fitch has a wealth of in the trenches experience in lubrication,
Electric motor bearings (i.e., electric motors that are intended to oil analysis, tribology and machinery failure investigations. Over the past
be periodically relubricated) two decades, he has presented hundreds of courses on these subjects. Jim
Bearings with speed factors greater than 50,000 (DN) has published more than 200 technical articles, papers and publications.
Bearings with no purge path He serves as a U.S. delegate to the ISO tribology and oil analysis working
Bearings with a possibly restricted purge path
group. Since 2002, he has been director and board member of the Interna-
Bearings with an alternate purge path that could send grease to
an unwanted internal compartment such as a lube oil sump
tional Council for Machinery Lubrication. He is the CEO and a co-founder
of Noria Corporation. Contact Jim at jfitch@noria.com.
4| SSeptember
b -O b 2012 | www.machinerylubrication.com
October hi l bi i
Contamination Control
JEREMY WRIGHT | NORIA CORPORATION

FROM THE
FIELD
Inhibiting RUST and
CORROSION to Prevent
Machine FAILURES
62%
Corrosion costs companies billions of Fe+2 Fe+3 + 1 e-
dollars each year. Much of this loss is The electrons provided from both oxidation
due to the corrosion of iron and steel. When steps are used to reduce oxygen.
exposed to moisture and oxygen, iron and steel O2 (g) + 2 H2O + 4e- 4 OH-
will react, forming an oxide. This oxide does The ferric ions then combine with oxygen to
not firmly adhere to the surface of the metal form ferric oxide, which is then hydrated with
of machinerylubrication.com
and will flake off, causing pitting. Extensive visitors say water is the factor varying amounts of water.
pitting eventually results in weakness and disin- most likely to cause corrosion in In laymans terms: Iron + Oxygen + Water =
tegration of the metal, leading to failure. machine components at their plant Hydrated Iron Oxide (Rust)
Obviously, because of the involvement with Other types of corrosion can occur in
water, rust occurs much more rapidly in moist conditions. However, machine components, namely corrosion from organic acids. These
there are a few other factors that determine the rate of corrosion. organic acids can form in multiple ways and can even be a
One example is the presence of salt. Dissolved salt increases the byproduct of the oil aging (oxidation). They are weak compared to
conductivity of the aqueous solution formed at the surface of the common inorganic acids but still hydrolyze well enough to damage
metal and enhances the rate of electrochemical erosion. Another most metals.
example is heat. The higher the temperature is, the higher the One example is acetic acid. It is mildly corrosive to metals,
corrosion rate will be. including iron, magnesium and zinc, forming hydrogen gas and
salts called acetates:
Fe + 2 CH3COOH (CH3COO)2 Fe + H2
In laymans terms: Iron + Organic Acid = Iron Acetate + Hydrogen
Rust and Corrosion Inhibitors

The best way to stop rust and corrosion is not to allow the metal
to come in contact with water, oxygen or acid. In essence, this is
exactly what rust and corrosion inhibitors do. These additives are
typically compounds that have a high polar attraction toward
metal surfaces. They
chemically bond to the
metal surface, forming a
protective film over the
underlying metal. This
film acts as a barrier that
Rust Formation does not physically allow
the metal to come in
The formation of rust is a very complex process that begins with contact with anything
the oxidation of iron to ferrous (iron +2) ions. that could promote
FeFe+2 + 2 e- corrosion. Some popular
For the next sequence of reactions, both water and oxygen are compounds being used
required. The iron (+2) ions are further oxidized to form ferric are amine succinates and
(iron +3) ions. alkaline earth sulfanates.
6| September - October 2012 | www.machinerylubrication.com
The rust-protective properties of an oil can be hard to evaluate
and are somewhat subjective. For best results, the lab must polish
Corrosion Inhibitor Options or sandblast a test specimen and then immediately coat it with the
oil to be tested. After coating, the lab can then begin subjecting the
Corrosion inhibitors are available in many forms with various specimen to conditions that accompany rust formation. ASTM
functions to protect equipment. Liquid-phase corrosion inhibi- D665, although denoted as Rust Preventative Characteristics of
tors ensure surfaces covered by the liquid will be protected by
Steam Turbine Oil, can be used for any formulation of oil. In this
the strong additives in the fluid. Vapor-phase protection may be
included with the liquid-phase protection or used in dry reser-
test, a steel specimen is immersed in a mixture of distilled or synthetic
voirs. It works by filling the headspace with a vapor that prevents sea water. Over a 24-hour period, the
corrosion. Surface coatings protect systems by adhering to the mixture is agitated and checked for
surface. Generally, surface coatings repel water from the surface the formation of the onset of rust.
and include an additive to reduce corrosion at the surface. Rust and corrosion are detrimental
to your reliability program. Remember
to always fight it at its root causes.
If rust formation cannot be prevented, the rust particles can
Eliminate the root causes of a failure
flake off and contribute to abrasive wear. The iron oxide is much
and you will reduce the likelihood of
harder than the steel surfaces it comes in contact with, so massive
that failures occurrence. Three-body Abrasion
amounts of three-body abrasion occur.
About the Author
Jeremy Wright is vice president of technical services for Noria Corporation.
The best way to stop rust He serves as a senior technical consultant for Lubrication Program Develop-
and corrosion is not to allow

ment projects and as a senior instructor for Norias Fundamentals of Machinery
Lubrication and Advanced Machinery Lubrication training. He is a certified
the metal to come in contact maintenance reliability professional through the Society for Maintenance and
with water, oxygen or acid.

Reliability Professionals, and holds Machine Lubricant Analyst Level III and
Machine Lubrication Technician Level II certifications through the International
Council for Machinery Lubrication. Contact Jeremy at jwright@noria.com.
www.machinerylubrication.com | September - October 2012 |7

ML COVER STORY
ChangeOptimizing Oil
Intervals in Heavy-Duty
8|
Vehicles
September - October 2012 | www.machinerylubrication.com
BY J. BENNETT F ITCH
41%
of lubrication professionals consider
where and how a vehicle is driven as the
most influential factor on the life of the
Sixty years ago a truck engine oil drain (or oil change) would engine oil, based on a recent survey at
have been performed as frequently as every 500 miles. machinerylubrication.com
Because of higher quality lubricants, cleaner fuels, improved filter
technology and more dependable engines, today it is possible to
have an oil drain interval as high as 50,000 miles or more on these 2. Driving Patterns and Conditions Where and how the truck
same types of vehicles. is driven.
Nevertheless, typical oil drain intervals remain around 25,000
miles, and little attention is paid to adjusting this standard due to 3. Oil Properties Quality and formulation performance of the
the diverse environments and other factors these vehicles face. For engine oil.
example, two identically produced vehicles may experience a very Engine Design, Age and Conditions
different oil life; one may reach close to 50,000 miles, while the Engine fuel efficiency is perhaps the most directly correlated
other might be starving for fresh oil by 15,000 miles. This variance factor to the life of the engine oil. It is improved by combustion
in engine oil life is the result of many factors from three main areas: efficiency, which can determine the type and amount of particles
1. Engine Design, Age and Conditions Engine design character- that are blown by the piston rings. Piston blowby is usually the
istics and numerous running conditions can affect oil life primary source for ingression of contaminants into the oil. This
factors from exposures to contaminants and other conditions. can include dirt, water, soot, fuel, nitrogen oxide (NOx) and
www.machinerylubrication.com | September
www.machinerylubrication.com | July- October
- August 2012 |9
COVER STORY
partially burned hydrocar-

bons (HC). Not only does the
combustion efficiency play a
role, but other engine design
factors such as seal efficiency,
temperature control and
emissions control methods
influence the type and
concentration of contami-
nants in the oil.
Some measureable engine
Figure 1
characteristics such as total
operating hours and mileage are unavoidable and will likely lead to Driving Patterns and Conditions
a shortened oil drain interval. However, maintaining a healthy oil- The conditions an engine oil must endure are reflected in the
flow system is manageable by consistently providing sufficient conditions the truck encounters. Driving in extreme temperatures,
filtration and seals. In critical components such as filters, the failure for example, is not a healthy environment for the engine oil. On the
mode does not stop with merely a shorter oil life when subpar one hand, cold starts can cause the oil to thicken, which can impair
bearing and cylinder wall lubrication at start-up. On the other hand,
high heat environments will not only lead to a drop in viscosity but
can also result in harmful chemical reactions such as oxidation
within the oil and shorten oil life. Additionally, severe external condi-
tions like dirt roads and high air humidity increase the probability
that these airborne contaminants will invade the oil, usually by way
of the air intake and through the combustion chamber.
While engine oil has the potential to become contaminated by
several external conditions, any factor that influences fuel efficiency
also affects the life of the oil. Lower fuel efficiency implies that your
engine is not operating at an optimal state, which forces it to work
harder. As a result, your engine oil is also working harder. Some of
these fuel-efficiency factors include steep roads, high loads, stop-
and-go driving, lugging and even the style of driving.
Where and how heavy-duty trucks are driven can result in a
range of fuel efficiency from 2 to 7.5 miles per gallon (MPG). The
Figure 2
MPG number is a useful indicator for determining the engine oils
duty cycle. Engine manufacturers such as MaxxForce and Cummins
conditions are experienced. Figure 1 shows how poor filtration can have recently decided to recommend an oil drain interval based
produce a chain reaction of damaging effects on the engine as well largely on the vehicles fuel-consumption rate.
as higher operational costs. Figure 3 shows how the oil drain interval for the 2010 Maxx-
Filtration is the counter to contamination. Therefore, it is Force engines can range from 18,000 to 40,000 miles. This is
important that the dirt-holding capacity of the filter be in-line with
the anticipated or needed oil drain interval.
In addition to filtration and seals, another engine characteristic
that has an effect on oil drain intervals is the oil capacity or sump How Times Have Changed
size. Basically, with an increased volume of engine oil circulating
within the engine, there will be a decrease in contamination concen- The trucking industry has come a
tration. Larger sump size also means more oil additives and less long way in the past 60 years.
thermal distress. As a result, engine manufacturers that offer the 1949 Oil Drain Interval
largest sump size generally allow for the industrys longest recom- According to its maintenance
mended oil drain interval. guide, Gulf had an oil drain
While all engines are designed to provide healthy conditions for interval recommendation
between 500 and 1,000 miles.
the oil to flow, even the best designed models have some level of
anticipated contamination over time, either generated from 2012 Oil Drain Interval
internal or external sources. Consequently, it is the responsibility of Today, the oil drain interval may
the truck owner to ensure that optimal maintenance and healthy be as much as 50,000 miles.
conditions are stabilized.

