November - December 2017

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November - December 2017

TABLE OF CONTENTS

AS I SEE IT 2 COVER STORY

Managing the Perils of Short-volume 100 Ways to Improve Your Lubrication Program
Oil Changes To commemorate its 100th issue, Machinery Lubrication presents 100 things
you should know to develop a world-class lubrication program.

6
HYDRAULICS 28
How Directional Valves Affect Oil Flow
in Hydraulic Systems

LUBE-TIPS 36

IN THE TRENCHES 38
Best Practices for Lubricating
Paper Machines

PERSPECTIVE 44
Selecting Lubricants
for Pharmaceutical Facilities

TRAINING AND CERTIFICATION 50

Online Tools Can Simplify
the Certification Process

2017 LUBE ROOM CHALLENGE

Getting Bottom-line Results from a Lube Room Transformation
Designing a proper lube room not only is an important step in the journey toward
lubrication excellence but can also increase a company’s bottom line.

18
BACK PAGE BASICS 54
4 Grease Tests for Centralized
Lubrication Systems

EDITORIAL FEATURES DEPARTMENTS 42 Test Your Knowledge

34 Get to Know 32 Product News 43 Bookstore
37 Now on MachineryLubrication.com 41 Product Supermarket 48 Ask the Experts
 Jim Fitch | Noria Corporation

AS I SEE IT Oil Changes

Managing the Perils of

Short-volume Oil Changes

The term “short-volume oil change”

(SVOC) relates primarily to circulating
oil systems. An SVOC occurs when an
oil change (either scheduled or condi-
tion-based) only involves draining and refilling the oil in
the system tank or sump. All or some significant portion
of the oil remaining in the oil lines, hoses, bearings,
pumps, filters, actuators, valves, heat exchangers, etc.,
is not changed. In other words, it is a partial oil change.
From a practical standpoint, when oil is drained from
machines, there is always some residual amount that, at
minimum, occludes to interior surfaces and becomes
trapped in low regions, quiescent zones, and other nooks
and crannies. For example, after an oil drain, diesel
engines typically retain approximately 15 percent of their
previous oil. When the engine is refilled with new oil, you
end up with an 85-to-15 new-oil-to-used-oil blend.

“
The main concern with this practice is the influence
the used oil has on the health of the blended new oil
charge. If the used oil was low in volume and relatively
healthy, the performance and life expediency of the associated accelerated wear when the machine is restarted
new oil blend can be acceptable. Conversely, if the used
due to delayed lubrication (dry start). These conditions
oil was contaminated and/or heavily degraded from
It takes less than extended use, the performance and life expectancy of
are the result of the time required to refill the lines and
components with oil, purging out air, etc. Of course,
5 percent oxidized the new oil blend can be sharply affected. For instance,
it takes less than 5 percent oxidized oil mixed with new many large systems have auxiliary pumps that pre-lube
oil mixed with new oil to reduce the oxidation stability of the new oil by the system. Other machines may not have this feature.
oil to reduce the more than 90 percent. Furthermore, performing a complete system drain
can disturb sludge, sediment and deposits. To read
oxidation stability Why Perform a Short-volume more about this, see my article on oil flushing tips to
of the new oil by Oil Change? address the fishbowl effect at MachineryLubrication.com.
There are several good reasons to perform an SVOC. Unless these solid impurities can be fully purged from
more than
One is that it’s simply less disruption to the system. This the system, they can mobilize within the machine and
90 percent.” includes avoiding the risk of dry start conditions and cause new problems (e.g., motion impediment, restricted

2 | November - December 2017 | www.machinerylubrication.com


oil ways, etc.). Leaks may also occur suddenly
in areas where there was no leakage. For more
information on this condition, see my article on
oil clotting and the adrenaline effect at Machin-
eryLubrication.com.
Unlike an SVOC, where perhaps only 40
percent of the actual oil charge is drained (see
Figure 1), a full-volume oil change (FVOC) can
take much longer. Additionally, there is much
more oil involved and higher associated costs.
That said, the service life of an FVOC should
be disproportionally longer than an SVOC.
For example, the life of an FVOC may be three
times longer than a 40-percent SVOC (40
percent new oil blended with 60 percent used
oil), and this assumes the used oil is relatively
healthy and contaminant free.
One way to define a lubricant’s remaining
useful life (RUL) in a machine is to identify
the remaining useful life of the additive system.
Most additives are sacrificial. In other words,
they give up their life to save the oil and the
machine. As such, if they don’t die, they aren’t
effective. While they are working, they are
depleting. Eventually, no reserve additives are
60% Oil Volume
Figure 1. In many large-volume circulating oil systems, changing the tank oil alone results
in nearly 40 percent of the full volume being drained and changed.
left. Of course, you should change the oil long
before this point.
For simplicity, let’s assume the antioxidant
concentration of new oil is 100. At the time
of the SVOC, the used oil had an antioxidant
level of 25. The 40-percent SVOC resulted in a
blended antioxidant concentration of 55, or 55
percent RUL of the blended oil. This equates
to just more than half of the new oil’s designed
service life.
Lurking Dangers
Perhaps the most serious hazard relates to
current oxidation of the oil being drained. These
oxides spread rapidly like food coloring in a
pitcher of water. They typically consist of chem-
ically reactive hydroperoxides and free radicals
that can burn through antioxidants coming in
with the new oil in short order.
You might think of these reactive chemicals
as an infection. It’s like sending nine healthy
people into a room with a person ailing from
a contagious disease. The good health of
the nine doesn’t cure the disease of the one.
On the contrary, you end up with 10 very
40% Oil Volume
Machinery
Lubrication ML
PUBLISHER
Mike Ramsey - mramsey@noria.com
GROUP PUBLISHER
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EDITOR-IN-CHIEF
Jason Sowards - jsowards@noria.com
SENIOR EDITOR
Jim Fitch - jfitch@noria.com
TECHNICAL WRITERS
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Garrett Bapp - gbapp@noria.com
CREATIVE DIRECTOR
Ryan Kiker - rkiker@noria.com
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ADVERTISING SALES
Tim Davidson - tdavidson@noria.com
800-597-5460, ext. 224
MEDIA PRODUCTION COORDINATOR
Libby Bahlinger - lbahlinger@noria.com
CORRESPONDENCE
You may address articles, case studies,
special requests and other correspondence to:
Editor-in-Chief
MACHINERY LUBRICATION
Noria Corporation
1328 E. 43rd Court • Tulsa, Oklahoma 74105
Phone: 918-749-1400 Fax: 918-746-0925
Email address: editor@noria.com
MACHINERY LUBRICATION Volume 17 - Issue 6 November-December
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CONTENT NOTICE: The recommendations and information provided in
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AS I SEE IT

SVOC FOLLOWED
DOUBLE OIL CHANGE BY LINE PURGE
SVOC Approximate percentage of old oil Approximate percentage of old
Percentage of remaining old oil after the remaining after draining and refilling oil remaining after performing an
MACHINE OR tank is drained and refilled with new oil. the tank, followed by oil circulation. The SVOC, followed by diverting old line
SYSTEM This is machine dependent. drain-and-fill is then repeated. oil to waste.
A 60% 36% 12%
B 40% 16% 8%
C 30% 9% 6%
D 20% 4% 4%
E 10% 1% 2%
F 5% 0.25% 0.5%

Figure 2. The amount sick people. Any time a lubricant is oxidized (e.g., a means when new oil enters a machine, some of the
of used oil remain- viscosity increase, dark opaque color, elevated acid varnish and deposits from the previous oil can be
ing in a system after number, pungent odor, etc.), a complete system flush cleaned away quickly. This devarnishing occurs when
performing an SVOC, is required to purge the infection. Oil analysis can help the oil has residual IHC aided by a higher operating
a double oil change
and an SVOC followed
schedule oil changes well in advance of base oil oxida- temperature. Much of this can be lost due to an SVOC.
by a line purge (refer tion. Although less common, a similar problem occurs To learn more about IHC, read the article titled “What
to the narrative on the when a system is infected with microbial contamina- is Your Oil’s Impurity-holding Capacity (IHC)?” at
following page) tion (bacteria or fungi). MachineryLubrication.com.
One of the advantages of an oil change is the oppor-
tunity to expunge ghost riders from your oil. Ghost Better Demulsibility
riders are the microscopic hard particles that accumu- Most lubricants should demulsify water rapidly to
late in oil over time. They are smaller mitigate damage to the oil and the machine. Solid and
than the pore size of the onboard oil dissolved impurities of nearly all

44%
filter. If you are using a 10-micron types build up in used oil and can
oil filter, particles smaller than inhibit demulsibility. These are
10 microns will circulate freely passed on to the blended new and
and unabated by filtration. The used oil after an SVOC.
filter selectively removes only the
particles larger than 10 microns. of lubrication professionals
Improved Air-handling
As new particles ingress during perform short-volume or partial Ability
normal operation, the small ghost oil changes at their plant, based For the same reasons an
riders continue to grow in popula- on a recent survey at
FVOC is beneficial for demul-
MachineryLubrication.com
tion until the oil is changed. sibility, it is also good for a
The problem with these ghost lubricant’s efficient air release and
riders is that they can do many low foam tendency/stability.
harmful things to machines. For instance, anywhere
there is elastohydrodynamic lubrication (e.g., rolling-el- Longer Filter Life
ement bearings), these small particles can readily bridge The impact of soft contaminants (sludge, varnish
the working clearance, damaging bearing surfaces in insolubles, oxides, dead additives, etc.) on filter life can
the load zone. Where boundary lubrication exists be substantial. Soft contaminants are the product of oil
(starts, stops, slow-moving surfaces, misalignment, aging. As such, they are purged with FVOCs but less so
starved oil conditions, etc.), the ghost riders will cause with SVOCs.
the vast majority of the damage (three-body abrasion
and surface fatigue). Good Oil Analysis Baseline
The following are additional benefits of an FVOC Another disadvantage of an SVOC relates to oil anal-
versus an SVOC: ysis. Good oil analysis needs a reliable and consistent new
oil baseline. Most oil analysis alarms are set as an offset
Machine Devarnishing to this baseline. If the baseline has been corrupted by
New oil usually has a relatively high impurity-​ blending new oil with old oil, so too is the effectiveness
holding capacity (IHC) compared to used oil. This (precision) of the oil analysis data interpretation.