COVER STORY
significant compared to the previous non-varying recommendation Drain Interval for Regional and Line Haul, Based on MPG
of 25,000 miles, which was the standard guideline for years. Now, MILES/KILOMETERS
not only will better fuel economy save you on gas, but it should also 50,000 Extended drains possible with oil sampling and review
save you on engine oil consumption. (80,000)
40,000
Oil Properties (64,400)
Diesel engine oils licensed by the American Petroleum Institute 30,000

(48,300)
(API) and the European Automobile Manufacturers Association 20,000
(ACEA) are formulated to provide the best engine-protecting (32,200)
properties and to deliver the longest service life possible. However, 10,000
(16,100)
even the highest quality oil can be challenged by a range of factors
that escalate its own degradation. Not only are the initial condi- 0
4.5 5.0 5.5 6.0 6.5 7.0 7.5
tions (cleanliness, age, etc.) of the engine oil critical but also Drain intervals with centrifuge oil filter Truck MPG
whether the right performance grade of engine oil is selected to Drain intervals without centrifuge oil filter
counteract the stressing conditions and exposures that can Figure 3. The oil drain interval for some engines can range
from 18,000 to 40,000 miles.
shorten an oils life.
Control of Particles and Other Contaminants shorten oil life by combining with other contaminants and condi-
Although one tiny particle might not seem too destructive, it has tions. This may include:
the power to single handedly generate as many as 20 new particles Sludge and Soot Formation of sludge deposits through a
from the time of ingression to when finally removed, obliterated or combination of solid contaminants and moisture results in
settled away. After repeated exposure to particle ingression, increased engine wear and shortened oil life.
contaminated oil may appear to act more like the engines death- Water and Coolant Ingression Moisture, glycol and acids
blow than its lifeblood.
promote corrosion, additive depletion and oil oxidation.
In addition, whenever solid contaminants are present within the
oil and are not filtered out quickly, the effects can involve more Fuel Dilution As fuel becomes diluted, oil films can thin,
than just the sum of the contaminants themselves. These solids can promoting oil oxidation and loss of viscosity.
Figure 4. Whether based on driving, engine or oil conditions, root causes can lead to an increased concentration
of oil contamination and produce a shorter oil life and eventual engine failure.
Choosing Premium Engine Oils long term. Short-term effects include the loss in fuel efficiency
Premium engine oils, which are typically synthetics, are adver- from the declined condition of the engine oil until the next oil
tised to improve performance like fuel economy, startability and drain. Long-term effects involve permanent damage of internal
overall engine cleanliness. However, if the objective is to achieve engine components, which leads to costs related to repairs,
the best engine protection while being cost-effective, then a rebuilds and downtime.
premium engine oil is not always the answer. This argument is It can be quite challenging to determine exactly when this ideal
similar to the decision of whether to buy a hybrid vehicle. For moment to change the engine oil occurs. If the condition of the
instance, if a hybrid provides X amount of fuel-economy engine oil is known continuously, this moment would be:
improvements and costs you Y more to
purchase, it will take you Z years before the
cost-savings benefit applies. If Z is long after
you sell the vehicle, you will have lost money.
Likewise, premium engine oil provides X
benefits, costs you Y more and will take you
Z amount of time to reap these benefits.
Sometimes Z is long after another unfore-
seen or uncontrollable failure occurs, resulting
in a premature oil drain at the very least.
Viscosity and Engine Oil Grades

Since viscosity varies with temperature, it is
important that the engine oil maintains a suit-
able viscosity across the full range of operating
temperatures. To achieve this, high molecular-
weight additives such as viscosity modifiers (or
VI improvers) have thermal-viscosity character-
istics that reduce the rate of change.
The standard engine oil for heavy-duty
trucks has long been 15W-40. At this viscosity
grade, the viscosity level is balanced between
providing sufficient wear protection while mini-
mizing the energy-robbing viscous drag forces.
Nevertheless, if a newer, higher quality engine is
used that is less susceptible to internal engine
wear, then a lower viscosity engine oil such as
10W-30 or 5W-30 may become a preferred
alternative since it will offer improved fuel
economy and oil drain intervals.
Figure 4 shows how these root causes,
whether they are based on driving, engine or oil
conditions, can lead to increased stress and oil
contamination, thus producing a shorter oil life
and eventual engine failure. Any one of these
root causes has the potential to adversely
affect the oil drain interval. Keeping the engine
oil running smoothly and cleanly is key to
increasing the life of the oil and the engine.
The Optimal Oil Drain Interval

The optimal time to change the engine oil is
the moment when the damaging effects of the
deteriorating oil conditions are more signifi-
cant than the costs and time saved by
extending the interval any further. These
damaging effects can be either short term or
www.machinerylubrication.com | September - October 2012 | 13
COVER STORY
When the engine oils attributes Engine Properties That Can Affect Engine Oil Life
degrade to its condemning limit.
Engine Design Emissions Control Oil Capacity and
When there is a loss of base number
Efficiency Methods Flow Rates
(BN) associated with lubricant condi-
tions leading to internal corrosion. Oil Filter Efficiency
Combustion Efficiency EGR and back pressure
When agglomerated soot and (Fuel Economy) on piston seals Oil Sump Size
sludge begin to form and there is a Inefficient Seal Designs Concentrations of NOx,
potential for it to settle or attach on Heat Control soot and other
particles in combustion
internal engine components. chamber
However, since these conditions are
not always known through normal truck
Driving Conditions That Can Affect Engine Oil Life
operation, the best answer lies with the
operators ability to monitor the quality Extreme
of the oil at any given moment either in Fuel Efficiency (MPG) Extreme Environments
Temperatures
real time (on-line sensors) or periodically
by oil analysis. Driving patterns Cold start conditions Dirt roads and
construction sites causing
Oil Analysis Routes (city, highway,
mountains)
Hot ambient conditions
(+90F) more opportunities for
Although oil analysis can be successful contaminant ingression
High loads, altitudes
in determining the optimal oil drain High air humidity
interval, it isnt cheap. For this reason, it is Extended idling
essential that a proper procedure (for Figure 5
both sampling and testing) is performed
in order to obtain useful results. Some basic elements that are
Symptomatic Diagnoses
The health of the engine oil is critical to the health of the engine
important to follow include:
and the vehicle as a whole. In many ways, the engine oil in a vehicle
Optimum and consistent sampling intervals and methods
can be compared to circulating blood in the human body. For
Thorough operating and maintenance records including MPG, example, engine oil is circulated throughout various engine compo-
oil type, maintenance logs, make-up oil volume, driving nents to provide wear protection that keeps the engine functioning
patterns, idling time, run time/distance, etc. properly, helps maintain a good engine temperature, cleans out
Optimum test slate and data interpretation strategy contamination, and contains characteristics that inhibit corrosion
and improve sealing.
One of the main properties of an engine oil is the ability to Likewise, the blood in a human body is circulated throughout
neutralize acids. To help improve this ability, engine oil is formulated various organs to provide nutrients that keep the body functioning
with alkaline additives (typically detergents). This alkalinity, which properly, helps maintain a good body temperature, cleans out
can be measured as the BN, provides a good evaluation of an impor-
metabolic waste, and contains characteristics that inhibit infec-
tant aging property of the oil. This is because the BN will drop as the
tious diseases, bacteria and parasites. Engine oil is filtered by an oil
oil begins to oxidize or become excessively contaminated with glycol
filter, and blood is filtered by organs such as the spleen and liver.
or acidic combustion blowby. Just as fuel efficiency may be the single
most influential factor that decreases oil life, BN is perhaps the Fuel Economy vs. Average Speed Calibration Map ODI Estimations
single most reliable direct measure of engine oil degradation. 7
Other important factors include soot load, soot dispersancy, Highway, Light Loads
contamination and additive depletion. 6.5
40,000 miles
Operator and Fleet Owner Estimations 6
400 hours
When estimating the optimal oil drain interval, fleet owners

and owner-operators have different challenges and advantages. City School Bus
5.5
Fleet owners can utilize a large number of data from common 30,000 miles
routes to develop truck-based and route-based trend analysis, 5
which can be very reliable. Owner-operators of trucks driven 300 hours
solely by one or two people can make reasonable estimations 4.5
Heavy Loads in
Heavy Loads in Steep Grades
due to the drivers understanding of the vehicles tendencies and Construction Sites
20,000 miles
operating history. The operators ability to monitor the driving 4
style, operating environment (e.g., climate, ambient dust and 10 20 30 40 50
Average MPH
terrain), selected engine oil and filter, engine efficiency, etc., can Note: This is only a theoretical representation
and is not based on test data.
also help achieve the optimal oil drain interval. Figure 6

If a calibrated map similar to this was formu-
Published Algorithms for Calculating the Oil Drain Interval lated with an algorithm incorporating all the
engine oil factors mentioned previously, a
Kublin Method
cubic inches more reliable method of pinpointing the right
(virgin BN)(10)(oil capacity) (mpg) = oil change
horsepower time for an oil change could be determined.
The best part about this method is that
Paradise Garage Method
all the information can already be supplied by
(tested BN) the engines control module. If onboard
tested miles + tested miles = oil change
(virgin BN) sensors were included to provide more infor-
mation about the contamination levels in the
Heidebrecht Method
oil, then the reliability of this method could be
(total oil)(virgin BN target BN) expected to increase considerably.
= oil change
(cylinder bore)()(no. cylinders)(compression ratio)(neutralization) In summary, the end of oil life is influenced
Figure 7 by a complex array of factors. Many of these can
be monitored, controlled and used to optimize
Blood is useful not only because of what it provides the body but the oil drain interval. These include driving patterns, oil analysis,
also because of what it can indicate about the condition of the algorithms, onboard sensors or any of the other methods previously
body. When a patient goes to the doctor with an unknown illness, described. Furthermore, the benefits extend far beyond keeping the
the doctor will first try to determine the cause by using the known oil clean. Contamination in engine oil is damaging to the engines
symptoms. If this is not enough, a blood sample can be taken and operation, but it can also provide clues to subpar engine operation,
examined in a lab. The blood acts as a signature of the body as a premature engine failure and less than optimal oil life.
whole, offering additional clues as to the cause of the illness.
Engine oil provides this same kind of signature for the engine and all About the Author
the components through which it flows. An engine may have observa- Bennett Fitch is a technical consultant with Noria Corporation. He is a
tional symptoms of how well it is operating, but sometimes these are mechanical engineer focusing on machinery lubrication and maintenance
not enough to indicate engine failure. If an oil sample is taken and in support of Norias Lubrication Program Development (LPD). Contact
examined in a lab, the particles found can offer clues that could predict Bennett at bfitch@noria.com.
failure long before any signs are observed.
While understanding the condition of the
engine oil in order to detect clues of an engine
failure is important, the changing condition of
the oil is also a means of failure. To identify the
optimal oil drain interval, consider all the
factors and symptoms.
Increasingly, vehicle manufacturers,
including heavy-duty truck manufacturers,
offer in-dash indicators to alert the driver
when the engine oil needs to be changed.
However, many of these are based solely on a
single factor, such as mileage or engine hours,
to assist the driver with when the oil was last
changed. In some higher end vehicles, more
sophisticated methods are utilized, including
direct measurements, algorithm methods or a
combination of the two.
Direct measurements may employ a
variety of onboard sensors through electric
capacitance or a micromechanical resonator,
which can detect and roughly measure the
amount of contaminants in the oil. Algo-
rithmic methods use several variables
provided by the engines control module,
including oil temperature change, oil level,
miles per gallon and average miles per hour.
Figure 6 demonstrates how just two
measurements (miles per gallon and average
miles per hour) influence the oil drain interval.
Contamination Control
PETE OVIEDO NORIA CORPORATION
VIEWPOINT
HOW PARTICLE
Ingression IMPACTS
EQUIPMENT Reliability
85%
Ingression can be defined as a going in Most workers must deal with real-world
or entering, a right or permission to conditions and may need to repair equipment
enter, or a means or place of entering. If you out in the field. In these situations, take time
have attended one of Norias Fundamentals of to prep the area prior to opening an inspec-
Machinery Lubrication courses, Im sure you tion door or bearing housing. This would
understand the importance of reducing, mini- of lubrication professionals say include at the very least cleaning away debris
mizing and eliminating particle ingression. particle ingression has caused from the inspection door or knocking off dust
Because of the negative impact particle problems for their plants equip- from overhead beams or adjacent machines.
ingression has on equipment reliability, it is ment, according to a recent survey Often it is the little things that make a big
at machinerylubrication.com
critical to recognize the effects, how particles difference. Maintaining a clean area as well as
enter equipment and what you can do to clean tools and performing proper flushing of
reduce or eliminate ingression. the equipment to remove any debris left behind
Particle ingression leads to contact fatigue, spalling, pitting, can increase machine reliability. You have to give your equipment
brinelling and cratering. Surface fatigue often develops from the best opportunity to perform its intended function, and mini-
denting due to hard or soft particles. This creates a stress riser mizing or eliminating in-service ingression is essential to achieve
(berm). Repeated high loading (stress reversals) on berms or parti- this objective.
cles causes surface fatigue and eventually the formation of pits.
This leads to larger pits followed by spalls.
Particles can enter equipment through various means, such as It is paramount to take all
through a process or a mechanical service that is performed after a
failure or inspection. Therefore, it is paramount to take all precau-
precautions to minimize or
tions to minimize or eliminate any contaminants (dust, water, etc.) eliminate any contaminants from
from coming into the equipment. coming into the equipment.
Ingression can also occur due to process conditions. This