4 | November - December 2017 | www.machinerylubrication.com

 ML

SVOC Alternatives
Fully purging a system of oil can
be a difficult challenge. This is espe-
cially true with completely flooded
lines and system components. The
procedure may require partitioning
the system, followed by breaking
into lines in low zones to drain
used oil and aided by air vents in
higher zones. There are a couple of
alternatives to consider based on the
machine, the operating conditions
and the need for an FVOC. These
include the following (see also the
table in Figure 2):
Bleed-and-Feed
This type of oil change normally
can be performed on the run for
stationary equipment without the
loss of machine runtime. The process
involves the progressive draining
of tank oil and the addition of an
equal amount of new oil, all while
the oil remains circulating. For
heavily degraded lube oil, it may
take the equivalent of three or four
oil changes (in new oil volume) to
achieve the target level of oil quality
and performance.
Alternate procedures can achieve
similar results depending on the
machine/system involved.
Role of Oil Analysis
Oil analysis and Inspection
2.0 can substantially improve
the outcome of SVOCs and miti-
gate the risks. This is largely the
practice of carefully monitoring
the aging health of the used oil
and recognizing the sudden and
escalating presence of a problem.
Issues might include premature oil
oxidation, the need for dehydration
or portable filtration, rising varnish
potential, the need for additive
reconstruction and abnormal ghost
rider concentration.
For large and critical systems,
the timing of the oil change is key.
The best way to ensure good timing
is to allow the oil to talk to you
through effective oil analysis and
inspection. When done correctly,
these methods will enable you to
achieve optimum results. ML
About the Author
Jim Fitch has a wealth of “in
the trenches” experience in lubri-
cation, oil analysis, tribology and
machinery failure investigations.
Over the past two decades, he has
presented hundreds of courses on
these subjects. Jim has also published
more than 200 technical articles,
papers and publications. He serves as
a U.S. delegate to the ISO tribology
and oil analysis working group. Since
2002, he has been the director and
a board member of the International
Council for Machinery Lubrication.
He is the CEO and a co-founder of
Noria Corporation. Contact Jim at
jfitch@noria.com.

Double Oil Change

This will require a machine stop-
page. The tank is drained and refilled
in the same manner as with a normal
SVOC. The oil is then brought back
to operating temperature while
circulating. Afterward, the oil tank
is drained and refilled again.

SVOC Followed by a Line Purge

After the tank has been drained
and refilled with new oil, the auxil-
iary pump is started and the new
oil is pushed into the system. The
old oil is not returned to the tank
but rather diverted to waste until
most of the old line oil has been
discharged. The tank is then refilled
to the correct level, and the return
line is reconnected to the tank.

www.machinerylubrication.com | November - December 2017 | 5

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COVER STORY

6 | November - December 2017 | www.machinerylubrication.com

 ML

To commemorate its 100th issue,

Machinery Lubrication presents 100 3
things you should know to develop
a world-class lubrication program.
Whether you are in the initial stages of implementing
a new program or already have a well-established
program in place, you should find numerous ideas
that can help, with advice from each of the 100 issues.

1. Be Proactive
When applied correctly, a proactive maintenance
strategy can double or triple lubricant service life.
This is achieved by reducing the conditions that
stress an oil (cleaner, cooler, drier, etc.).

2. Know Your
Lubrication Needs
The next time you award a supply contract for
lubrication, take the time to actually determine your
company’s needs. The process may reveal that you
have been paying for services that you don’t value or
would prefer to buy elsewhere.
3. Skills Foster
Reliability
If what you want most is to avoid machine failure,
then what you need most are maintenance skills that
foster intrinsic machine reliability.
4. Set Target
Cleanliness Levels
The first step of a contamination control program
is to identify a machine’s target cleanliness level.
A specific quantifiable number (ISO Code, for
instance) should be assigned to each machine based
on contaminant tolerance, operating environment
and motivation for machine reliability.
5. Design Simple Lube
Inspection Routes
Design lubrication inspection routes comprised
almost entirely of questions that the inspector can
answer “yes” or “no,” or as “OK” or “not OK.” This
keeps the process fast and simple.
6. Replace Business as Usual
Achieving lasting excellence in machinery lubri-
cation is neither difficult nor complex. It simply
requires a clear sense of purpose and the tenacity
to replace the old business as usual with a new one.
7. Consider Single-point
Lubricators
Depending on the application, single-point lubri-
cators can extend the life of rotating equipment and
increase reliability while significantly reducing the
cost of applying the lubricant.
8. Use Performance
Metrics
If used properly, a performance metric works like
a compass. It helps you find your bearings and get
on the right track when performance is substandard.
Once the organization is performing on target,
metrics help to keep it on track and facilitate contin-
uous improvement.
9. Follow the Root-cause Trail
Machines don’t just die; they’re murdered. If you
follow the root-cause trail, you will likely find a
smoking gun in the hands of one or more well-inten-
tioned individuals (operator, craftsman, technician,
mechanic, engineer, etc.) who simply didn’t know
any better.
10. Achieve a Cultural
Transformation
No single product or training course will accom-
plish cultural transformation because people resist
change by nature. A cultural transformation requires
a clearly defined and cohesive plan that may take a
considerable period of time to fully accomplish.

machinerylubrication.com | November - December 2017 | 7

 COVER STORY - 100th ISSUE
11. Requirements for a
World-class Lube Program
The best lubrication programs, often referred
to as world class, are those that have world-
class lubrication technicians, use world-class
lubricants and deploy world-class procedures.
12. Collaborate for
Lubrication Excellence
Lubrication excellence is a collaborative
process. By taking an active role in testing new
lubricants and giving constructive feedback to
your supplier, incremental improvements in
lubricant quality are bound to result.
13. Don’t Waste
Your Money
Saving money by buying cheap oil is almost
always a false economy. On the other extreme,
buying quality oil to remedy bad lubrication is
also a false economy.
14. Know the Dangers
of Grease Incompatibility
Contemplating a switch of grease products
brings to light the critical issue of compati-
bility. Before implementing a new product,
plant and maintenance engineers must weigh
all consequences of grease intermixing and the
impact on equipment reliability, production
levels and the bottom line.
15. Plan and Research
for a Better Lube Room
A world-class lube room is not built over-
night. The planning and research required
16
8 | November - December 2017 | www.machinerylubrication.com
14
are more time-consuming than the actual
construction work.
16. The Importance
of a Good Education
Training and education develop top-drawer
lubrication skills and can give the dollop of
grease and the rolling-element bearing a long,
happy life.
17. How to Sell Your Project
It is incumbent upon the lubrication
professional to translate a technically oriented
program proposal into results that a manager
understands and values. Whether you are
selling your project to the executive suite or
the maintenance managers, fit the message to
the audience.
18. Ensure Fluid Cleanliness
Maintaining fluid cleanliness is a job that’s
never done. It involves a relentless cycle of
sampling and remedial action as necessary
to ensure the appropriate cleanliness level is
continuously maintained.
19. Slow Down When
Applying Grease
Do not rush the application of grease, as this
can lead to oil bleeding in the feed line. Instead,
apply using a constant force. Also, if the action
is too fast, grease will leak at the labyrinth seals.
20. Detecting Bearing
Distress
Through the prudent use of temperature
and vibration monitoring equipment, routine
oil analysis, lubrication system evaluations and
machine operational performance reviews,
bearing distress may be identified and evalu-
ated before catastrophic failure occurs.
21. When to Outsource
Lubrication
Under the right circumstances, when
machinery lubrication is outsourced to create
value and competitive advantage, not just to
cut costs and/or window-dress the organiza-
tion, it can be a winning strategy. It can help
foster or perpetuate a “best-in-world” attitude.
22. Beware of Overheated
Hydraulic Systems
Continuing to operate a hydraulic system
when the fluid is over-temperature is similar to
operating an internal combustion engine with
high coolant temperature. Damage is guaran-
teed. Therefore, whenever a hydraulic system
starts to overheat, shut it down, identify the
cause and fix it.
23. Invest in Reliability
Improvements made to assure proper lubri-
cation of your equipment will yield benefit
 COVER STORY - 100th ISSUE
regardless of its age. However, early, reliability-​
focused investments to build a lubrication
program that works and to accessorize equip-
ment for lubrication excellence will compound
over time and maximize your returns.
24. Understand
Wear Modes
It is estimated that 70 percent of machines
are removed from service due to degrada-
tion of mechanical surfaces. Degradation
may occur as a result of abrasive, adhesive,
erosive, corrosive or fatigue-induced wear. A
clear understanding of how these wear modes
develop will assist the lubrication technician in
understanding the importance of his/her role
in improving machine reliability.
25. Make Oil Filters
Last Longer
Oil filters last longer when they don’t get
plugged with particles. Therefore, the best
strategy comes from working backward by
tracing the particle ingression pathway.
26. The Key to Lubrication
Program Success
While there are a number of excellent
companies that offer outstanding products
and services to support precision lubrication,
it is the people — and more importantly their
attitudes and the pervasive culture within the
plant — which will do more to help the success
or failure of the lubrication program than any
other single factor.
27. Select the
Right Lubricant
Selecting the proper lubricant is important
to sharply reduce long-term costs. The best-fit
product selection can mean longer lubricant
life, reduced machine wear, reduced incipient
power losses and improved safety.
28. Keep It Simple
Excellence in lubrication is a simple concept.
It is about getting the right lubricant in the right
place at the right time, making sure that lubricant
is supplied in the right quantity and ensuring the
lubricant is kept clean, dry and cool.
10 | November - December 2017 | www.machinerylubrication.com
25
29. Follow Manufacturer
Instructions
When relubricating electric motor bear-
ings, always follow the motor manufacturer’s
specific instructions and do not use any
lubricants other than those approved by the
manufacturer.
30. Paying for
Performance
Properly selected high-performance lubri-
cants may create cost reductions many times
greater than the price differential between the
product types. Selecting a performance option
should be based on the effect derived from a
carefully engineered change, with the expected
results calculated into commonly accepted
financial terms.
32
31. Don’t Blame the Lubricant
The universal panacea to a real or perceived
lubrication failure is to blame the lubricant.
Naively, we go looking for a better lubricant,
when in actuality it may simply be how lubri-
cation is performed that is at fault.
32. The Value of Oil Analysis
If used correctly, oil analysis can be a
valuable predictive and proactive diagnostics
tool. If used incorrectly, it can be a frustrating
exercise in futility.
33. Match the Lubricant
to the Application
Selecting lubricants for industrial gearing
is similar in most applications. To identify the
best choice for a given application, the right
viscosity, base oil and type of lubricant must
be selected and the appropriate performance
properties evaluated.
34. Knowledge Is Power
When decisions are made to make improve-
ments to your lubrication program, it is crucial
that you decide what knowledge and to whom
it must be disseminated to facilitate and ensure
the quality of implementation and execution
of these items.
35. The Importance
of Proper Sampling
Without proper sampling methods, the
value of oil analysis will be lost or severely
diminished. The problem often lies in incon-
sistent and invalid data. Unless you can take
consistent, repeatable samples, it is impossible
to establish useful alarms levels.
 COVER STORY - 100th ISSUE
36. Use Your Senses
An effective proactive/predictive mainte-
nance program requires tools such as vibration,
thermography and oil analysis to scan, inspect
and determine the condition of machinery.
However, your eyes, ears and nose can also
be valuable condition monitoring tools and
require little training to be utilized effectively.
37. Make Better Use
of Filter Carts
Portable transfer/filter carts are versatile
and can be used for more than just transfer-
ring fluids. Other possible uses include offline
filtration, cleaning stored lubes, flushing after
machine repair and rebuild, flushing during
equipment commissioning and draining a
reservoir or sump.
38. Prevent Lubrication
Mistakes
How can you error-proof against lubrica-
tion mistakes? One obvious way is through
tagging — applying color- and shape-coded
tags to machines, transfer devices and storage
tanks to ensure that the wrong oil or grease is
not accidentally added.
39. The Drive
for Cleaner Fluid
Fluid cleanliness is really no different than
driving: They both require a clear under-
standing of the target, an ability to validate the
target is being met, and a mechanism to take
correct action when a deviation is observed.
40. Establish Lube
Procedures
Lubrication procedures often vary from
technician to technician based on convenience
or preconceived notions of best practice. These
methods of personal choice can depart signifi-
cantly from OEM- or industry-defined best
practices. The correct procedure needs to be
established and routinely applied.
41. You Can’t Buy
Lubrication Excellence
Don’t be lulled into a false sense of secu-
rity that you can buy your way to lubrication
12 | November - December 2017 | www.machinerylubrication.com
37
excellence. Think about lubrication excellence improve system performance, and reduce wear
as a change in the process of lubrication, and deposits.
rather than a solution that can be purchased,
46. How to Schedule
set and forgotten.
Oil Changes
42. New Oil Is Seldom Clean
Don’t schedule oil changes on large
In the majority of cases, new oil is not volumes of lubricants unless your oil dictates
suitably clean for most applications. Whether the need. Deploy oil analysis to determine the
tote tanks, drums or bulk tanks are used, it
need and timing of the oil change instead of
is usually simple and inexpensive to install
the calendar.
high-quality filters at the dispensing station to
achieve a desirable cleanliness for the new oil. 47. A Winning Combination
43. Benefits of Storing Oil Reliability emerges from the optimum
in Bulk Tanks combination of quality lubricants and
best-practice lubrication. Don’t spend more
It is often easier to maintain low particulate
contamination levels when oils are stored in
money on premium lubricants hoping you
42
bulk tanks because they are normally closed
to the atmosphere and the oil is dispensed via
a pump or tap.
44. Manage the Life Cycle
of Your Lubricants
To extract the maximum value from lubri-
cants and the lubrication program, lubricants
must be properly managed from cradle to
grave. This means adopting best practices for
receiving, storing, dispensing, maintaining
and finally disposing of used lubricants.
45. Eliminate Air
in Lubricated Systems
It may be impossible to completely elim-
inate air from lubricated systems, but steps
should be taken to reduce it as much as can
reasonably be expected. Eliminating exces-
sive air will likely give more life to your oil,