usually is the result of damaged seals or breathers and in-service
equipment temperature changes, which can produce moisture
within the machinery.
Faulty seals can allow contaminant ingression, which may lead
to surface degradation. Machinery inspections should be
performed routinely. Repairs, modifications and purchasing
improved seals may be necessary to improve equipment reliability.
Keep in mind that not all seals are created equal. A proper
assessment of your equipment as it pertains to temperature and
the type of lubricant that you are using is crucial. Many times the
lubricant and the seal may be incompatible, which can result in oil
leaks. Remember, if you observe oil leaking out, there is an oppor-
tunity for contaminants to get inside the equipment.
Six to seven percent ($795 billion*) of the gross national product is
required just to repair the damage caused by mechanical wear. The selection of breathers and monitoring breather condition
MIT Professor Ernest Rabinowicz provide another method of reducing ingression. Whether you are
3 Types of Particle Ingression
There are three general types of solid particle ingression:
built-in, ingested and generated.
Built-in contamination consists of manufacturing debris
such as burrs, machining swarf, weld spatter, abrasives, drill
turnings, filings and dust. It can also include service debris
that occurs when machines are opened for routine repairs and
preventive maintenance.
Ingested particle ingression means that particles are coming
into the machine and the lubricant under normal operating
conditions (from the outside to the inside). These could be
process particles (pulp, pulverized coal, ore dust, cement, clays,
process chemicals, etc.), atmospheric contaminants (the result of
ambient or road conditions near the machine), or combustion
debris from internal combustion engines (soot, fly ash, induction
air and contaminated fuel).
Generated particle ingression is when the machine makes its
own particles. This can occur on internal surfaces through corro-
sion, mechanical wear, cavitation, exfoliation, etc. The oil also
has the ability to break down and form particles (sludge, oxide
insolubles, carbonization, coke, etc.).
using them to eliminate dirt or water ingression, breathers are

imperative for machine health. They must be selected according to
the machinery conditions and environment. Frequently, breathers
are not monitored properly. Like oil filters, they have an intended
purpose and function well; however, once they reach the end of
their life cycle, it is important to replace them promptly.
Remember, education is key. Understanding how ingression

affects oil and equipment life is critical. Look beyond the obvious.
Whether it is a color change of a breather, oil leaking from a seal, or
water ingression in the oil, recognizing the effects of ingression can
help you act promptly to improve machine reliability.
About the Author
Pete Oviedo Jr. is a senior technical consultant with Noria Corpora-
tion, focusing on machinery lubrication and training. He has more than
20 years of experience with machinery and rotating equipment, as well
as an understanding of laser alignment, balancing rotating equipment,
thermography, magnetic particle and ultrasonic flaw detectors. Need help
with your lubrication program? Contact Pete at poviedo@noria.com.
ML LUBE TIPS
GEAR ALIGNMENT
AFFECTS LUBRICATION
Worm gearing alignment affects lubrication. If the worm is
located off the worm gear centerline, there may be entering The Lube Tips section of Machinery Lubrication magazine
corner contact. This wipes the lubricant off the worm gear teeth and features innovative ideas submitted by our readers. Additional tips
the worm thread like a squeegee, causing the mesh to be starved for can be found in our Lube-Tips e-mail newsletter. If you have a tip
lubricant. The resulting wear is progressive and almost always leads to share, e-mail it to us at editor@noria.com. To sign up for the
to the need to replace both the worm and the worm gear. Lube-Tips newsletter, visit www.machinerylubrication.com and
An easy way to prevent click on the Newsletters link at the top.
this type of failure is to
perform a contact pattern
Sight Gauge Simplifies Inspection
check when the worm gear
Consider adding a vertical sight gauge to
and worm are installed or
critical gearboxes that are not fitted with a
being replaced. Most texts
on worm gearing show both dipstick or a sight glass, where the only
acceptable and unaccept- way to check the oil level is to take out
able contact patterns for the level plug.
this unloaded condition. If Fitting a sight gauge allows the
in doubt, contact the worm oil to be checked on the run and
gear drive vendor or the can indicate the oil level even if the
drive manufacturer. gearbox is mounted in an unusual
Oil analysis would show orientation. However, there are
this condition as high levels some important points to
of copper from the worm remember: First, fit the gauge to a
gear. The copper levels will low point (preferably the drain) and
increase over time rather not the level plug, as you could overfill
than decrease, as is the case for normal break in. Visual inspection the box. Second, to avoid mistakes, mark
would show wear on the worm gear tooth from the tip to the root at the static level and the running level on the gauge.
the edge of the tooth that sees the thread entry into mesh. There may Third, make sure the gearbox has a breather. Otherwise, a partial
also be a transfer of bronze from the worm gear to the worm thread.
vacuum could be set up, also giving a false reading.
Rule of Thumb for Selecting Oils Advice for Tracking Oil Loss
The pour point is the lowest temperature at which an oil will
If you decide to implement a program to
flow. This property is crucial for oils that must flow at low tempera-
control oil losses, one of the first steps
tures. A commonly used rule of thumb when selecting oils is to
you should take is to check records of
ensure that the pour point is at least 10 degrees C (20 degrees F)
the amount purchased compared
below the lowest anticipated ambient temperature.
with the amount sent for
How to Store and Preserve Parts disposal. Try to account for
Try using a vacuum-packaging unit (the kind used for storing the difference by looking
food for freezing) to help with parts storage and preservation. This for leaks, products
quick and simple method can be utilized to keep items clean and consumed in the
dry. Parts can be sealed in plastic, with a desiccant bag for good process, evapora-
measure. It can also be used to keep small parts organized until tive losses and
they are needed, such as a matched set of coupling bolts, springs or products wasted due to
electronic parts. contamination or misapplication.
Hydraulics
HYDRAULICS BRENDAN CASEY
AT WORK
MANAGE HOW TO
COMPLEX Hydraulic
PROBLEMS
In 1935 the U.S. Army Air Corps held a fly-off between The story doesnt end there, but first let me explain my reason
two aircraft vying to win the contract for the militarys next for recounting it here and why it has relevance to all of us today
long-range bomber. The competition was regarded as a mere nearly 80 years after the event. Its a story about coping with
formality because Boeings Model 299 was the logical choice. It complexity and a graphic illustration of how technological advance-
could carry five times as many bombs as the army had specified and ment and the complexity it often creates brings with it what Atul
fly faster with twice the range of previous bombers. Gawande describes in his book, The Checklist Manifesto, as entirely
At the allotted place and time, a small crowd of army brass and new ways to fail.
manufacturer representatives watched as the Model 299
test plane taxied onto the runway. The airplane took off
effortlessly and climbed steeply to 300 feet. The small group Maintenance professionals not only
of spectators watched in horror as the plane suddenly stalled
and dropped out of the sky. The Model 299 test plane
must be competent problem-solvers,
exploded in a fireball when it smashed into the ground, but they also must be able to wrestle
killing two of the five crew members, including the pilot.
The subsequent investigation revealed there was no
with complexity and win.
mechanical fault with the aircraft. The crash had been
caused by pilot error. The Model 299 was significantly more Believe it or not, complexity is a science all on its own. In Gawa-
complex than any previous aircraft. This new plane required the ndes book, he references the work of two professors in this field,
pilot to manage four engines, each with its own air-fuel mix, retract- Brenda Zimmerman of York University and Sholom Glouberman of
able landing gear, wing flaps, electric trim tabs, variable-pitch the University of Toronto, who have come up with a three-tier clas-
propellers and many other bells and whistles. While doing all this, sification system for the different kinds of problems we face in the
the test pilot had forgotten to release a mechanism that locked the world: simple, complicated and complex.
elevator and rudder controls. Simple problems, they suggest, are like baking a cake. Theres
As a result, the Boeing aircraft was deemed too much airplane a recipe and sometimes a few basic techniques to learn, but once
for one man to fly. The army declared Douglas competing design these are mastered, following the recipe results in a high proba-
the winner, and Boeing nearly went bankrupt. bility of success.
Complicated problems are like sending a spaceship to the
moon. There is no straightforward recipe. Unanticipated
The Power of Checklists setbacks go with the territory. Coordination and timing
are critical to success. However, once youve figured out
Under conditions of complexity, our brains are not enough, said
how to send one rocket to the moon, the process can be
Atul Gawande during a recent lecture series. We will fail. Knowledge
has exceeded our capabilities. But with groups of people who can work
repeated and perfected.
together and take advantage of multiple brains preparing and being Complex problems are like raising a child. Every child is unique.
disciplined, we can do great and ambitious things. As we turn to some- While raising one child provides experience, it doesnt guarantee
thing like a checklist, what we see is something that is lowly, humble, success in raising another. In these situations, expertise is valuable
overlooked and I think misunderstood. But when we pay attention to but not necessarily sufficient. The outcomes of complex problems
where our weaknesses are and then pay attention to how something
are also highly uncertain.
like a checklist works to supplement the failings of our brains and the
This hierarchy of problems has merit, but its telling that the
difficulties teams have in making things come together, what you realize
is that an idea like this can be transformative. people who came up with it are professors of complexity and not
simplicity. I have an alternative problem-classification system that
20 |SSeptember- O t b 2012 | www.machinerylubrication.com
t b October hi l b i ti
will never make it into any academic
journal but that has practical application
all the same. It involves obvious and invis-
ible problems.
Obvious problems are the ones we can
80%
of machinerylubrication.com
visitors use checklists for
hydraulics. In Insider Secrets to Hydraulics, I
expound the benefits of developing and
using a pre-start checklist to prevent
infant mortality. In Machinery Lubrication,
the idea of an equipment pre-purchase
or should see and address but happily maintenance work at their plant. checklist has been advanced and discussed
ignore while we get consumed trying to in some detail. More recently, Ive devel-
find invisible ones. For instance, global oped a process and accompanying
warming is still in many respects an invisible problem. On the checklist for effective troubleshooting. These examples are by no
other hand, thousands of coal furnaces billowing smoke into the means exhaustive.
atmosphere all over the world are an obvious problem. If the Clearly the pace of technological advancement shows no
focus was on fixing the obvious problem (global pollution and signs of slackening. If anything, its accelerating. This means
smog), the long-running argument about the invisible problem maintenance professionals of the 21st century not only must be
(global warming) may not even be necessary. competent problem-solvers, but they also must be able to
Both of these problem-classification systems have application. wrestle with complexity and win. Checklists can be a big
For example, according to the professors definition, troubleshooting help. Modern-day pilots are trained to rely on them. Why
is a complex problem. Success in one troubleshooting assignment shouldnt we?
doesnt guarantee success in another. Experience is valuable but not
necessarily sufficient. In addition, the outcome is often uncertain. About the Author
This doesnt mean the cause of the problem is always invisible. Brendan Casey is the founder of HydraulicSupermarket.com
Often its not. A problem can be complex in appearance, but its and the author of Insider Secrets to Hydraulics, Preventing Hydraulic Fail-
causation (and solution) can be quite obvious. This is why the ures, Hydraulics Made Easy, Advanced Hydraulic Control and The Definitive
troubleshooting process should always begin with the checking and Guide to Hydraulic Troubleshooting. A fluid power specialist with an
elimination of all the easy and obvious things first. Resist the temp- MBA, he has more than 20 years of experience in the design, main-
tation to go looking for the invisible unless or until you have to. tenance and repair of mobile and industrial hydraulic equipment.
These days, increasing complexity combined with an overwhelming Visit his Web site at www.HydraulicSupermarket.com.
amount of work and a severely limited amount of
time often mean the only way to survive is by
addressing the biggest problems to their shal-
lowest depth. This is a frustrating, futile and
sometimes deadly position to be in.
It was no different back in 1935. Despite the
Model 299 being declared too much airplane
for one man to fly, a few army insiders were
convinced it was flyable. So several aircraft
were purchased as test planes, and a group of
army test pilots got together to figure out what
to do. They concluded that flying this new
plane was too complicated to be left to the
memory of any one man, regardless of how well
he was trained. So they created the very first
pilots checklist.
The result, as outlined in Gawandes book,
was that the Model 299 went on to fly 1.8
million miles without a single accident. The
army ended up ordering 13,000 units of what
became the B-17 bomber, an aircraft that gave
the United States a decisive air advantage
during World War II.
This outcome is a great advertisement for the
value of checklists as a tool for coping with
complexity (and the perils of relying on memory).
The use of checklists is something Ive long
regarded as having practical application in
OIL ANALYSIS SYSTEM
The new OilExpress 4 system from PerkinElmer was created to provide faster oil
analysis. It features a Spectrum Two FTIR spectrometer and multi-
PRODUCT NEWS
tip sampling capabilities with a synchronized multi-tasking

autosampler. Designed to monitor for contaminants and
degradation products in oil, the system also enables
a reduction in cost per sample and a diminished envi-
ronmental impact by delivering up to 100 samples per
hour, as well as an 80-percent reduction in solvent and
waste volumes compared to previous models.
PerkinElmer
www.perkinelmer.com
800-762-4000
AUTOMATIC LUBRICATOR
The Memolub One LPS is a low-pressure, single-point
automatic lubricator with a simple operation and low
environmental impact. It is designed to save time, money,
labor and bearings with precise metered lubricant injection,
simple programming and replaceable lube cartridges. The
Memolub One LPS can be remotely mounted up to 6 feet
from the lube point, minimiz-
ing the danger of accessing
critical points. The replace-
able lubricant cartridge and
battery pack are the only
consumables required.
Memolub International
www.memolub.com
WATER-IN-OIL MONITOR
800-635-8170 The E+E Elektronik series EE36 transmitter pro-
vides online monitoring of moisture content in
oil. The device measures water activity and oil
temperature at line pressures up to 300 psi (20
bar) and calculates the absolute water content
in parts per million. Besides two analog outputs,
the EE36 features an optional alarm output and a
pluggable display. The capacitive humidity sensor
element ensures stability, accuracy and resistance
against chemical pollutants.
E+E Elektronik
www.epluse.com
781-828-6200
CONTAMINATION SENSOR
The HYDAC Metallic Contamination Sensor MCS 1000 monitors metallic par-
ticle contamination in lubrication uid. An ideal supplement to optical sensors,
the device can identify metallic particles greater than 100 microns. Particles are
detected by inductive measurement in which a coil
system serves as the core element of the sensor.
The MCS 1000 continuously monitors the status
of the system and provides information on any
early stage damage to prevent plant downtime.
HYDAC
www.hydac.com
49-6897-509-01
22 September - October 2012 | www.machinerylubrication.com

FILTRATION UNIT
Y2K Fluid Powers new compact ltration unit is
ideal when space is limited for use or storage.
Engineered for ushing small gearboxes and/
or lube systems, the hand-held power
lter unit will accept various lter
media sizes to meet application
requirements. It comes with a 1-hp
motor, 3-foot electric cord, differen-
tial visual indicators, steel dust plugs,
suction and discharge hoses with quick
disconnects, and a pump capacity of
up to 5 gallons per minute.
Y2K Fluid Power
www.y2kfluidpower.com
888-925-8882
DESICCANT BREATHER
The new Guardian breather from Air
Sentry features an internal check valve
that isolates the adsorbent from exhaust
air. Constructed with a chemical-, tem-
perature- and impact-resistant casing,
the breathers have metal reinforcement
molded into each end cap to protect against
vibration and incorporate a pressure gauge to
provide an additional visual indicator of lter
condition. The new design also allows more than one cartridge to
be used in a single installation, extending the service life of each
breather while reducing cost and maintenance intervals.
Air Sentry
www.airsentrybreathers.com
855-242-2792
FILTRATION STATION
The new Asset Management Filtration Station
(AMFS) from Schroeder Industries offers ltra- SWITCH PLATE
tion with uid-quality monitoring, tracking and LUBRICANT
reporting capability via an enhanced software The new UltraLube switch plate lubri-
program. The AMFS is equipped with an onboard cants are formulated with natural
PC and controller that logs all of the data while seed oils and additives to protect
ushing, ltering and monitoring to ISO clean- railway switches from wear as well as
liness codes. The ltration station can prevent rust and corrosion. Recom-
be programmed to run until the desired mended for use in environmentally
cleanliness codes are achieved. The sensitive areas near waterways, the
touch-screen display provides real- lubricants were created to be poured,
time graphics for easy monitoring of brushed, wiped or sprayed on rail-
the ltering progress. road switches. They help inhibit dust
Schroeder Industries and dirt buildup while resisting wash-
www.schroederindustries.com out from rain or melting ice.
800-722-4810 UltraLube
www.UltraLube.com
800-545-1689
www.machinerylubrication.com | September - October 2012 23

ML 2012 SALARY SURVEY
LUBRICATION
Professionals SEEING
BIGGER Paychecks
When Machinery Lubrication recently asked its audience of lubrication professionals about their occupa-
tion, including their salary, benefits and tenure, the responses revealed evidence of an economic recovery
and growing optimism in the overall job market. Do you agree? Take the survey for yourself and see where
you fit in with other lubrication workers.

2012 SALARY SURVEY

ML CROSSWORD PUZZLER
Get a Printable Version
of This Puzzle Online at:
MachineryLubrication.com/puzzle
1 2
4 5
7 8
10
11
12 13
14
15
16
Get the solution on page 34

LUBRICATION PROGRAMS
BY M ARC VILA F ORTEZA , PETRONOR, SPAIN
Using Oil Analysis and

Daily
Inspections
Improve Lubrication
to
I In large industrial plants where a great number of machines

are installed, it is necessary to implement an effective lubrica-
tion-management system. This type of system can help ensure
that machines are well-lubricated and, if a fault or any abnormal
situation is detected, further analysis or a corrective action can
be carried out.
To make the system work, a machine database with well-
defined lubrication points and scheduled lube routes is required. It
is also essential to make good use of the data collected daily by the
lubrication crew. If this information is promptly introduced into
the database and generates an alarm when the machine is in poor
condition, the reliability engineer can fix many potential problems.
Lubrication routes and preventive maintenance (PM) can be
modified automatically by lubrication software based on simple
oil analysis and field inspection infor-
A field inspection should provide information
mation provided by the lubrication on the lube oil system conditions and the
crew. These tailored routes can mechanical condition of the machine.
improve effectiveness by focusing on of lubricant also should be delivered to the proper lubricating
critical machines, which are checked points in the right quantity and on schedule to optimize the
more frequently depending on the human and material resources.
condition of the lube oil and the When implementing such a system, several key factors
lubrication system. must be taken into account to allow for the effective moni-
toring of the machines at a reasonable cost. The following
Lubrication Management tasks should be performed during the design of any lubrica-
and Scheduled Lube Routes tion-management system:
Before providing details on Develop a Machine Database
tailoring lube routes, lets define
This first step involves recording all the machines to be lubri-
what an effective lubrication-
cated in a database, along with their lubricating points and the
management system is as well as its
appropriate lubricant. The database should be flexible enough
main objectives. Generally, the
to adapt to such changes as machine revamps or oil type
purpose of a lubrication-manage-
upgrades. It should also allow for the historical recording of inci-
ment system is to schedule and plan
the lubricating tasks of the machinery dents that are documented on the lubrication routes.
The information collected by the
lubrication crew will help the reli- in the plant and to properly manage Audit Lubricant Types
ability engineer focus his analysis
only on the critical machines and
the field information supplied by the Once a machine database has been developed, the location
their specific problems. lubrication crew. The correct grade of the lubricant service stations and the machines that use those
lubricants must be studied in order to optimize the distance trav- not only to perform good quality work but also to provide reli-
elled by the lubrication crew. At this point, it is also important to able daily information regarding the lube and mechanical
standardize the lubricant types to a minimum that meets the condition of the machines inspected during the route.
machine manufacturers requirements. In addition to performing all the work and inspections
detailed in the routes, any qualified member of the lubrication
crew should be able to:
Carry out simple corrective maintenance jobs related to the
lubricating systems.
Perform quick visual inspections of the lube oil quality
(moisture, particles, color, debris, etc.) and report its status
in the lube route guideline table.
Ask his or her manager or the reliability engineer about
further analysis of critical machines that are considered to
be in poor condition.
Report any other observed anomaly that could affect the
machine or personal safety.
This template was designed for use as a lubrication route guideline. The information collected about the machines condition
Create Lubrication Routes must be reliable in order to allow for a complete subsequent
The lubrication specialists or the reliability engineers must analysis by the reliability engineer. This is of great importance
create the lube routes. These routes consist of a series of points because any information reported by the lubrication crew will
to be lubricated (divided into geographical areas or into help the engineer focus his analysis only on the critical machines
production units) with related tasks to be performed on a and their specific problems. This will save time and labor, as the
detailed schedule. field information is first filtered by qualified personnel, which
simplifies the job of the reliability engineer.
Design a Template If special care is taken during the filtering of the field informa-
A template can be designed for use as a lubrication guide
tion to register all of the data consistently and with a coherent
when performing field work. The template should include all the
structure, the task of the reliability staff will be simpler and the
relevant information for the lubrication operators such as iden-
historic data will be easier to search.
tification numbers of the machines to be inspected, lubricating
points, the lubricant to be used at each point and tasks to be
performed. There should also be open fields in the guide table in
order to note any observation or anomaly detected.
Establish a Procedure for Work Orders
Lubrication work orders should be generated with a frequency
that allows for proper planning of the work and should be deliv-
ered with the specific work plan attached. Also, be sure to print
and detail the work plan for the personnel who will actually carry
out the job to avoid unscheduled work and downtime.
Determine Who Performs the Lube Routes
It is important to decide which members of the staff will be in
charge of lubricating the machinery to avoid delays in the task
execution. Keep in mind that in this type of work, any problem
will affect all subsequent lubrication routes, which can cause
serious damage to machinery.
This is an example of a lube oil alarm panel.
If all of these steps are followed during the implementation of
a lubrication-management system, it will be much easier to
achieve the desired result in terms of machine reliability.
Using Field Inspections from Lube Routes
Depending on the work experience of the lube staff and the
The Importance of Reliable Field Data available time intended for the lubricating tasks, the lubrication
Once the lubrication plan has been created and the material operator should provide the following information about the
and human resources required are clear, it is essential to utilize machine condition:
qualified personnel (or contact a qualified lubrication company) Visual analysis of the lube oil condition (water contamina-
to carry out the lubrication tasks. Qualified personnel is needed tion, debris, oil temperature, color, etc.)
Lube oil system condition (oil leaks, tank cleanliness and about the machine status can be used to improve the schedule and
superficial condition, oil filters, oil drains, etc.) inspect the machines that are in poor condition more frequently.
The difficulty lies in how to combine all of this data and find useful
Mechanical condition of the machine (vibration, noise,
rules to be incorporated in the software. Any strategy should be in
bearing temperature, etc.)
accordance with the general lubrication schedule and should not
Miscellaneous (information on new machinery installed at change planned work orders.
the plant, reports of other problems in the plant that affect The lubrication frequency of points in poor condition that
the lubricated machines, etc.) need to be inspected again will correspond to the maximum
number of lube points included in the same processing unit of the
All of this information should be recorded by the lubrication
plant. For example, lets say the available lubrication frequencies in
crew in the report table of the route for the
inspected machine. This data should be added to
the system database as soon as possible in order
to help the engineer promptly solve any problems
Qualified personnel is needed to provide

reliable information regarding the lube
and mechanical condition of machines
inspected during a route.
detected within the machines. Remember, the

reliability engineer takes care of the machines,
and the faster the information is added to the
system, the faster he or she can analyze the
machine condition with the most advanced
predictive technologies.
By updating your lubrication-route software, you
can automatically include in the next planned route
every lube point that has been found to be in poor
condition. With this automatic process, the lube
points that are deficient are revised more frequently
until the correcting actions have the desired effect.
An alarm system for the machines lube condition
can also be implemented based on the information
collected from the lubrication routes.
From this starting point, there are multiple strat-
egies that can be implemented to optimize the
lube-route schedule based on the machine condi-
tion and how often anomalies are detected. If an
integrated system is employed, other information
one unit will be a multiple of a fixed number of days (15, 30, 45, 60
days, etc.). This method allows the mechanical workshop to
manage only the planned work orders. The difference is that the
number of lube points will be slightly increased depending on the
machines oil status.
There are other improvements that can be implemented when
tailoring lubrication routes and PMs based on the information
collected from field personnel, including:
The status of the lube point inspected in the last route can be
included in the guideline table for the next route. This allows
personnel to pay more attention to the most critical points.
Any valuable information or pending work orders on the
machine can be included in the guideline table and taken
into account by the lube operator.
Any automatic alarm or advice intended for taking further
action like oil analysis, vibration measurements, etc., will
improve the performance of the system.
Other information based on the machine type and the
organization of the reliability and maintenance depart-
ments can be utilized.
From page 28
S C O R I N G
A T
F R P H
A visual analysis of the lube oil condition in the inspected
M A G N E T I C P L U G B O E
machine should be reported by the lubrication crew.
T O L R
B I O D E G R A D A T I O N Y M A
G Y M A B If an organization has obtained reliable information from
U O I L I N E S S L S the lubrication routes, it is critical to process all of this data in
D E H Y D R A T O R I R S O order to optimize the frequency of machine lube inspections.
C R V I S C O M E T E R This is especially effective if you have lube points that are in
H H A R D N E S S O Z A P poor condition and require more frequent inspections.
U L N A B T Inspecting problematic points more often ensures better
N G A P T I I
control of their status and helps the reliability engineer to take
K E S O I L O
S T R A I G H T O I L W O I N
corrective action sooner.
R O D N T Also, if the industrial plant has a computerized reliability
B M E Y system with predictive, preventive and other related machinery
R A T E O F S H E A R R condition information, the combination of this data (such as
X R vibration and oil analysis) will allow for improved system perfor-
mance, as more complex and effective strategies may be used.