can spend less on lubrication. There is no
substitute for vigilant inspection, frequent
and thorough oil analysis, and well-deployed
lubrication practices.
48. Keep Tabs on Oil Filters
Keeping tabs on the performance of oil
filters is essential to machinery reliability. Yet
too often, many people in the maintenance
field seem to be oblivious to the importance
and methods of doing so. The best strategy is
a proactive strategy.
49. Evaluate Your PMs
Preventive maintenance is among the most
common root causes leading to the need to
perform corrective maintenance. It need not
be. Evaluate your PMs and eliminate tasks that
fail to add value or actually create failure.
50. What to Consider
Before an Oil Flush
The risks of not performing a needed oil flush
include oil starvation from line restrictions and
motion impediment of critical machine parts.
And, postponing a needed flush can make
matters substantially worse. Therefore, before
planning and performing an oil flush, know
the pitfalls and countermeasures.
51. Expand Your
Wear Debris Universe
Take wear debris analysis to another level
by digging deep to expand your wear debris
universe. Develop new in-house skills and
tactics that enable weak signals to be detected
and virgin particles to be found and analyzed.
52. Monitor Water
Contamination
Water is one of the most destructive contam-
inants in oil, and it would serve you well to
monitor it on a consistent basis when dealing
with sensitive or critical equipment.
53. Know the Bearing Type
Know the type of bearing being lubricated.
A sealed bearing can’t be regreased. Shielded
or double-shielded bearings can be greased but
slowly so as not to overpressurize the cavity
and push the bearing shield against the cage.
51
54. Send the Right Signals
Sealable and reusable (S&R) containers serve
as a visual sign of maintenance excellence.
Conversely, use of fossilized oil cans serves as
a constant reminder of maintenance neglect
and program stagnation.
55. Use the FIFO Method
For both oil and grease, be aware of
their respective shelf life. Exceeding OEM
shelf life may render the product useless or
severely hamper its performance. For this
reason, it is best to use the first-in, first-out
(FIFO) method.
56. Develop Lube
Guidelines
Lubrication instructions need to provide
guidelines that are simple and easy to
understand but also contain specific details
for how to perform a task according to
prescribed best practice.
57. Employ Dynamic
Route Planning
Instead of walking to and from the lube
room, locating and gathering different tools,
and handling paperwork before executing the
work, employ dynamic route planning, which
allows those tasks that logically fit together to
be done at the same time, no matter what their
prescribed frequency.
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ML
58. Make Lubricant
Consolidation Easier
It can be difficult to consolidate lubri-
cants based solely on their names, but when
considering their performance properties, the
consolidation efforts are clearer and easier.
59. Add a New Dimension
to Oil Analysis
Effective oil analysis may be as much about
data presentation as it is about the data itself.
By leveraging the full resources of computer
software, including multimedia, oil analysis
can take on a whole new dimension.
60. Design a Better
Lube Room
A properly designed lube room must be
functional, safe, expandable and provide all
necessary storage and handling requirements for
the facility. Lube room designs should allow the
maximum storage capacity without allowing for
too much bulk oil and grease storage.
61. Consider Machine
Criticality
Be fully aware of machine criticality.
Changing the use or specification of lubricants
in mission-critical equipment should not be
done without skillful engineering.
62. Dangers of Overgreasing
Overgreasing can have many of the same
negative side effects as undergreasing, plus the
added cost of high lubricant consumption. Do
not exceed the properly calculated amount of
grease when performing greasing activities.
58
| November - December 2017 | 13
 COVER STORY - 100th ISSUE
63. Continuously Improve
Your Lube Program
A lubrication program needs constant
refinement and continuous improvement.
It is easy to slide back to the old ways of
doing things if not careful, especially if the
organization has a high turnover rate in the
labor force.
64. Handle Oil Drums with Care
Avoid damage to oil drums and other large
containers during handling. Negligent handling
can cause leakage or ingression of dirt.
65. Make Modifications
for Reliability
Lubrication-enabled reliability is not high
science. Any maintenance organization can
accomplish it with proper training, planning
and deployment. Much of it is behavior based and
just good old common sense. It’s about making
modifications of people, machines, procedures,
lubricants and metrics.
66. The Value of Machine
Inspections
Simple inspections on all types of machines
provide invaluable information as to their
condition as well as reassurance that they are
operating in a reliable manner.
67. Check Your Additive
Package
Whether they are enhancing, suppressing
or imparting new properties to the base oil,
additives play an important role in the lubri-
cation of machinery. When the additives are
gone, they’re gone, so don’t forget to check
your additive package.
68. Not Just Any Lubricant
Will Do
Machines don’t just need some lubricant or
any lubricant. Rather, they need a sustained
and adequate supply of the right lubricant.
69. Know the Factors
That Influence Oil Life
The end of oil life is influenced by a
complex array of factors. Many of these can
14 | November - December 2017 | www.machinerylubrication.com
65
be monitored, controlled and used to optimize
the oil drain interval.
70. Check Sight Glasses
It’s not enough just to put a sight glass
on a machine and walk away. These devices
should be monitored. They are windows into
what is happening with your oil and can give
you a first-hand account of any problems that
are occurring.
71. Keep Oil Clean
Keeping the oil clean is the first order
of business if extended oil replacement
intervals are the goal. In turn, achieving
extended oil replacement intervals often
makes it economical to use superior-quality
synthetic lubricants.
72. Advantages of
Hard-piping Machines
Hard-piping machines to a fixed oil supply
is one way to address a lack of available labor
to handle oils. Since this reduces the number
of hours it takes to perform an oil change, the
75
plant can run more efficiently with the staff
it already employs.
73. Contamination Control
Advice
The control of contamination in machinery
is pointless if contaminated or below-specifi-
cation lubricants are used, or if clean lubricant
is being handled so carelessly that it enters
machines in a contaminated state.
74. Create Electronic
Lube Procedures
Get your lubrication procedures in an elec-
tronic form, preferably on your company-wide
intranet or onto an internet account for those
moving toward web-based application support.
When procedures are electronic, they can be
updated globally, attached to work orders and
linked to like machines in your computerized
maintenance management system.
75. Add Accessories
If you truly want to make strides toward
becoming a world-class program, you will
need to make equipment modifications.
By adding accessories such as desiccating
breathers, quick connects, external level
gauges and sample ports, you can transform
a small gearbox to world-class standards in
terms of contamination control, maintain-
ability and reliability.
76. Share Responsibility
for Reliability
Reliability needs to have shared respon-
sibility. It must be fixed in the DNA of the
machine as well as in the minds of operators

and maintainers. It’s like a reliability chain –
every link in the chain must be equally strong
for the chain’s full length to bear the load.
77. Monitor Wear Debris
By vigilant monitoring of wear debris as
well as understanding the forces at play during
the break-in period, you can ensure that your
machines will have a longer life and experience
fewer breakdowns.
78. Don’t Neglect
Lubricant Disposal
Proper handling techniques do not end when
the oil has been put into service. Once the life
of the oil has been exceeded, you must ensure
the lubricant is captured and disposed of both
safely and in an environmentally friendly way.
79. Manage Change
Your lubrication strategy will depend on
the scope of the project, the size of your
company and the cultural maturity of your
organization. The bigger the organization
and the project, the more relevant a good
change-management initiative becomes, and
the more resources will be needed for a seam-
less and faster implementation.
80. Ensure Multiple
Sampling Locations
Most circulating and hydraulic systems
should have both a primary and secondary
sampling location to ensure that any identified
failure mechanism can be tracked back to the
component causing the problem.
81. Value Knowledge and Skill
Make education and job competency a big
deal. Knowledge and skill should be appre-
ciated, respected, celebrated and reinforced.
Use education as a team-building tool to bring
people together with shared goals and create
opportunities for coaching.
82. Control Leaks
Leakage control makes good sense for a
number of reasons. Not only are there lubri-
cant consumption savings but also reliability
and safety benefits.
83
83. Trend Oil Analysis Data
Simply obtaining a snapshot of data from
an oil sample is essentially worthless without
something to which to compare it. This is
why trending data in oil analysis reports is so
beneficial. It not only allows you to determine
if the current oil properties are unfavorable
but also if they will become unfavorable in
the near future.
84. Visit Your Lubricant
Blender
If you have the opportunity, visit your blend-
er’s plant and check out their processes. See if
they are putting the same emphasis on keeping
81
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ML
lubricants clean as they are on blending and
formulation specifications.
85. Match Synthetic Oils
to Machinery Needs
Synthetic oils can be tremendous assets to
any lubrication program, but they must be
matched to the machinery’s needs to get the
optimum benefit from them. When making
the transition from mineral base fluids to a
synthetic base, be sure to flush the system to
minimize any residual compatibility issues that
may remain.
86. Develop a Plan
for Used Lubricants
All plants should have a coordinated plan for
managing used lubricating oil, including how
much oil is reclaimed and how much is recycled.
87. Emphasize the Reasons
for Change
When implementing change, such as when
designing or redesigning a lubrication or reli-
ability program, people need to know why the
change is being made and how it will affect
them. Understanding the need for change is
the first step in creating new behaviors within
a facility.
88. Question Viscosity
Recommendations
Don’t assume the lubricant in your machine
has the right viscosity simply because it is the
| November - December 2017 | 15
 COVER STORY - 100th ISSUE
one specified in the machine’s
service manual. Challenge
conventional recommendations
for viscosity. Some machines
are operating at conditions far
afield from that intended by the
machine designer.
94. Keeping
89. Identify the Oils Fluid
Cause of Oil Leakage In some applications, it is nearly
Any time there is oil leakage
in a system, there’s a reason for
it. The entire system should be
analyzed, and the cause of the
leaks identified.
95. Consider Water-
90. Handle Lubricants based Fluids
Carefully
Most lubricants should be
handled with care and proper
personal protective equipment
(PPE). Create a barrier between
you and the lubricant. Wear
gloves and safety glasses as
well as oil- or chemical-resis-
tant boots. If possible, keep all
exposed skin covered.
91. Determine the
Correct Oil Level
The best time to decide on
the appropriate oil level for
your equipment is when the
machinery first arrives at your
facility. Once the correct oil level
is identified, it must be clearly
marked in the field.
92. Watch for Foam
Contaminants frequently
affect a lubricant’s foam
tendency and stability as well
as water separability. If you
detect more foam than normal
or demulsibility issues, it may
be an indicator of lubricant
contamination.
93. Find the Source
of a Heat Problem
16 | November - December 2017 |
The next time a heat problem
occurs in one of your systems, 100
look for oil that is flowing from a
higher pressure to a lower pressure
in the system. That’s where you’ll
likely find your problem.
impossible for oil to remain fluid invest in training for your team 100. Water Contami-
at all ambient temperatures. In members in order for them to
execute your procedures properly.
nation Can Affect
these situations, the use of an oil
heater is recommended.
Oil Viscosity
99. Check Your A common misconception is
Oil Analysis Lab that water will reduce the viscosity
Most oil analysis practitioners of a lubricant. In fact, if an exces-
assume the data from their labo- sive amount of water is “whipped”
Water-based fluids are an
ratory is accurate and irrefutable, into the oil in such a way that
alternative when fire resistance
is imperative and typical lubri- but this may not always be the it forms a stable emulsion, the
cant properties like viscosity or case. Routine checking of your viscosity can increase, sometimes
lubricity are less important. lab is crucial. dramatically so. ML
96. Test New Oils
It is critical to your oil analysis
program that you sample and test
oils upon receipt. The possibility
of receiving the wrong oil or
lubricants that do not meet the
required specifications is very real.
97. Choose the Right
Lubricant to Reduce
Air Pollution
One of the more overlooked
aspects of a lubricant is its ability
to influence environmental emis-
sions. By selecting the proper oil,
you can help to reduce some of
the harmful contaminants that
are spewed into the environment
without sacrificing the needs of
the machine or the performance
of the lubricant.
98. Invest in Training
Even if you have invested large
amounts of resources in your
program, you may still need to
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 After
2017 Lube Room Challenge

Getting
Bottom-line Before

Results from
a Lube Room
Transformation
Machinery Lubrication recently asked readers to participate in its annual Lube
After

Room Challenge by submitting exceptional lube rooms that incorporate best-​practice

features. Several readers met the challenge with evidence of how their lubricant
storage and dispensing methods have been transformed. The following entries show-
case how designing a proper lube room not only is an important step in the journey
toward lubrication excellence but can also increase a company’s bottom line.

Aleris
The Aleris rolling mill in Clayton, New Before
Jersey, supplies foil and light-gauge aluminum
coiled sheet. For its lubricant storage, the mill
had been utilizing seven different areas across
the manufacturing floor. The plant also had just
one filtration unit for all its oils, and this unit
was seldom used or maintained.
Drum pumps and makeshift hoses and
fittings were employed to transfer oil to open, The Aleris mill had stored its lubricants in seven different areas across the manufacturing floor.
unlabeled containers. The drum pumps were
not segregated, so nothing prevented them from After
being used in different oils. There was also no
filtration of the oil during the transfer process,
including when bulk hydraulic oil was trans-
ferred from tanker trucks into reusable totes.
After reviewing previous equipment failures
and gearbox inspection reports, the mill made
several modifications. Additive packages on The new lubricant storage area has been consolidated into one climate-controlled
some oils were changed. A color-coding system location with a loading dock and waste oil collection.

18 | November - December 2017 | www.machinerylubrication.com

LUBE ROOM CHALLENGE

was developed and employed throughout
the facility. The lubricant storage area was
consolidated into one climate-controlled
location away from the manufacturing floor
and equipped with a loading dock and waste
oil collection.
Now, drum and platform filter carts
are utilized, and single-station filter and
dispensing areas have been installed. There
are dedicated transfer hoses and oil containers,
as well as filtering of transferred oil. Bulk
hydraulic oil transfers are made from tanker
trucks through filters into storage tanks and
then from the bulk storage through filters into
filter carts. The filter carts are used for topping
off reservoirs.
Aleris also launched a corporate reliability
program, which began with an evaluation of
all company plants. This evaluation consisted
of everything from work management and
lubrication to contractor management.
Every plant was graded on a scale of 1-5 in
11 different areas. Of these areas, lubrication,
work management and training were chosen to
be the focus of the plants’ initial efforts.
The emphasis on lubrication led to the
formation of a lubrication technical advisory
group (TAG). This group was comprised of
representatives from each of the plants and
tasked with creating a general lubrication
corporate technical manual. Monthly calls
were scheduled to discuss the project and to
Aleris recently hosted a face-to-face event
assign areas of responsibility. Noria consul-
with representatives from plants around the
tants were also brought in to help finish the world to edit its corporate standards manual.
manual, which has become a complete training
guide for the development of best practices in essential for Aleris as it establishes a lubrication
lubricant storage, preventive maintenance and audit program and minimum requirements for
leak management. This new manual will be all of its plants.

Bunge
Just a few years ago, the Bunge plant in
Lehliu, Romania, had no lubrication room
or filtering area for lubricants. Grease was
dispensed by hand and easily contaminated.
After the company determined changes
were needed, a lube room was built inside a
mechanical workshop building.
The Bunge lube room features eight oil filters and four grease-dispensing units. Each type
The new room features four grease-​
of oil is now filtered before entering a machine.
dispensing units and eight oil filters, with the
goal of using each filter for only one type of ress. Today, each type of oil is filtered, and The Bunge facility continues to see
oil. Although only five of the oil filters and two grease is no longer contaminated. All transfer improvements in the performance of its
of the grease-dispensing units are currently containers, grease guns and storage units are lubricants and is now strictly following new
in use, the plant has made significant prog- also clearly labeled. procedures for lubricant storage and handling.

City Utilities of Springfield, Missouri Before

City Utilities (CU) is a municipally owned utility serving Springfield,
Missouri. CU owns and operates two coal-fired generation units as well
as a number of gas turbines and a landfill gas-to-energy project. In 2015,
a lubrication management survey revealed many areas for improvement
throughout the power generation facilities, including lubricant chemistry,
cleanliness, testing, and lubricant storage and handling.
A system of separate dispensing tanks had been in service for some
time. However, the tanks were open to the atmosphere, had no filtration
capability, and utilized a single pump system and combined piping for
filling and dispensing all stored lubricants. In addition, the tank system
was located in an open area of the station adjacent to an open delivery
and maintenance bay, which was exposed to dust and other pollutants
associated with the coal-fired power plant.
In 2017, a storage and handling system was placed into service. A
new state-of-the-art dispensing system is now located in a closed room The lubricant storage and dispensing areas at the City Utilities
plant had been cluttered and disorganized.