OIL ANALYSIS
BY R AY GARVEY, EMERSON PROCESS M ANAGEMENT
Analysis
Vibration
and Oil
Techniques Reveal
and Severity
Root Cause
W When evaluating mechanical defects in roller elements and

gears commonly found in rotating machinery, there are several
techniques that can be applied to reveal root cause and severity.
One is wear particle analysis using either a filter patch or glass
slide. Another technique is a wear particle ferrous-density
measurement method often referred to as ferrous index. A
third technique is an impact-detecting vibration stress-wave
Industrial plant maintenance departments typically use walk-
around and on-line vibration analysis together with periodic oil
analysis to determine condition-based maintenance on rotating
machines like pumps, motors, compressors, gearboxes, turbines,
fans and rolls. Figure 1 shows how vibration and oil analysis
collectively address proactive condition monitoring by finding
root causes before damage occurs, as well as by identifying
analysis method called PeakVue. component failures in progress, which might range from incip-
Each of these techniques independently provides insights as ient to catastrophic.
to the nature of a damage-causing mechanism, including abra- PeakVue Technology
sion, fatigue, boundary wear or corrosive wear. Root cause and The PeakVue technology is a highly sensitive and trendable
severity information learned from these techniques can then impact-detection method for quantifying defects in roller
guide operators to call for the best proactive and corrective elements, bearing races and gear teeth. It is a unique stress-wave
actions. Uncorrected, these mechanisms will produce significant analysis technique distinguished from demodulation, shock pulse,
mechanical deterioration. spike energy and other peak detection methods in that PeakVue
detects and holds a scalar maximum peak value
from each oversampled plurality of sample values
PROACTIVE - ROOT CAUSE PREDICTIVE - FAILURE IN PROGRESS
collected during each sample interval.
Vibration Misalignment, imbalance, resonance, Identify alarming defects using normal For example, Figure 2 is a comparison of
looseness and incorrect assembly and PeakVue vibration analysis. demodulation with PeakVue in six different
cause mechanical damage. Observe each of the four failure measurements of the same vibration signal
Extend machinery life by reducing stages: initial to catastrophic. having a periodic impact. The three plots on
dynamic loads. Measure severity and predict failure. the left show how demodulation captures and
represents only a small fraction of the total
Oil Dust and other particles cause Detect damage early.
signal, so the portion detected is substantially
Analysis abrasion. diminished by the sampling bandwidth (1,000
Analyze metal particles from
Water and fluids cause corrosion. mechanical defects. hertz top, 200 hertz middle and 50 hertz
Poor lubrication causes adhesion. Identify root cause and severity bottom). The three plots on the right reveal
Extend machinery life by keeping oil using wear debris analysis. how PeakVue captures and consistently repre-
clean, dry and fit for use. sents the same data independent from
bandwidth selection.
no root cause = no damage = very long life failure
Ferrous Index for Ferrous Density
Time Abnormal wear mechanisms of abrasion,
Figure 1. Vibration and oil analysis reveal proactive root fatigue, boundary wear or adhesion along with
causes and predictive failures in progress. corrosion are common to rotating machinery such as gearboxes,
OIL ANALYSIS
Wear Particle Analysis

Wear particle analysis is a direct approach to visualizing
damaging causes and effects taking place in lubricated machinery
by capturing and viewing particles extracted from lubricating oil.
ASTM D7684 is a new Standard Guide for Microscopic Charac-
terization of Particles from In-Service Lubricants. It provides
excellent recommendations for terminology and techniques,
such as filter patch analysis or analytical ferrography, and offers
insight as to what is likely happening inside the rotating machine.
This new guide defines rolling contact fatigue wear as being
caused by loaded rolling contact typically between the roller and
race in bearings or between gear teeth in the vicinity of the pitch
line, typically forming spall-type pitting and releasing rolling
contact fatigue particles. Rolling contact fatigue particles are
Figure 2. Demodulation (left) vs. PeakVue (right) showing waveform for described as flat platelets, with a length more or less equal to
bandwidths of 1,000, 200 and 50 hertz respectively (top to bottom). their width, with smooth surfaces, random, jagged and irregularly
shaped circumferences, and a major dimension-to-thickness ratio
pumps, motors, compressors, rolls, presses and transmissions. A in the range of approximately 5:1 to 10:1 or more.
ferrous-density measurement like ferrous index is an excellent
method for detecting abnormal wear in the 5- to 60-micron size
range. This is usually the result of abnormal fatigue caused by
cyclic loading and boundary wear where lubrication is inadequate.
This ferrous-density measurement is highly sensitive to wear
debris or dust contamination produced by abnormal abrasive wear.
It is a measure of wear particles typically containing iron alloy
particle debris in sizes as small as 5 microns and extending to at
least 60 microns. This size range is frequently produced by abnormal
severe sliding (boundary lubrication) wear or fatigue wear.
The ferrous index is defined in ASTM D7416 as a ferrous-
density-type parameter measuring the relative concentration
and size of magnetically responsive iron particles greater than 5
microns collected on a dielectric-permittivity sensor.
Figure 3. An ASTM D7416 minilab reports ferrous

index and wear particle analysis.
Emerson, Spectro Form Alliance

Performing Ferrous Density
and Wear Particle Analysis Onsite
Emerson and Spectro Inc. recently announced an alliance to
combine technical innovation and expertise to deliver best-in-class oil
analysis solutions. By combining Emersons oil analysis application for The onsite minilab shown in Figure 3 can be used to measure
the process industry with Spectros extensive oil analysis product line wear, contamination and chemistry parameters of lubricant
and expertise, users can gain more meaningful and accurate informa- samples, including ferrous index and wear particle analysis.
tion on the condition of their machinery. Industrial plant maintenance departments employ onsite
Under the new agreement, Spectro gains rights to a suite of
analytical tools like this to get immediate feedback with retest
Emerson-developed and patent-protected intellectual property in the
capability if needed.
field of oil analysis for predictive machine maintenance. Included in
this portfolio is Emersons AMS Suite oil analysis software module as On the following page is an example of PeakVue and oil anal-
well as the CSI 5200 Machinery Health Oil Analyzer, which is part of ysis, including wear particle analysis, combining for effective
the Trivector minilab package. identification of root cause and severity. PeakVue data from a
Effective Oct. 1, Spectro will become the exclusive worldwide bearing pedestal is shown in Figure 4, while Figure 5 reveals wear
supplier of the Spectro 5200 Minilab product and services offering. particle analysis results from the same machine. Together, these
The onsite minilab is used to quickly test incoming and in-service
technologies indicate a problem of inadequate lubrication.
lubricants with immediate retest when needed, enabling improved
lubricant contamination control with effective root-cause detection
In conclusion, vibration and oil analysis each provide valu-
and elimination. able insights into the health of machine components and
lubricant systems. The combination of PeakVue, ferrous density
38 SSeptember
b -O b 2012 | www.machinerylubrication.com
October hi l bi i
Figure 4. PeakVue data from a bearing pedestal.
and wear particle analysis produce three independent perspectives

into the root cause and severity of an anomalous condition. Armed
with this information, predictive maintenance technicians are able to
accurately recommend appropriate corrective actions in order to
improve maintenance and plant reliability.
Figure 5. Evidence of boundary lubrication (sliding wear) due to

inadequate lubrication revealed by wear particle analysis.

ML GET TO KNOW
Myers Helps to
UPGRADE Nissan
Lube Program
Donald Myers serves as a mechanical maintenance and lubrication
technician for Yates Services, which is a contractor at the Nissan
assembly plant in Smyrna, Tenn. After starting out in production-
assist jobs like separating parts and picking wiring harnesses to send
to the assembly line, Myers now works with the conveyor and lubrica-
tion crew. He currently directs all floor activities for the
lubrication-management program, which is in the first year of a five-
year plan to turn the plant into a world-class lubrication facility.
Q Are you planning to obtain additional training or

Name: Donald Myers Company: Yates Services achieve higher certifications?
Age: 40 Years of Service: 21 years
A Next, I am going for my MLT Level II certification. One reason is,
Title: Mechanical Maintenance Location: Smyrna, Tenn.
of course, to make myself a stronger member of the workforce, but
and Lubrication Technician
another is to have a better understanding of what is happening with
a certain lubricant inside a hydraulic system or gearbox. I like what
Q What types of training have you taken to get to your one of my instructors used to say: Im going to teach you the why,
current position? not just the what.
A To get into maintenance, I had to be able to weld, and there Q Whats a normal work day like for you?
were a couple of older guys willing to teach me and let me practice
A I work a production shift, so most things are running. If there
during my lunch breaks. To keep moving up in the maintenance
are no breakdowns, we do preventive maintenance and check/
group, I had to take some night classes at a local vocational school.
top-off reservoirs. We may receive a bulk oil delivery and take a
The most helpful were on electricity, motor controls and program-
sample for our lab to verify before putting it into service. Lately, I
mable logic controllers (PLCs).
have been building portable oil-dispensing filter carts as an upgrade
Q When did you get your start in machinery lubrica- to our lube program.
tion and how did it happen?
Q What is the amount and range of equipment that you
A During those first few years of production-assist jobs, I would help service through lubrication/oil analysis tasks?
volunteer to work shutdowns with the maintenance groups until I A There are hundreds of hydraulic reservoirs in the plant, ranging
got a chance to move up. We are a multi-tasked crew, but the last from one to 1,400 gallons, as well as hundreds of gearboxes and
five years for me have been mostly all lubrication-oriented. countless grease fittings.
Q What professional certifications have you attained? Q What have been some of the biggest project successes
A I have certificates in motor controls; PLC; heating, ventilation in which youve played a part?
and air conditioning (HVAC); and automotive repair. In high school, A The latest is by far the largest. We started out in the stamping
I attended a hydraulics/pneumatics course that was sponsored by plant, color-coding lubricants and buying sealable and reusable
Nissan. My latest achievement was obtaining a Machine Lubrica- (S&R) containers for top-offs. Then, we added kidney-loop systems
tion Technician (MLT) Level I certification through the International and implemented new procedures to control contamination. This
Council for Machinery Lubrication (ICML). project has since spread plant-wide.
Q How does your company view
machinery lubrication in terms
of importance and overall busi-
ness strategy?
A Everyone knows the importance of lubrica-

tion, just like in the old example of changing
the oil in your car for added value and
longevity. But several months ago, Chad
Crane (one of my many bosses) took an ICML
course and came back on a mission take a
good lubrication program and make it world
class. I think we are well on our way.
Q What has made your company

decide to put more emphasis on
machinery lubrication?
A The dollar is always a huge factor, but I

also think it is a matter of us just trying to be
better. With the leadership we have here at
Nissan, they know that in order to build reli-
able vehicles you have to have reliable
equipment. With this combination, it can only
guarantee success.
Q What do you see as some of the

more important trends taking
place in the lubrication and oil
analysis field?
A I would like to think conservation and the

green initiative will be a big incentive for
taking better care of our equipment and lubri-
cants. The longer a lubricant can stay
efficiently in service, the less of an impact oil
change-outs or spills from damaged equip-
ment can have on the environment. Think
about it. You have to buy new oil, and then you
have to recycle the old oil. There are also oily
rags and containers that all have to be taken
care of. Everything we do has an impact, and
as an industry, I hope we are all doing our part
to lessen the negative ones.
Get to Know You?