20 | November - December 2017 | www.machinerylubrication.com

 ML

away from the dust and heat of the plant.

The new dispensing system features separate
pumps, filters and piping for each lubricant,
and every tank utilizes desiccant breathers for
ventilation. Dispensing jugs used for transfer-
ring smaller quantities of fluid are also stored
inside closed cabinets in the new lube room,
as opposed to open shelving. For larger quan-
tities, transfer pumps with filters specifically
matched to the application are now used. To
minimize the chances of cross-contamination,
lubricant tanks and jugs are coded with a color
and shape which correspond to coded tags on
the lube points of various machines.
Bulk lubricant storage has been another
area of significant improvement. Oil barrels
previously were stored both inside and
outside in a very disorganized manner. The
lubrication management survey also revealed
many consolidation opportunities. Through
consolidation and organization, the lubricant
inventory has been reduced from more than
100 barrels to nearly 30. Furthermore, every
new barrel of oil is sampled prior to entering
the inventory.
After After
Lubricant barrels are now stored in a racking system, and a new lubricant storage and
dispensing system was placed into service in 2017.
Other lubrication program improvements lubricants showed only 60 percent at a severity
that have been or are being implemented include of 0 or 1 (good/acceptable) and 24 percent
regular sampling of machinery, sealing up lubri- with a severity of 3 or 4 (bad/unacceptable).
cation systems, improving in-line filtration, Today, 90 percent have a severity of 0 or 1, and
installing desiccant breathers and adding quick only 3 percent remain at a severity of 3, with
disconnects to facilitate clean oil transfers and
none in the severity 4 range.
lubricant filtering. The organization currently
has three technicians who are trained and certi- Although there is still quite a bit of work
fied as a Level I Machine Lubricant Analyst, remaining to achieve world-class status,
with more to receive training in the future. the improvements that have been made are
When the utility first began implementing paying off in greater equipment reliability and
these changes, the overall state of in-service economic benefits.

International Paper
The International Paper mill in Port Wentworth, Georgia, manufactures
specialty grades of pulp that can be found in products around the world. In
2011, the mill formed a reliability team to help eliminate lubricant contami-
nation and improve overall equipment reliability, product safety and quality.
One of the team’s primary focuses was on lubricant storage and distri-
bution. The mill had many remote lube areas, and contamination control
was minimal. Lubricant labeling was either missing or not standardized.
Oil also was not filtered from the drums.
The reliability team developed standard operating procedures for labeling
transfer containers and purchased filtration carts. A 5-S room was created
for consumables such as sight glasses, breathers and filters. Battery-operated
grease guns with gram counters were procured, and all the site’s grease
guns were calibrated. The team also worked with its lubricant supplier to
consolidate its lubricants. Samples are now taken from incoming oil drums.
For storing grease, shelving with clear labeling was installed, and the first-in,
first-out (FIFO) method employed.
In 2016, a centralized distribution system was implemented. The lube
room, which came as a packaged unit, is climate-controlled and sealed to
prevent contamination. The facility’s most common oils are pre-filtered and
stored in stackable totes. This has greatly reduced the inventory of full drums
and the need for partial drums.
The mill’s future plans include purchasing color-coded transfer carts
and staging them in the lube room. Installing hose reels and quick connects The International Paper mill’s most common oils are pre-​
will allow these carts to be easily moved and avoid having to carry jugs of filtered and stored in stackable totes, reducing the inventory
oil up and down stairs. of full oil drums and the need for partial drums.

www.machinerylubrication.com | November - December 2017 | 21

LUBE ROOM CHALLENGE

Koniambo Nickel
Located on the South Pacific Island of Before After
New Caledonia, the Koniambo Nickel indus-
trial complex is one of the world’s largest
nickel producers, including a mine, smelter
and power station. Storage and dispensing of
lubricants previously were carried out from a
cluttered 20-foot container situated next to
the power station. With oil funnels and drum
pumps open to the environment, high levels of
contamination were introduced into new oils
prior to their use in equipment. It was clear
the site needed new equipment and a culture
change regarding its lubrication practices.
After Koniambo Nickel reviewed various Storage and dispensing of The new custom-designed lube room is equipped with
types of lube rooms, it determined that the lubricants at the Koniambo racks for dispensing containers and oil drums, bunded
“plug-and-play” units provided many advan- Nickel industrial complex were flooring, intrinsic lighting and power, an eyewash
tages, such as avoiding the cost of building a previously carried out from a station, and a patch kit workstation.
dedicated facility while offering the convenience cluttered 20-foot container.
of receiving a unit that was fully set up.
Due to the mine’s location, an insulated combustible liquids. Side air vents with air filter options. A patch kit workstation is utilized to
ceiling and secondary skillion roof were fitted pads help to reduce dust. The room is also kept monitor oil cleanliness and assist with activities
to the container to reduce the internal tempera- closed for dust suppression. such as the use of filter trolleys.
ture. The 20-foot lube room was then custom Racks were installed for dispensing Now that its lubricant storage and
designed and equipped with fire extinguishers, containers and 20-liter drums. A color-coding handling practices are in order, the site has
an eyewash station, bunded flooring, intrinsic system is employed for the dispensing stands turned its focus to improving lubrication
lighting and power, and air-operated pumps and containers. The dispensing stands also management, including installing sight glasses
for the storage and handling of flammable and feature filtration, taps and quick-connect and upgrading its breathers and sample valves.

Lakeside Foods
The Lakeside Foods plant in Owatonna,
Minnesota, produces canned vegetables for the Before After
retail and food-service sectors. To determine the
proper lubricants for its equipment, the facility
worked with a local oil specialist to conduct a
complete plant survey. Following the survey, the
site was able to consolidate many of its prod-
ucts and transition to 100 percent food-grade
lubricants. All equipment was also individually
tagged to indicate which fluid is required.
By switching from drums to bulk tanks,
plant personnel now have an immediate visual
indication of when oil is running low and no
longer must guess how much oil is left in
drums. This also has eliminated the need to
store empty oil barrels and provided a much
neater appearance.
In addition, the facility was able to switch
from five different oil vendors to one. In doing
so, annual oil expenses at the plant have been Before a plant survey, the Lakeside oil Switching to bulk tanks has provided a
reduced by 32 percent. Purchasing has also been room was dirty and unorganized. visual indication of when oil is running low
streamlined, freeing the maintenance supervisor and eliminated the need to store empty oil
to spend more time on equipment maintenance. barrels.

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 ML

Mosaic
The journey to world-class lubricant storage
Before After
for the Mosaic Four Corners phosphate mine in
central Florida began in 2015. A companywide
“awakening” to the need for better lubrication
practices had occurred a few months earlier. The
mine’s first focus was on creating a lubricant
storage area from which subsequent lubrication
improvements could take root.
Bulk oil totes had been scattered throughout
the plant and stored outside in the muddy and
humid environment. Because the bulk totes
were stored outside, the mine’s portable oil A storage shed was chosen as the location of the
containers were also filled outside and kept in new lube storage area.
work carts overnight.
A storage shed was identified as an excellent
location for the new lube storage area. The shed
was cleaned out, the floor sealed and a berm
constructed so oil would not permeate or escape
the shed in the event of a spill. Small repairs to
the shed also had to be made to prevent dirt and
rain from entering.
The new lube storage area is a shared space
All portable oil containers are now filled by
between three maintenance crews (a total of Bulk oil totes previously had been filters through quick connects. Anything in the
35 mechanics). A daily 5-S walkthrough is stored outside with a secondary
containment that stayed full of lube area that can be moved has lines marking
performed as well as a monthly audit. the designated areas for storage.
rain water.
Safety is a critical concern at Mosaic, and
the lubrication area is no exception. A binder breathers for every drum and tote, and new The results have been remarkable. The 5-S
containing all lubricant material safety data portable oil containers, which are filled by a score from the monthly audit has averaged
sheet (MSDS) information is kept on a shelf filter-through quick connect. The lubricant 98 percent. All oil going into the lubrication
in the area. The berm around the inside of the
stock has also been reduced and relocated to area is now quarantined until it is filtered.
space was painted yellow to prevent trips and
the area so extra totes are not stored outside. This has increased oil cleanliness for the bulk
falls. Fire extinguishers are placed in accessible
areas. The space also includes proper signage, a Without management support, the new storage containers.
portable eyewash bottle and a rolling ladder for lubrication area would not have been possible. The world-class lubrication area continues
accessing the top of bulk oil totes. The total cost of the project was nearly to be a positive influence on the mine’s improve-
In addition, industry best practices are now $43,000, with most of the expenses related ment efforts, providing a sustainable resource
followed, such as the use of a color-coded lubri- to sealing the floor, installing the berm and for mechanics where lubrication-related items
cant identification system, filters and desiccant replacing the overhead door. are easily accessible.

Mueller Co.
The Mueller Co. plant in Albertville, Alabama, is an iron foundry and
Before After
fire-hydrant manufacturing facility. The site had been storing lube oils
alongside paint and thinner materials in a building where the roll-up doors
were always open. This resulted in the oils being exposed to dust, high
humidity, high summer temperatures and below-freezing winter tempera-
tures. To help correct this issue, a portable lube room was purchased and
installed. The plant now is able to pump oils into labeled storage totes
via low-micron filtration, with each oil having its own labeled pump. All
oils are filtered out of the drums and into these totes. The environment is
temperature-controlled at 70 degrees year-round. A dehumidifier and proper
oil transfer containers are also employed. Additionally, the lube room is Before a new portable lube room The new lube room is temperature-​
locked to everyone except the lubrication specialists and their supervisors. was installed at the Mueller plant, oil controlled and allows oils to be
In 2017, these efforts have saved the plant more than $38,000 in oil costs drums were exposed to dust, high pumped into labeled storage totes
alone, which for a small facility is a big deal. humidity and extreme temperatures. via low-micron filtration.

www.machinerylubrication.com | November - December 2017 | 23

 LUBE ROOM CHALLENGE
NIPSCO
Located on the shores of Lake Michigan,
the Michigan City and Bailly generating
stations are coal-fired power plants which are
24 | November - December 2017 | www.machinerylubrication.com
owned and operated by the Northern Indiana
Public Service Co. (NIPSCO). Both facilities
had been using older lube rooms and needed to
update their lubricant storage and dispensing
systems. A single transfer pump was being
utilized to remove oil from drums, and filtra-
tion of new oil also was not standardized.
NIPSCO sought reliability improvements.
The company worked with its lubricant distrib-
utor to improve its lubricant storage and
handling practices. Maintenance personnel
learned that proper lubricant handling can be
a critical step in equipment reliability.
The new oil storage rooms employ
individual pumping systems to eliminate
cross-contamination of lubricants. Inline
filtration and desiccant breathers help to
ensure oil cleanliness. Oil and grease inven-
tories were consolidated, and wall charts have
been updated to clearly display equipment
and product names. A safety cabinet was also
purchased to store sealed lubricant transfer
containers, which are dedicated by product and
used for handling smaller oil quantities. While
work continues on labeling equipment fills
with the correct lubricant nametags, consider-
able progress at both facilities has been made
with excellent results.
Before
The lube room at the Michigan City generating
facility was old and needed to be updated.
After
Individual pumping systems and inline filtration
are now employed at the Michigan City plant.
 ML

Owens Corning Before

Just a year ago, the Owens Corning composites
plant in Aiken, South Carolina, realized its lubricant
storage and handling practices had become a problem.
This resulted in the site’s lube room being cleaned
and painted. Better lighting was installed, as well as
heating, ventilation and air conditioning (HVAC).
Oils and equipment were tagged to prevent misap- A year ago, the lube room at the Owens Corning plant was quite dirty
plication of lubricants. Policies and procedures were and unorganized.
developed for the lube room along with safety and
emergency instructions.
The room is now explosion-proof with its own
fire-​suppression system. An automated system noti- After
fies the staff when oil sampling is needed. Each week,
personnel are also required to clean the lube room,
inspect for leaks, filter the oil in storage and restock
the inventory.
Of course, the upgraded lube room only marks the
beginning of the facility’s journey to excellence. The
improvement process continues one machine at a time.
The plant still has a long way to go, but the employees
are learning a lot and have already seen measurable
gains on the company’s bottom line. The area has since been cleaned and painted along with the addition of better
lighting and tagging of oils and equipment.

Sheboygan Wastewater
Treatment Facility Before
The Sheboygan Regional Wastewater Treat-
ment Facility in Sheboygan, Wisconsin, cleans
the wastewater for more than 68,000 residents in
seven local communities. When a construction
project reduced its oil storage room by 58 percent Oil storage at the Sheboygan Wastewater Treatment Facility had been messy with dirty drums
to only 315 square feet, the facility had to find and oil rags scattered around the area.
a way to consolidate its lubricant inventory and
locate a proper in-plant storage area. The site’s
oil storage was also messy, with dirty drums After
and oil rags lying around, as well as leaking and
outdated drum pumps.
A new lube storage and dispensing system
was purchased, which included color-coded
labels, quick filter assemblies, spill containment
and sight gauges for inventory control. By stan-
dardizing its oil type and getting rid of obsolete
oil, the plant was also able to eliminate seven
50-gallon drums.
The new lube room is now clean and well-lit.
The walls have been painted, and an epoxy
coating has been applied to the floor. The facility
not only was able to save valuable space, but its
oil storage is now neat and organized. The result
has been a cleaner and safer environment for the The oil room is now clean and well-lit, with painted walls, an epoxy coating on the floor, and a
plant’s lubricants and employees. new lube storage and dispensing system.

www.machinerylubrication.com | November - December 2017 | 25

 LUBE ROOM CHALLENGE

Wiegel Tool Works lids. Having designated containers for each oil The oil room project has been a major
Wiegel Tool Works (WTW) is a metal- has helped to prevent cross-contamination. success. Since the room has been in place,
stamping manufacturer in Wood Dale, Illinois. In addition, the entire oil room was WTW has received positive feedback from its
Established in 1941, the company specializes completely remodeled. Floors were painted staff and seen lube-​related mistakes decrease
in complete turnkey packages, including with industrial-grade paint to eliminate oil significantly. Employee attitudes toward the
engineering, prototypes, tool construction and stains and provide for easy cleanup. Two room have also changed. With its continuous
wire/electrical discharge machining. Through new cabinets were purchased to store the oil improvement culture, WTW plans to pursue
the years, the company has invested heavily containers, with each cabinet having color-coded new ideas for creating an even more efficient
in new technology and equipment. As part of locations for individual containers. oil room in the future. ML
its continuous improvement culture, manage-
ment identified the oil room as the next key
improvement opportunity.
The original oil room did not meet best
Before
practices and was due for a redesign. Oil drums
were stored on racks and the floor. No level
gauges were used on drums, which resulted
in poor inventory control. Each oil drum also
did not have its own designated pump. This
increased the risk of cross-contamination,
as pumps were interchanged across drums.
Proper identification of oils and oil containers Oil drums were on racks and the floor in the original oil storage room at the
was another major problem. Wiegel Tool Works plant.
At the beginning of the improvement
project, WTW’s lubricants were examined,
and the consumption rate and storage capacity
After
were determined. An efficient and cost-​effec-
tive method of storing oils was employed, with
the facility’s highest running oils stored in
300-gallon rack systems. The average running
oils are stored in 120-gallon and 65-gallon bulk
storage systems with color-coded tanks. These
systems have dedicated pumps, filters and
breathers for each oil. The plant’s low running
oils are kept in 55-gallon drums and stored on
a spill-containing rack system. This new layout
offers a compact footprint, allowing more oil to
be stored in less space.
All oils now have a designated container,
location, color and shape for easy identifica- The oil room’s new layout allows more oil to be stored in less space while helping to prevent
tion. The oil containers also have color-coded cross-contamination.
Be a LUBExpert

Grease Bearings Right

Right Lubricant

Right Location

Right Interval

Right Quantity

Right Indicators
sdtultrasound.com/lubexpert
1-800-667-5325 • 905-377-1313
 Al Smiley | GPM Hydraulic Consulting
HYDRAULICS
How Directional
Valves Affect Oil Flow
in Hydraulic Systems
Directional valves are some of the most funda-
mental components of a hydraulic system. When
a directional valve is sized for an application, it
must be large enough to handle the volume of
oil necessary to operate the cylinder or hydraulic
motor. For applications that require less than 10-15 gallons
per minute of oil flow, a direct solenoid-operated valve is used
(as shown in Figure 1). To shift the valve spool, current is
applied to the valve coil. This creates magnetism within the
coil, which pulls in the plunger. The plunger then acts on a
pushpin, which shifts the valve spool. The solenoid generates
approximately 30 pounds of force to shift the spool. Once
the spool shifts, oil is ported through the valve and then to
the cylinder or hydraulic motor.
Spool
Coil
Plunger
Figure 1. A direct solenoid-operated valve
28 | November - December 2017 | www.machinerylubrication.com
Two-stage Valves
On systems where higher flow rates are required,
two-stage valves are normally employed. A typical two-stage
proportional valve is shown in Figure 2. The top valve is
known as the pilot valve. The purpose of the pilot valve is to
direct pilot pressure to shift the main spool. Since these are
larger in size than the direct operated valves, more force is
needed to shift the main spool. Instead of using very large
solenoids that demand high current to operate, hydraulic
pressure is utilized to shift the main spool.
There are springs on both sides of the main spool
which hold it in the center position when the pilot valve is
not shifted. The springs are usually rated between 50-115
pounds per square inch. When the main spool on this
particular valve is in the center position, the “P,” “A,” “B”
and “T” ports are blocked.
Two-stage valves may be internally or externally piloted.
In Figure 2, notice the pilot plug (circled in red) on the left.
This plug blocks flow from the “P” port of the main spool to
the “P” port of the pilot valve. When this plug is installed in
the valve, pilot pressure must come from an external source
and be connected to the “X” port on the valve manifold.
Many presses and mobile equipment employ a separate pump
for supplying the pilot fluid. In some cases, oil is ported
downstream of the pump through a pressure-reducing valve
and then to the “X” port. By utilizing a separate pump or
pressure-reducing valve, a lower pressure is used to shift the
main spool. This prevents damage to the spool instead of
using the higher system pressure to shift the valve.
When current is applied to the pilot valve coil (as shown
in Figure 3), magnetism in the coil causes the pilot spool to
shift to the right. Pilot fluid then flows from the “X” port
through the pilot valve and to the pilot cavity on the right
side of the main spool. Once the pilot pressure builds up
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HYDRAULICS
enough to overcome the spring acting
on the opposite side, the main spool
will shift to the left. Once shifted, the
system volume at the “P” port of the
main spool will flow through the “P”
and “A” ports and then to the actuator
(cylinder or hydraulic motor). The oil
that exhausts out of the actuator flows
into the “B” port, which is connected
to the “T” port inside the valve. The oil
will then flow out of the “T” port and
return to the reservoir.
When the main spool shifts (as in
Figure 3), the oil on the left side of the
T A P B X Y spool is ported through the pilot valve
Figure 2. A typical two-stage proportional valve spool. Notice in Figure 2 that the circled
pilot plug on the right is blocking the
flow passage from the tank port of the
pilot valve to the tank port of the main
spool. When this plug is installed, a
line must be connected to the “Y” port
on the manifold to externally drain the
valve. This provides a flow path for the
oil that exhausts out of the main spool’s
pilot cavity and pilot valve to return to
the tank.
In some instances, both pilot
plugs are removed from the main
valve housing. In this case, there are
no external lines connected to the “X”
and “Y” ports on the valve manifold.
In Figure 4, the pilot plugs have been
T A P B X Y removed. This opens the internal pilot
passage from the “P” port of the main
Figure 3. Current applied to the pilot valve coil
valve to the “P” port of the pilot valve.
Once the pilot valve is shifted, system
pressure is directed through the pilot
valve to shift the main spool, as previ-
ously described. When the main spool
shifts, the oil that exhausts out of the
opposite pilot passage will flow through
the pilot valve and then into the tank line
of the main spool. This is what is known
as an internally piloted and internally
drained valve. Valves can be internally
drained as long as there are no flow
surges or pressure spikes in the tank line
that affect the shifting of the main spool.
T A P B X Y Replacing
Two-stage Valves
Figure 4. A main valve housing with the pilot When replacing a two-stage valve,
plugs removed
it is important that the piloting and
30 | November - December 2017 | www.machinerylubrication.com
draining arrangements are the same
as the removed valve. This applies to
proportional and AC voltage-operated
valves. In certain instances, valves
are internally piloted and externally
drained. In other cases, they may
be externally piloted and internally
drained. Refer to the valve’s part
number to ensure the valve you are
installing is the same as the one that was
removed. Just because it mounts on the
same manifold does not mean it is the
same valve. For example, a closed-center,
externally piloted and drained Vickers
valve has the following part number:
DG5S8-2C-E-T-30. The “E” designates
that the valve is externally piloted, while
the “T” indicates that it is internally
drained. If a DG5S8-2C-E-30 valve is
put in its place, the valve will not work
because it is externally drained. This
means the internal drain port is plugged
and the main spool will not shift, since
no line is connected to the “Y” port.
I recall an instance at a plywood
plant where they had replaced a valve
on the lathe with the exact part number
as the valve they had taken off. When
the new valve was installed, the spool
wouldn’t shift and allow the spindle
cylinder to extend and clamp the log.
After changing several other compo-
nents, they found that although the part
number was the same, the equipment
manufacturer had removed the pipe
plugs from the original valve but failed
to change the part number. Once the
pipe plugs were removed, the valve and
spindle cylinder operated normally.
If you and your vendor do not
have a valve in stock with the config-
uration you need, a valve usually can
be converted by removing or installing
pipe plugs. On the proportional valve
used in the examples, the pilot plugs
are accessed by taking the pilot valve off
the main stage and removing them with
an Allen wrench (Figure 5). On some
valves, the pilot pressure plug is accessed
through the “P” port of the main spool.
Another important thing to
remember is that pilot and drain lines
and passages are small and can plug.
 ML