Want to be featured in the next Get to
Know section or know someone who should be
profiled in an upcoming issue of Machinery Lubri-
cation magazine? Nominate yourself or fellow
lubrication professionals by e-mailing a photo
and contact information to editor@noria.com.

ML
TEST your
KNOWLEDGE This month, Machinery Lubrication continues its Test Your Knowledge section
in which we focus on a group of questions from Norias 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. Viscosity-index improver additives:

A) Lower the viscosity of the oil
B) Are large molecular structures that
can shear down and become less
effective
C) Help prevent oxidation which leads
to viscosity changes
D) Lower the viscosity index of the oil
E) Are not really additives at all
2. Which of the following describes microscopic water droplets dispersed in

stable suspension in oil?
A) Dissolved water
B) Evaporative solution
C) Emulsified water
D) Free water
E) None of the above
3. Inspection of used filter elements:

A) Is useless
B) Should only be done by highly
trained lab technicians
C) Can provide useful information about wear debris
D) Costs too much money
E) Is difficult because it requires complex instruments
Although used oil filters are often overlooked, testing them can help you avoid potential problems.
Inspecting used filter elements is valuable, especially in identifying wear metal type, shape, concentration, etc.
3. C
of the oils saturation point forms a stable emulsion that will not separate by gravity even at high temperatures.
bonding between oil and water molecules. Depending on oil type and condition, some or all of the water in excess
Emulsified water represents water globules in stable suspension in oil. This generally is because of the strong
2. C
shear force and become less effective. As a result, multi-grade oils should be selected carefully for the application.
the viscosity index of multi-season (multi-grade) oils. These long-chain molecules can shear down under high
Viscosity-index improvers are large molecular structures (long-chain polymers) added to the base oil to increase
1. B
Answers:

PRODUCT SUPERMARKET
GARZO Model 108B controllers main- SIMPLIFY MOTOR CHANGE-OUTS

tain oil levels in engines and compressor This stainless-steel oiler replenishes and ENSURE ELECTRICAL SAFETY.
crankcases to prevent equipment dam- oil after equipment washdown. The 5 Motor Plugs allow technicians to
age and save oil. The standard valve oz. polycarbonate reservoir dispenses quickly connect/disconnect motors.
assembly works with atmospheric tanks at a controlled rate of 15-30 minutes. Safety features protect from electri-
or up to 15 psig oil supply pressures. Corrosion resistant and suited to food cal hazards and simplify NFPA 70E
GARZO, Inc. processing and packaging operations. compliance. FREE samples available.
www.garzoproducts.com/108.html Oil-Rite Corporation Meltric Corporation
713-466-8679 www.oilrite.com www.meltric.com 800-433-7642
tmpafford@garzoproducts.com 920-682-6173 mail@meltric.com
IFH Groups Fluid Storage and Dis- Freedom from sludge and varnish!
pensing Systems offer spill contain- Lubricant deposits cripple pro- One Eye Industries for all your
ment systems that prevent costly ductivity and prots. Fluitecs ESP magnetic and industrial ltration
clean-ups and potential nes. Avail- Technology removes products in needs. Our ltration solutions have
able with 2-, 3- and 4-container solution and in suspension, ensur- applications in all industries. We
wide outboard console mounting ing your lube systems stay deposit- manufacture an extensive product
systems. IFH the original. free. Guaranteed Results. line utilizing new magnet technology.
The IFH Group, Inc. Fluitec One Eye Industries, Inc.
www.ifhgroup.com www.uitec.com www.oneeyeindustries.com
800-435-7003 888-557-9575 877-888-8727
info@ifhgroup.com info@uitec.com info@oneeyeindustries.com
9070 Smart Vibration Analysis Meter Know when to lubricate with UE Checkuids LTJ Series oil sampling
$495. Analyze & interpret readings; Systems Ultraprobe 201 Grease ports offer safer, more convenient
ISO alarm & BDU reading indicate Caddy. Sensing ultrasound, Grease sampling with results you can count
machine & bearing condition; Caddy isolates bearing sounds, on. The high-ow design safely col-
clear picture of 1X (unbalance), 2X making it easier to listen in noisy lects samples while equipment is
(misalignment), & 3X (looseness) plant environments. Wear on a running, and installation can be
machine problems; 800-line spectrum holster or attach to grease gun. made in minutes.
Test Products International UE Systems, Inc. Checkfluid, Inc.
www.testproductsintl.com www.uesystems.com www.checkuid.com
jweidner@testproductsintl.com info@uesystems.com 800-223-1325 866-652-8728

PAID A DVERTISING SECTION
DuPont Krytox Fluorinated Greases

and Oils are chemically inert, insolu-
ble in common solvents. Temperature
range -103 to 800 F. Compatible
with plastics, rubber, ceramics and
metals. Nonammable, oxygen com-
patible, no silicones or hydrocarbons.
H-1/H-2 food grades available.
Miller-Stephenson Chemical
Company, Inc.
www.miller-stephenson.com
203-743-4447
Fundamentals of Machinery Lubrica-

tion provides more than 24 hours
of foundational training on best
practices for machinery lubrication
and oil sampling. It lays the ground-
work for establishing a world-class
lubrication program and is a Level I
certication prep course. This online
training format allows 24/7, any-
where accessibility.
Noria Corporation
store.noria.com 800-597-5460
This DVD includes instructive videos

and animations to give viewers a
better understanding of electric
motor bearings and how to lubri-
cate them properly.
Noria Corporation
store.noria.com
800-597-5460

NOW ON
ML MachineryLubrication.com
Find more great articles and content from Factoring Residual Oil into Wear Rate
Machinery Lubrication magazine online. From It is important to have reliable information
Web exclusives and industry news to videos, white about the percent of residual oil that is left
papers, buyers guides and more, everything that behind during a normal drain and refill. If this
relates to machinery lubrication is available now information has not been determined through
on www.machinerylubrication.com. experience or from the original equipment
Contamination Control Strategies manufacturer, then it is necessary to take an
initial sample approximately 10 hours after the
for Planned Oil Cleanliness unit has circulated the oil and before taking a
Despite the good intentions of many organi- second sample at a reasonable interval after-
zations, real improvements in contamination ward. Discover how to offset residual levels and
control often remain an elusive concept. They determine the new wear rate by reading this
know that invisible particles are one of the article on the ML site.
largest single contributors to progressive wear
of machinery. Yet with each passing year, no Reliable Plant 2012
significant enhancements in maintenance prac- Conference Highlights
Watch this video for highlights of the 13th
annual Reliable Plant Conference and Exhibition
held in Indianapolis on May 1-3, 2012. The inter-
national conference, which is the premier event
tices resulting in greater fluid cleanliness are

implemented. Read this article on the ML site
to understand why most organizations fail at for lubrication, oil analysis and reliability profes-
planned and executed fluid cleanliness. sionals, drew nearly 1,000 industry experts,
Pre-lubrication Procedure for decision-makers and practitioners from around
the world. Access this 1-minute, 52-second video
EMD Locomotives at www.machinerylubrication.com.
This video shows the type of pre-lubrication
that is required if an EMD locomotive has been The Death of a Lubricant
Just how long can a lubricating oil last?
While it is nearly impossible to answer this
question concretely, you can certainly consider
various operating conditions and monitor the
lubricant properties to help determine the
optimum time for changing out a lubricant
before it reaches the point of condemnation.
Find this article on the ML site to understand
how to optimize lubricant change intervals,
thereby maximizing machine life by keeping
shut down for more than 48 hours. Step-by-step live lubricant in the system.
instructions detail how to open the engine sump
cover, insert the pre-lubrication pump inlet pipe
into the engine sump, open the main lube oil pump
By the Numbers
discharge pipe dummy, connect the pre-lube pump of lubrication professionals
outlet pipe to the main lube pump discharge pipe
dummy hole, etc. Access this 5-minute, 59-second
video at www.machinerylubrication.com.
85% do not lter grease or use
ltered grease at their plant,
according to a recent poll at
machinerylubrication.com

ML CERTIFICATION NEWS
LABORATORY-BASED
Technician SKILLS to be
STANDARDIZED
BY SUZY JAMIESON, ICML
Since its inception in 2001, the International Council for ment that has received a 98-percent approval rate by the
Machinery Lubrication (ICML) has been active in supporting participating ISO member countries.
the development of international standards. ICML has even had the The categories were developed with a laboratory technician,
honor of having its Machine Lubricant Analyst (MLA) program be laboratory analyst and senior laboratory analyst/manager in mind.
used as the basis for the International Organization for Standard- Candidates will be expected to have had a minimum of 100 hours
ization (ISO) 18436-4, the first ISO standard for qualification and per month of actual testing/analysis experience, with 12, 24 and 36
assessment of field-based lubricant analysts. months of experience being required for categories I, II and III,
After the successful approval by member bodies of this standard, respectively. Training will also be necessary. A minimum of 24, 48
ICML has once again played an important role in the development of and 80 hours of cumulative training on the pertinent areas of the
yet another part to the 18436 series, leading the project manage- body of knowledge for the chosen category must be undertaken as
ment of part 5 of the series: condition monitoring and diagnostics of part of the qualification process.
machines requirements for qualification and assessment of Subject areas for category I include sample handling and prepara-
personnel part 5: lubricant laboratory technician/analyst. tion, lubricant health monitoring, reagent management and
Through its position as an international council, ICML was able instrument calibration. Personnel certified to this level are expected to
to canvass the opinions of experts across the globe with the objec- be able to perform simple tasks related to the proper handling and
tive of aiding the development of a pertinent document to be used testing of machinery lubricant samples in a laboratory setting
by laboratories worldwide for qualifying and assessing the set of according to established procedures. This would include being able to:
skills needed by technicians and analysts. Properly and safely receive and handle lubricant samples
ICMLs Laboratory Lubricant Analyst (LLA) committee, with the Ensure laboratory testing equipment is within calibration as
help of laboratory managers from around the world, has done per specified procedures
extensive work based on the original ICML LLA certification to
Recognize sources of error
bring it to the ISO-desired three-tier proposal. The result is a docu-
Prevent and control errors related to handling, testing and data
Perform testing using established procedures and standards
About ICML with an understanding of the common laboratory tests
Report results as determined by established criteria
The International Council for Machinery Lubrication (ICML) is a Identify whether data obtained through testing is reasonable
vendor-neutral, not-for-profit organization founded to facilitate growth and Inspect data from individual test methods
development of machine lubrication as a technical field of endeavor. Among
its various activities, ICML offers skill certification testing for individuals Demonstrate basic knowledge and good laboratory practices
in the fields of machine condition monitoring, lubrication and oil analysis. Category II candidates will be required to receive more training in
ICML is an independently chartered organization consisting of both paid
lubricant health monitoring, including testing for wrong or mixed
professional staff members and volunteer advisors. It provides lubrication
lubricants, water/glycol coolant/soot/fuel/air and particle contamina-
and oil analysis standard development support, scholarship, skill-based
testing and certification, and recognition of excellence. For more information, wear particle (debris) monitoring and analysis, data interpretation
tion about ICML, visit www.lubecouncil.org. and quality control, as well as lubricant roles, functions and failure
modes. Personnel in category II are expected to be qualified to:
Perform sample analysis and interpretation Understand the principles of other condition monitoring methods
Set up routine testing schedules and test slates Assist in establishing acceptance criteria when none is available
Verify calibration of laboratory instruments as per specified Conduct or direct training and training examination of
procedures testing personnel
Recognize all forms of lubricant contamination and undertake Provide guidance and supervision to category I and II personnel
all associated test methods
This standard is expected to be available by the end of 2012,
Recognize data that is a change from the norm with worldwide adoption beginning immediately thereafter.
Diagnose lubricant failure mechanisms and modes
Perform wear particle testing and basic analysis
Customize tests
Report results
Demonstrate advanced knowledge (per
ISO 17025)
Provide guidance and supervision to cate-
gory I personnel
To qualify for category III, candidates will be
required to receive further training in wear
particle (debris) monitoring and analysis, as
well as data interpretation, quality control and
lubricant roles/functions/failure modes.
Besides these subjects, training will cover
sensorial inspections, environmental effects on
results, alternate technology data correlation
and personnel training. Individuals classified as
category III must be qualified to perform and/
or direct all types of lubricant analysis. They
should also be able to:
Perform advanced testing and analysis
Manage an analysis program
Set up testing schedules and test slates,
including design and set up of special tests
and interpretation of results when estab-
lished standards do not exist
Establish new techniques
Interpret criteria, standards and specifications
Prepare or approve procedures and
instructions, including calibration of labo-
ratory testing equipment
Interpret data and prepare reports for
appropriate personnel based on advanced
lubricant testing and wear debris analysis
Conduct advanced diagnosis of lubricant
failure mechanisms and offer possible
machine failure mechanisms that relate to
those lubricant failure characteristics
Perform audits in accordance with ISO 17025
Establish the laboratory certification
program and documentation
CERTIFICATION NEWS
RECENT RECIPIENTS OF ICML CERTIFICATIONS