If a new valve is installed and the actuator will not

operate, check the pilot and drain passages. This can
be done by removing the pilot valve from the main
valve’s housing and disconnecting the pilot and drain
lines from the manifold. Blow air into the pilot and
drain line passages on the manifold. If air comes out
the pilot and drain ports on top of the main spool, the
passages are clear.
With a greater understanding of how these valves
work as well as their proper applications, you should
be able to better troubleshoot your hydraulic systems
for improved equipment reliability and availability. ML

About the Author

Al Smiley is the president of GPM Hydraulic
Consulting Inc., located in Monroe, Georgia.
Since 1994, GPM has provided hydraulic training,
consulting and reliability assessments to compa-
nies in the United States, Canada, the United
Kingdom and South America. Contact Al at
gpm@gpmhydraulic.com. Figure 5. Pilot plugs can be removed with an Allen wrench.

PRUFTECHNIK is a leading single-source solution provider for

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www.machinerylubrication.com | November - December 2017 | 31

 PRODUCT NEWS
HIGH-TEMPERATURE
GREASES
1 4
The new Molykote G-900x
Series greases from Dow
Corning are formulated to
provide high-temperature lubricity
for applications ranging from auto-
motive to industrial and chemical
equipment. The silicone lubricants
offer corrosion resistance and
high thermal stability across a
wide temperature range (minus
35 to 220 degrees C) for increased
lifespan. A combination of phenyl
and fluoro functional branches
built on a siloxane backbone form
the copolymer used in the greases.
They also have formulation
capabilities with various thickener
systems and are compatible with
most plastics and elastomers.
Dow Corning
www.dowcorning.com
800-248-2481
32 | November - December 2017 |
SYNTHETIC MOTOR OIL MULTI-PORT ADAPTER
2 3
ExxonMobil’s new
synthetic motor oils are
guaranteed to provide
protection for one year between
oil changes or 20,000 miles,
whichever comes first. The Mobil
1 Annual Protection motor oils
have been specifically formulated
to offer maximum wear protec-
tion as well as increase resistance
to oil breakdown and protect
engine parts from sludge and
deposits, resulting in extended
engine life. Available in 0W-20,
5W-20 and 5W-30 viscosities,
the oils are recommended for
all types of modern vehicles,
including high-performance,
turbocharged, supercharged,
multi-valve and fuel-injected
engines found in passenger cars,
SUVs, light vans and trucks.
ExxonMobil
www.mobiloil.com
800-662-4525
1 3
1
www.machinerylubrication.com
The Hub from Luneta is
a multi-port adapter for
equipment with limited
or inaccessible port locations.
It features four lateral ports,
which allows easy installation
of oil level sight glasses, bottom
sediment and water (BS&W)
bowls, drain valves, quick
connects for attaching filtration
equipment, etc. Constructed
from heavy-duty, powder-coated
cast aluminum and zinc-plated
steel, the Hub has a large-diam-
eter, 12-inch pilot tube for high
viscosity sampling. The sample
port is also recessed into the body
to prevent inadvertent impacts.
Luneta
www.luneta.com
888-742-2021
ELECTROSTATIC
LUBE OIL FILTER
The new Orbitron
3000 is an electrostatic
lubrication filtration
system that serves as an alter-
native to chemical cleaning and
flushing. It incorporates a 22-cell
electrostatic filter to purify
lubricants used in mechanical
operating systems across a wide
variety of industries. The unit is
compact (about the size of a small
refrigerator) and can eliminate
contamination at a rate of 5
gallons per minute. Submicron
contaminants are identified as
they are collected. Once the
lubricant is purified, the Orbitron
3000 begins removing any
buildup accumulated over time.
Orbitron Companies
www.orbitronco.com
952-292-0754
4

METALWORKING FLUID
5 8
Cimperial 35-880 from
Cimcool is a high-per-
formance metalworking
fluid intended for use in a
number of heavy-duty machining
and grinding operations. It
is formulated with a unique
technology to ensure stability and
pH buffering as well as corrosion
protection. The boron- and form-
aldehyde-free fluid is designed
especially for the manufacture
of aircraft components made
from aluminum, titanium, steel,
stainless steel, nickel-based alloys
and cobalt-based alloys.
Cimcool
www.milacron.com
888-246-2665
5
AUTOMATIC
LUBRICATOR
6 7
The new TLMP
automatic lubricator
from SKF is engineered
to provide reliable relubrication
of multiple lube points in
industrial applications as well
as agricultural and off-road
vehicles. Capable of supplying
one to 18 lubrication points,
the TLMP is packaged as
a complete kit, including a
lubricator, required tubing
and connectors. The lubricator
features pluggable outlets and
is easy to install and program
via its keypad with an LED
display. The cycle control sensor
ensures lubricant is delivered to
the outlets, while the filter helps
to avoid grease contamination
from airborne particles.
SKF
www.skf.com
267-436-6000
MULTI-PURPOSE
GREASES
The WD-40 Specialist line
of greases is formulated for
automotive, construction
and farming professionals dealing
with a variety of specialized
lubrication challenges. The new line
includes the Superior Performance
True Multi-Purpose Grease, which
is designed to provide lubrication
under extreme-pressure, high-tem-
perature and severe conditions; the
Heavy-Duty High Temperature
Grease, which can withstand heavy
mechanical loads and extreme
temperatures; and the Heavy-Duty
Extreme Pressure Grease, which
features exceptional load-carrying
ability, anti-wear protection and
high dropping point properties.
The interchangeable greases are
intended to protect against rust
and corrosion and not cause cross-​
contamination issues.
WD-40
www.WD40Specialist.com
888-324-7596
8
ML
TRUNK PISTON OILS
Shell’s new Argina and
Gadinia trunk piston oils
incorporate base number
retention and viscosity control
to address the faster oxidation
that leads to deposit formation
or lubricant contamination.
Developed for the medium-speed
engine market, the Argina range
includes four grades: the S2 for
residual, blended and distillate
fuels; the “mainstream” S3 and
S4; and the S5, which offers extra
protection from deposits and
extended oil life. The Gadinia
S3 was designed to control oil
consumption in modern engines
burning distillate fuels.
Shell
www.shell.com
800-237-8645
 GET TO KNOW

Knight Shines as
Reliability Leader
for Mueller Co.
Alan Knight has been keenly aware of the importance of performing lubrication the right way
since his time as a leader of a reliability program assessment team. However, he did not actually take
a hands-on role until he became the site reliability engineer at Mueller Co. At the time, Mueller had
just begun trying to improve its lubrication program. Knight soon took over the lube program and
helped the site employ best practices. The result has been a 75 percent drop in bearing failures due
to lubrication issues over the last few years. Knight and his team are now working hard to eliminate
the remaining 25 percent.

Name: Alan Knight
Age: 50
Job Title: Senior Reliability
Leader
Company: Mueller Co.
Location: Albertville, Alabama
Length of Service: 3 years
Be Featured in the
Next ‘Get to Know’
Section
Would you like to be featured in
the next “Get to Know” section
or know someone who should be
profiled in an upcoming issue of
Machinery Lubrication magazine?
Nominate yourself or fellow lubri-
cation professionals by emailing a
photo and contact information to
editor@noria.com.
Q: What’s a normal work day like for you?
A: The morning begins with a daily meeting
between maintenance and operations manage-
ment to discuss the day’s schedule as well as
any issues that may have arisen overnight. From
there, it’s reviewing any break-in work orders
from the previous day. Afterward, I check in with
the condition-based maintenance (CBM) tech
and lube specialists to discuss any challenges,
accomplishments and improvements. I am part
of the management staff, so some days involve
several meetings, but the rest of the time is
usually spent on program analysis and improve-
ments, whether it be in precision maintenance or
working with engineers and operations managers
to solve problems on the floor.
Q: What is the amount and range of equip-
ment you help service through lubrication/
oil analysis tasks?
A: We only have about 400 rotating assets, but
they vary from smaller gearboxes on conveyors
to large gearboxes on our sand mullers, and
medium-sized (20-gallon) hydraulic systems to
large (300-gallon) fire-resistant hydraulic systems
for our furnaces. We also have large and small
fan systems as well as many computer numerical
control (CNC) machines. As far as oil analysis
goes, we currently perform sampling and analysis
on the top 20 percent of our most critical assets.
Q: On what lubrication-related projects are
you currently working?
A: I am currently working to fully integrate ultra-
sound-assisted lubrication into the daily routine of
our assets that require grease. Additionally, we are
working to expand the role of operators in our lubri-
cation programs as asset owners. My goal is to also
have our own mini-lab at some point in the future.
Q: What have been some of the biggest project
successes in which you’ve played a part?
A: The biggest success so far has been the
reduction in the amount of oils we use. We have
reduced oil costs by more than $100,000 for the
last two years. That’s huge for a facility this size,
as we only employ approximately 450 people for
all three shifts, including administrative staff.
Q: How does your company view machinery
lubrication in terms of importance and overall
business strategy?
A: The attitude is changing across the company,
partly as a result of what we have achieved so
far in Albertville and our sister plant in Chat-
tanooga, but also because we have put the right
people in place who understand the true value of
lubrication excellence.
Q: What do you see as some of the more
important trends taking place in the lubrica-
tion and oil analysis field?