The International Council for Machinery Lubrication (lCML) would like to congratulate professionals worldwide who
have recently achieved certified status through ICMLs certification programs. ICML offers certification in the areas of oil
analysis and machinery lubrication. The following is a list of recently certified professionals in the area of machinery
lubrication who have attained their status as a certified Machine Lubricant Analyst (MLA), Machine Lubrication Techni-
cian (MLT) or Laboratory Lubricant Analyst (LLA).
Alliant Energy Compaia Teck Minera Holcim Inc. Noria Corporation Roquette America Inc.
Darian DeJong, MLA I Quebrada Blanca S.A. Nick Vandegraaf, MLT I Gerald Putt, MLT I Jacob Wilcox, MLT I
Roberto Ramos Hernandez, Thomas Kurtz, MLT I
AngloGold Ashanti Holcim Philippines Inc. Sappi
MLA II Kevin Lemery, MLT I
Kris Stewart, MLT I Reb Galla, MLT I Jacobus Labuschagne, MLA I
Nana Yaw Nti Owusu-Adanse, Covidien North Atlantic Refining
Hormel Foods SC Johnson
MLT I Daniel Schmidt, MLA I Limited
Dustin Ambort, MLA I Jerry Behling, MLT I
Andrew Phillips, MLT I Aaron Collier, MLA II
Dictuc Michael Scott, MLA I
Hayden Grant Sing, MLA I Shell Australia
Francisco Gonzalez Poblete, Peabody Energy
Grant Young, MLA I MLA II International Paper Michael Brown, MLA I
Stephen Voogt, MLA II
James Cook, MLT I State Farm Insurance
Ascend Performance Dow Chemical Pemex Gas & Petroquimica
Peter Curley, MLT I
Materials Earl Becnel, MLT I Basica
George Gerber, MLT I
Anthony Scott, MLT I
Erik Han, MLA I
Wendell Wood, MLT I Fernando Enrique Tellez Teknor Apex Tennessee
E.I Dupont de Nemours & Co.
Ashland Specialty Ingredients Cerecedo, MLT I James Tippett, MLT I
Tayler Burgess, MLT I & MLA I JMHarwood
Eddie Rudolph, MLA I Carlene Fontenot, MLT I & MLA I Petro-Canada America Thilmany Papers
Wade Hill, MLA I
Atlan-tec Inc. Chris Hudnall, MLT I & MLA I Lubricants Joe Burton, MLT I
Traci Prejean, MLT I Johnson Controls Frank Hayes, MLT I
Alan Warwick, MLT I Total Lubrication Manage-
Mark Reynolds, MLT I & MLA I Christopher Verink, MLA I
Phillip Odom, MLT I PetroLabs India ment Company
Richard Smith, MLT I & MLA I Johnsonville Sausage
Atomic Energy of Canada Ajay Suvarna, MLT I & MLA I James Thibodeaux Jr., MLA I
Tiffany Sterling, MLT I & MLA I Kimberly Bassuener, MLA I
Denis Campion, MLA I Robert Dunaway, MLT I
Kenneth Taylor, MLT I PLI LLC
Ron Kellner, MLA I Robert Whitmire, MLT I Korea Gas Technology Brent Guard, MLT I
Paul Dienberg, MLA I
Brian Vernier, MLA I Paul Worley, MLT I & MLA I Corporation Unicco
Perrin VanderVeen, MLT I & Ahn Sung-Yoon, MLA I R&G Laboratories
Barrick Cortez Gold Mines Larico Burchett, MLA I
MLA I An Sung-Tae, MLA I William Tyson, MLT I
Shane Krause, MLA I Unicco - UGL Services
Charles Block, MLT I & MLA I Jung-Hyun Cho, MLA I Reliable Lubrication
David Yazzie, MLA I David Cochran, MLT I
Cody Welch, MLT I & MLA I William Mecabe, MLT I
Terrence Mondor, MLA I Ladish Forge Matthew Artis, MLT I
Milena Paker, MLA I Emprise Corporation Dennis Enoch, MLT I Rio Tinto Brandon Cyprych, MLT I
John Knox, MLA II Chuck Maglio, MLT I Mark Payne, MLT I Aaron Moore, MLT I
Baucom Enterprises of F-V
Exelon Corporation Austin Moore, MLA I
Michael Baucom, MLT I Lafarge North America Rock Valley Oil & Chemical Co.
Raymond DeAngelis, MLA II Jason Broyles, MLT I Miles Manthey, MLA II Valero
Bel Ray Chile Ltda.
Mark Lanius, MLA II Derek Eilks, MLT I Alejandro Pena, MLT I
Marcelo Maza Roman, MLA II LE Lubricants Inc.
Exxaro Raulito Reyta Bait, MLT I RockTenn Wausau Paper Company
Bodine Electric Obakeng Thekiso, MLA I James Cross, MLT I Thomas Shelton, MLT I
Kalyn Miller, MLA I Lubrication Engineers Inc.
Gateway Energy & Coke Co. Wayne Newsome, MLT I
James Ackley, MLT II Wells Dairy Inc.
Butler Machinery Bobby Kennedy, MLA II Raymond Jackson, MLT I
S. Randy Andringa, MLT II Paul Brewer, MLT I
Trice Butler, MLA II Jason Ray Johnson, MLT I
General Mills Jeffrey Calk, MLT II
Raymond Gossman, MLT I Westar Energy
C.C. Jensen Inc. Michael Chesson, MLT II Christopher Diener, MLT II
Lonnie Littles, MLT I Dennis Gudenkauf, MLT I
Steffen Nyman, MLT I & MLT II Corey Kriegermeier, MLT II Mike Hall, MLT II
Barton Anderson, MLT I Jason Heath, MLT I
Jeff Hiskett, MLT II
Cargill Inc. Georgia-Pacific Harry Cannavino, MLT I Jeff Larson, MLT I
Paul Llewellyn, MLT II Gerald Cook, MLT I
Rick Bowman, MLT I Christopher Morris, MLA I Stacy Rethman, MLT I
Brett Rausch, MLT II Mary Turner, MLT I
Kenneth Cook, MLT I Marc Charbonneau, MLT I Jacob Simon, MLT I
Adam Wilcox, MLT II Sidney Hale, MLT I
Robert Linell, MLT I Ian Spittle, MLT I Charlie Willard, MLT I
Daniel McKinney, MLT I Lubrication Engineers Denver Reid, MLT I Mike Wiltz, MLT I
Mark Wenke, MLT I GNPower Mariveles Coal International Danny Bryant, MLT I Troy Fisher, MLT I
Greg Capell, MLA I Plant Shaun Macdonald, MLT II
Ricky Bathan, MLA II
Chevron Karina Deln, MLA II MillerCoors Brewing ICML Certifications
Lee Brown, MLA I Russell Manlucu, MLA II Company LLA I = Laboratory Lubricant Analyst Level I
Chad Luikart, MLA I Orestes Moya, MLA II Sean OByrne, MLT II MLA I = Machine Lubricant Analyst Level I
Sarah Elaine Sauco Pumatong, Michael Sprague, MLT II MLA II = Machine Lubricant Analyst Level II
Comercial Importadora S.A.
MLA II
de C.V. Mississippi Lime Co. MLA III = Machine Lubricant Analyst Level III
Julio Guerrero Iniguez, MLA III Goodyear Napanee Terry Clark, MLA I MLT I = Machine Lubrication Technician Level I
Macario Juarez Gonzalez, MLA III Richard Gustavel, MLT I Thomas French, MLA I MLT II = Machine Lubrication Technician Level II

Industrial Lubricants
IN THE JOSH PICKLE NORIA CORPORATION
TRENCHES
UNDERSTANDING the
DIFFERENCES in
Base OIL GROUPS
57%
Almost every lubricant used in plants Group II base oils have better antioxidation
today started off as just a base oil. The properties. They also have a clearer color and
American Petroleum Institute (API) has cate- cost more in comparison to Group I base oils.
gorized base oils into five categories (API 1509, Still, Group II base oils are becoming very
Appendix E). The first three groups are refined common on the market today and are priced
from petroleum crude oil. Group IV base oils of lubrication professionals use very close to Group I oils.
are full synthetic (polyalphaolefin) oils. Group both synthetic and mineral-
based lubricants in their plant,
V is for all other base oils not included in
according to a recent poll at Group III
Groups I through IV. Before all the additives machinerylubrication.com Group III base oils are greater than 90
are added to the mixture, lubricating oils begin percent saturates, less than 0.03 percent sulfur
as one or more of these five API groups. and have a viscosity index above 120. These oils
are refined even more than Group II base oils and generally are
Group I severely hydrocracked (higher pressure and heat). This longer
Group I base oils are classified as less than 90 percent satu- process is designed to achieve a purer base oil. Although made
rates, greater than 0.03 percent sulfur and with a viscosity-index from crude oil, Group III base oils are sometimes described as
range of 80 to 120. The temperature range for these oils is from 32 synthesized hydrocarbons. Like Group II base oils, these oils are
to 150 degrees F. Group I base oils are solvent-refined, which is a also becoming more prevalent.
simpler refining process. This is why they are the cheapest base
oils on the market.
Did You Know? Group I
Group II base oils have been the most
Group II base oils are defined as being more than 90 percent
saturates, less than 0.03 percent sulfur and with a viscosity index of common base oils on the
80 to 120. They are often manufactured by hydrocracking, which is market over the last decade.
a more complex process than what is used for Group I base oils.
Since all the hydrocarbon molecules of these oils are saturated,
Group IV
Group IV base oils are polyalphaolefins (PAOs). These
API BASE OIL CATEGORIES synthetic base oils are made through a process called
Base Oil Category Sulfur (%) Saturates (%) Viscosity Index synthesizing. They have a much broader temperature range
and are great for use in extreme cold conditions and high
Group I (solvent refined) >0.03 and/or <90 80 to 120 heat applications.
Mineral
Group II (hydrotreated) <0.03 and >90 80 to 120
Group III (hydrocracked) <0.03 and >90 >120

Group V
Group V base oils are classified as all other base oils,
Synthetic
Group IV PAO Synthetic Lubricants including silicone, phosphate ester, polyalkylene glycol
(PAG), polyolester, biolubes, etc. These base oils are at times
Group V All other base oils not included in Groups I, II, III or IV mixed with other base stocks to enhance the oils properties.

The Changing Use of Base Oils
A recent study on the use of base oils in todays plants in comparison
to a little more than a decade ago found a dramatic change has occurred.
Present-day Group II base oils are the most commonly used base oils in
plants, making up 47 percent of the capacity of plants in which the study
was conducted. This compared to 21 percent for both Group II and III base
oils just a decade ago. Currently, Group III accounts for less than 1 percent
of the capacity in plants. Group I base oils previously made up 56 percent
of the capacity, compared to 28 percent of the capacity in todays plants.
An example would be a PAO-based compressor oil that is mixed with a

polyolester. Esters are common Group V base oils used in different
lubricant formulations to improve the properties of the existing base
oil. Ester oils can take more abuse at higher temperatures and will
provide superior detergency compared to a PAO synthetic base oil,
which in turn increases the hours of use.
Remember, whichever base oil you choose, just be sure it is appropriate
for the application, temperature range and conditions in your plant.
About the Author
Josh Pickle is a technical consultant with Noria Corporation, focusing on
machinery lubrication and maintenance in support of Norias Lubrication Program
Development (LPD). He is a mechanical engineer who holds a Machine Lubrication
Technician (MLT) Level II certification and a Machine Lubricant Analyst (MLA)
Level I certification through the International Council for Machinery Lubrication
(ICML). Contact Josh at jpickle@noria.com.

Oil Filters
BACK PAGE WES CASH NORIA CORPORATION
BASICS
The Importance of
DIRT-HOLDING
Capacity in OIL FILTERS
60%
The enemy to any lubricated machine is particle contam-
ination. In a perfect world, machines would be sealed up
to block the ingression of particles before any problems occur, of Lube-Tips subscribers
use surface or membrane
but unfortunately this isnt the case. We live in a dirty environ- oil lters most frequently
ment. Particles exist everywhere, and lubricated components at their plant
are constantly under attack from them. Whether the particles
are ingested by poor-quality breathers or dirty oil

from a recent top-up, the question remains what
Prolonging Filter Service Life can be done to get rid of them. The obvious solu-
Selecting the proper filter with a high dirt-holding capacity is only half the battle. tion is filtration.
You also must ensure these filters are put into use the right way. Filters can be expensive, Filters can extend the life of machines by removing
so naturally you want to prolong the life of the filter to cut down on the costs associated harmful particles before they can cause surface degra-
with changing them. dation of the lubricated components. There are two
One of the easiest ways to prolong the filter change-out interval is by simply over- common types of filters: surface or membrane filters
sizing the filter. As you can see in the chart below, by doubling the surface area of a filter,
and depth filters. Surface filters simply trap particles
you can expect three times the life from it.
There are different methods to oversizing filters. The most obvious is by increasing on the surface or face of the filter. Depth filters allow
the physical size of the filters you are using. This is somewhat costly, as equipment the oil to flow throughout the body or depth of the
modification is required to fit a larger filter in the lines. For some equipment where filter and trap particles throughout the media. Perhaps
space is limited, this may not the most crucial attribute of any filter is the ability to
11 even be feasible. That is when trap and hold dirt.
you should start looking at
10 Each filter has a specific pore size. This is the size of
putting filters in parallel.
By placing multiple filters the openings within the media through which the oil
9
in parallel, you double the and particles can pass. As the pore size gets smaller and
8 surface area in contact with the smaller, the differential pressure across the media
Relative Service Life, Years
oil, thereby reducing the face begins to increase as well. This differential pressure can
7 velocity (the pressure of the lead to a condition in which the bypass or cracking pres-
oil on the surface of the filter
6 sure of the filter is reached, allowing oil to flow through
media), and thus extend the
life of the filter. This means less virtually unfiltered. Also, if the pressure becomes too
5
filter changes and the ability to great, it can cause the actual filter media to burst.
4 capture more particles between Once particles are captured, it becomes a measure
change-outs. of how well the filter can retain them. This is known as
3 If the equipment wont the dirt-holding capacity of the filter. Several factors
permit the extra piping to put contribute to how well filters hold the contaminants
2
in a parallel circuit, there are
they catch. Weve discussed the pore size of the filters,
1 systems that stack filters one on
1 2 3 4 5 6 7 8 top of another to increase the
but pore density is equally important. Pore density can
Relative Filter Media Area overall length of the media, again be described as the number of pores in a section of the
Double the size of the filter and you allowing for the decrease in pres- filter. This is also known as the porosity of the filter. As
can triple the service life (dirt- sure the media is experiencing. pore size goes down, to maintain a low differential pres-
holding capacity).
sure across the media, the pore density must go up to

BACK PAGE BASICS
Shaft
Alignment
& Geometric
Measurement Fiberglass vs. Cellulose
capacity. This value is obtained through a test

known as ISO 16889 or the multi-pass test. In this
Cellulose (Wood Pulp) Filter Media standard test, a filter is put into a circuit that is filled
with oil. The oil circulates through the filter. A set
amount of sized particles is then released into the oil
to test the filters ability to capture them. A particle
counter before and after the filter measures the
difference in particles. The results of this test will
allow you to see how well or poorly a filter performs
against different particle sizes.
Keep these things in mind when selecting the
next filter to clean your oil and protect your expen-
sive machinery. Check the filters beta rating and
Rotalign ULTRA pore size. Obviously, there is a big difference
Vibration
between a 40-micron filter and a 3-micron filter
Fiberglass Filter Media when you are talking about the size of particles
Analysis
allowed downstream. Also, whenever available,
account for the volume of oil in contact with the verify the results of the ISO 16889 multi-pass test.
& Balancing surface. Thus, filter depth and size also affect the This not only will show you the efficiency of the
dirt-holding capacity. filter, but also how well it is able to retain the
Another thing to keep in mind when selecting particles it removes from the circulating oil.
filters is the material the media is composed of.
This not only has an effect on the longevity of the
filter and its adaptability to its environment but Perhaps the most crucial
also its dirt-holding capacity. Two common types attribute of any filter is the
of filter media are cellulose and synthetics. Cellu-
lose is comprised of wood pulp. These types of ability to trap and hold dirt.
filter media have a large fiber size and a less
consistent pore size throughout the entire filter. Some filter manufacturers dont show the
Cellulose has the advantage of being able to results of this test as it pertains to the dirt-holding
absorb some water from the oil it is filtering. capacity of the filter, but by pressuring them and
Cellulose filters tend to fail quicker in demanding to see the results, you can make the
VIBXPERT II
acidic environments as well as in high-tempera- best decision for you and your machines. If they
h
WatcOS ture applications. balk at the idea of providing the test results, there
DE
VI ine
Onl Synthetic filter media generally have a higher are labs across the country that can run the ISO
dirt-holding capacity than cellulose. This is due in 16889 test on the filter to give you the results.
part to their more consistent pore size throughout This is more expensive for the end user, but it
Easy-to-use the media. Synthetic fibers are smaller than cellu- offers the peace of mind that you have the right
solutions for your lose fibers, so they can be packed tighter together, filters for your applications.
maintenance needs! creating more pores in which to trap and hold About the Author
particles. Synthetic fibers also perform better in Wes Cash is a technical consultant with Noria
Sales Rentals Services the harsh environments that tend to destroy Corporation. He is a mechanical engineer who holds
cellulose filters. a Machine Lubrication Technician (MLT) Level I
In examining the technical sheets of filters, you certification and a Machine Lubricant Analyst (MLA)
may have seen a filters beta rating. This describes Level I certification through the International Council
how efficient the filter is at removing particles. for Machinery Lubrication (ICML). Contact Wes at
305-591-8935 www.ludeca.com
There also may have been a value for the dirt-holding wcash@noria.com.

Welcome to Machinery Lubrications Book-
store, designed to spotlight lubrication- The Professionals Guide to Mainte-
related books. For a complete listing of books
nance and Reliability Terminology
of interest to lubrication professionals, check
Authors: Ramesh Gulati, Jerry Kahn and Robert Baldwin
out the Bookstore at store.noria.com.
Maintenance and reliability involve many different people
BOOK STORE
in many different roles. If they
How to Select a Motor Oil and Filter are expected to work efficiently,
for Your Car or Truck productively and harmoniously
on tasks and projects, there is
Author: Jim Fitch
Publisher: Noria Corporation a need for a common language
for communication. This book
Before spending any more money
represents a significant step
on oil changes, synthetic oils,
toward improving the knowledge
premium filters, engine flushes or
of and communications between
oil treatments, learn what leading
members of the maintenance and
lubrication expert Jim Fitch
reliability profession. With more
recommends. With these sound
than 3,000 entries, the compila-
recommendations, youll know
tion reflects a virtual explosion of commonly practiced
exactly what to do the next time
concepts, ideas, methodologies and various approaches to
you change your oil for about
maintenance and reliability improvements.
the price of an oil change.
How to Grease a Motor Bearing Reliable Plant 2012 Conference

Training Video Proceedings
Format: CD-ROM
Format: DVD
Publisher: Noria Corporation
Publisher: Noria Corporation
Anyone responsible for the mainte- If you missed the learning sessions
nance, operation and reliability of at Reliable Plant 2012, you can
electric motors will benefit from still get the conference proceed-
this training video. It provides ings on CD-ROM. It includes the
plant personnel with an over- presentations in PDF format from
view of the best practices for nearly every educational session in
lubricating electric motor each of the two co-located confer-
bearings. You can use the ences: Lubrication Excellence and
video to train operators, lubri- Reliability World. The real-world
cation technicians, mechanics, case studies at Reliable Plant 2012 were full of practical,
electricians and maintenance personnel for years to come. experience-based information and tools for lubrication and
reliability programs.
Lubrication Fundamentals Use the Correct Oil Poster

Second Edition Publisher: Noria Corporation
Authors: D. M. Pirro and A. A. Wessol Make sure the right oil goes into the
This newly revised and expanded right machine with this laminated
reference book emphasizes the poster that shows a lubrication
need for lubrication and careful technician pouring hydraulic oil
lubricant selection. Thoroughly into a gearbox, causing it to smoke
updated and rewritten, the Second and vibrate. Bulleted tips instruct
Edition of Lubrication Fundamentals personnel to remember that oils of
discusses product basics, machine the same viscosity may be different
elements that require lubrica- types and to properly label all oil
tion, methods of application, containers, transfer devices and
lubrication, lubricant storage and machine oil fill ports. Hang this
handling, lubricant conservation and much more. poster to send a clear message that using the correct oil is critical.
For descriptions, complete table of contents and excerpts from

these and other lubrication-related books, and to order online,
visit: store.noria.com or call 1-800-597-5460, ext. 204

ML Sept Oct 2012

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

ML Sept Oct 2012

Caricato da

Copyright:

Formati disponibili

Contents

242012 SALARY SURVEY

More Editorial Features

AS I SEE IT JIM FITCH NORIA CORPORATION

Why You SHOULD

Fourier transform infrared (FTIR) spectroscopy, Karl Fischer, oil

When to Stop Pumping

JEREMY WRIGHT | NORIA CORPORATION

Rust and Corrosion Inhibitors

and corrosion is not to allow

with water, oxygen or acid.

www.machinerylubrication.com | September - October 2012 |7

partially burned hydrocar-

10 | September - October 2012 | www.machinerylubrication.com

Diesel engine oils licensed by the American Petroleum Institute 30,000

Viscosity and Engine Oil Grades

The Optimal Oil Drain Interval

When estimating the optimal oil drain interval, fleet owners

14 | September - October 2012 | www.machinerylubrication.com

PETE OVIEDO NORIA CORPORATION

Ingression can also occur due to process conditions. This

using them to eliminate dirt or water ingression, breathers are

Remember, education is key. Understanding how ingression

HYDRAULICS BRENDAN CASEY

tip sampling capabilities with a synchronized multi-tasking

22 September - October 2012 | www.machinerylubrication.com

www.machinerylubrication.com | September - October 2012 23

24 | September - October 2012 | www.machinerylubrication.com

26 | September - October 2012 | www.machinerylubrication.com

Get the solution on page 34

28 | September - October 2012 | www.machinerylubrication.com

BY M ARC VILA F ORTEZA , PETRONOR, SPAIN

Using Oil Analysis and

I In large industrial plants where a great number of machines

Qualified personnel is needed to provide

detected within the machines. Remember, the

34 September - October 2012 | www.machinerylubrication.com

BY R AY GARVEY, EMERSON PROCESS M ANAGEMENT

W When evaluating mechanical defects in roller elements and

Wear Particle Analysis

Figure 3. An ASTM D7416 minilab reports ferrous

Emerson, Spectro Form Alliance

and wear particle analysis produce three independent perspectives

Figure 5. Evidence of boundary lubrication (sliding wear) due to

www.machinerylubrication.com | September - October 2012 39

Q Are you planning to obtain additional training or

A Everyone knows the importance of lubrica-

Q What has made your company

A The dollar is always a huge factor, but I

Q What do you see as some of the

A I would like to think conservation and the

Get to Know You?

www.machinerylubrication.com | September - October 2012 | 41

1. Viscosity-index improver additives:

2. Which of the following describes microscopic water droplets dispersed in

3. Inspection of used filter elements:

42 | September - October 2012 | www.machinerylubrication.com

GARZO Model 108B controllers main- SIMPLIFY MOTOR CHANGE-OUTS

44 September - October 2012 | www.machinerylubrication.com

DuPont Krytox Fluorinated Greases

Fundamentals of Machinery Lubrica-

This DVD includes instructive videos

www.machinerylubrication.com | September - October 2012 45