34 | November - December 2017 | www.machinerylubrication.com

A: I’ll admit that I am not fully up to speed on all the
advancements, but the fact that more and more companies
are realizing the value of quality oil analysis and employing
best-practice storage and handling techniques is encouraging.

Q: What has made your company decide to put more

emphasis on machinery lubrication?
A: After 2008, we – like every other company – had to learn
to do more with less. Margins became tighter, and the need
for reliable assets to produce products became much more
necessary. Lubrication is the lifeblood of machinery, and
machinery is the lifeblood of our manufacturing processes.
As we demonstrate the value of using best practices for our
lubrication programs, it isn’t a hard sell. ML

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 LUBE-TIPS
The “Lube-Tips” section of Machinery Lubrication magazine features
innovative ideas submitted by our readers.

Tip for Replacing Oil Filters

When replacing top-suspended spin-on or threaded canister-type filters, fill them with fresh oil before instal-
lation. This will reduce the amount of time that the engine or machinery undergoes dry start-up by having an
extra amount of oil available. In some cases, it could also prevent filter damage when a gush of high-pressure fluid
hits a dry element.

How to Speed up Oil Changes

Use your circulation pump to speed up oil changes
in large circulation systems. Install a tee and two
Did You Know? isolating shut-off valves downstream of your circu-
Additional tips can be
lating pump. When draining your reservoir, connect
found in our Lube-Tips
email newsletter. To receive the hose to this tee and use your pump to move the oil
the Lube-Tips newsletter, from your reservoir to the scrap oil truck. This is espe-
subscribe now at
cially helpful for large, below-ground level systems.
MachineryLubrication.com.

Have Some TIps? Pay Attention to

If you have a tip to share, Your Oil Level Indicator
email it to When rolling-element bearings are lubricated from oil held
editor@noria.com.
in a sump, attention to the oil sump level indicator will not
only bring savings in terms of extended bearing life, but also
will lead to reduced bearing temperatures due to churning and
metal-to-metal contact resulting from possible oil starvation.
As a general rule, the lowest rolling element should be half
covered with oil when the bearing is stationary. This may seem
like a simple rule to observe, but it is surprising how often it is
completely overlooked. ML

36 | November - December 2017 | www.machinerylubrication.com

 NOW ON MACHINERYLUBRICATION.COM
Find more great articles and content from Machinery Lubrication magazine online. From web exclusives and industry
news to videos, white papers, buyer’s guides and more, everything that relates to machinery lubrication is available
now on www.MachineryLubrication.com.

FEATURED How to Preserve Equipment How to Detect Electrostatic

WHITE PAPERS
MachineryLubrication.
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in Storage
Preservation lubricants come in a variety of
different types to help preserve machinery in the best
possible condition. Read this article on the ML site to
discover the best course of action regarding the amount
of oil that machines should be stored with as well as
options for constantly purging stored equipment.
How Hydrolysis Can Affect Your Oil
Water contamination can affect machines in
a variety of ways, including leading to a chemical
breakdown of the oil or lubricant. This is known as
hydrolysis. Access this 1-minute, 34-second video
Discharges in Oil
As an oil’s conductivity decreases, the potential for
electrostatic discharge increases. The charge develops
from friction between the oil’s molecules as well as
between the oil and the surface of the piping, reser-
voir, filter housing, etc. Learn the factors that affect
an oil’s conductivity along with the best methods for
minimizing the charge potential by reading this article
on the ML site.
Hydraulic Gear Motors and
How They Work
Some lubrication professionals may not fully under-
stand how a hydraulic gear motor works. Access this
2-minute, 11-second video to get a detailed look at the
interior of a motor, its gears and body. See how oil
is pushed into the inlet port and through the outlet,
traveling between the gear teeth and the gear housing,
generating the rotation of the shaft. ML

BY THE NUMBERS

71
to find out the effects hydrolysis can have on your

%
oil and how to determine if your lubricant is prone
to hydrolyze.

10 Things You Should Know

of lubrication professionals
employ both an inspection
program and a condition
monitoring program to maintain
equipment at their plant, based
on a recent survey at
MachineryLubrication.com
About Varnish
Varnish is not easy to define because there is no
single type. Many things affect the kind of varnish that
forms, including the operating conditions, the type of
oil and the environment. Check out this article on the
ML site for a list of 10 things that should be under-
stood about varnish as it applies to lubrication.

www.machinerylubrication.com | November - December 2017 | 37

 Wes Cash | Noria Corporation
IN THE TRENCHES
Best Practices
for Lubricating
Paper Machines
“
In the current elec-
tronic age, many
people think of paper
as a dying industry.
While it’s true that more businesses
are going “paperless,” consider all the
MOST PAPER paper products that are still used in
MACHINES HAVE homes and offices every day. These
would include things such as paper
HUNDREDS, towels, hygiene products, diapers,
etc. All of these items are made in
IF NOT paper factories that were either built
for these products or have been
THOUSANDS, OF retooled to manufacture them. In
addition, these segments of industry
LUBE POINTS are growing, causing the demand
to keep the machines running at an
THAT REQUIRE all-time high.
One of the best ways to achieve
PERIODIC fault-free operation of paper machines
is to ensure the proper lubricant is
APPLICATION applied to the frictional surfaces.
Most paper machines have hundreds,
OF OIL OR if not thousands, of lube points that
GREASE.” require periodic application of oil
or grease. There are bearings, gears,
couplings, journals, cylinders and
valves which must all receive the
correct lubricant to survive the rigors
of the paper-making process.
Circulating Systems
Since paper machines often
have a high number of lube points
38 | November - December 2017 | www.machinerylubrication.com
Industrial Lubricants
in close proximity, they typically are
lubricated with circulating oil. In this
setup, oil is pumped from a central
reservoir throughout the system, with
supply piping running to the lube
points and return piping channeling
lubricant back to the reservoir. This
type of lubrication system is advanta-
geous for a variety of reasons.
Machines lubricated with circu-
lating oil tend to operate cooler than
those that are splash-lubricated. This
reduced operating temperature helps
extend the life of the lubricant and
the lubricated component. Besides
its cooling function, circulating oil
also can reduce the labor costs of
lubricating each point individually.
Although a lubrication technician
must monitor each line to ensure the
proper volume is being applied, phys-
ically adding oil to every point is not
required with these systems.
Circulating systems employ
pumps that force oil where it needs
to go. Since the oil is pumped,
there is an opportunity to filter it
and remove harmful contaminants
that may damage sensitive machine
components. It is not uncommon to
find multiple filter locations within
paper machine oil systems. Filters
located in the supply line can remove
contaminants before the oil goes
 ML

to work. Filters in the return line help scrub
contaminants that were recently ingressed by
the process. Off-line filters continually circulate
oil in the reservoir through filters to further
polish the oil. When all of these filters are
utilized in unison, not only will the circulating
oil be very clean, but vast amounts of machine
wear can be reduced.
Paper machine circulating systems normally
hold hundreds if not thousands of gallons of
oil. With this volume, the oil has adequate
residence time in the reservoir, allowing parti-
cles and water to fall out of suspension, air to
separate, and the oil to cool. There is also a
larger volume of additives to enhance the oil’s
lubricating properties. All of these factors can
combine to significantly extend the life of the
oil and equipment.
Bearings
Along with serving multiple functions
inside the circulating system, paper machine
lubricants must lubricate numerous component
types. Bearings are perhaps the most common,
particularly roll bearings tied to the centralized
lubrication system. These rolls help transport,
size and dry the paper. As the rolls turn, the
bearings must be simultaneously lubricated and
cooled. The flowing oil transfers heat away from
the bearing and provides the required lubri-
cating film for smooth, consistent operation.
If the bearing housing allows contaminants
into the system, the moving oil can carry these
contaminants out of the housing to the filters
or reservoir to be settled out of the system.
wet pulp is placed onto a web or screen and
then transported through the machine where
it is dried and fashioned into the desired thick-
ness. The press and calender sections are where
the finished product’s thickness is usually
formed. In these sections, the paper machine
lubricant may also be used as a hydraulic
medium. The oil provides the force required
to push the rolls together, determining the
paper’s thickness. The hydraulic pumps and
valves in these areas of the machine are highly
contaminant sensitive, so the oil must be kept
relatively clean throughout its operating life to
ensure the life of the components.
Leakage
With hundreds of pipe connections,
lube points and machine interfaces, paper
machines frequently are plagued by lubricant
leaks. This leakage also leads to two other
problems: capturing the leaked lubricant and
continuously topping up the oil reservoir.
Capturing the lubricant normally is
achieved with pans or rails, which collect and
funnel the used oil to a collection container.
Some facilities have attempted to reclaim and
recondition this leaked oil in order to reintro-
duce it into the machine. Provided the base
oil and additives are still healthy, this can be a
viable option, but it does have inherent risks.
If the oil cannot be fully filtered to remove
the gross contamination, it will become yet
another source of contaminant ingression for
the lubrication system. Also, the practice of
capturing and then reconditioning the lubri-
cant may not be cost-effective. The amount of
effort required to clean the oil to an acceptable
level would far outweigh the cost of buying
new oil and adding it to the reservoir.
Continually topping up the lubricant
can help to extend the time between oil
changes. The new lubricant brings with it
new additives and dilutes any damaged base
oil, thus improving the lubricating properties
of the oil overall. Some paper machines never
undergo a full drain-and-fill of the oil reser-
voir because of this practice of adding new oil
as the used oil leaks out.

Gears
In some paper machines, the centralized
lubrication system also lubricates gearing that
drives certain sections of the machine. Gears
present a different challenge than bearings in
that the load tends to be much higher. This
leads to greater stress on the lubricant film and
generally requires the use of additives to protect
the machine surfaces. The gears are commonly
simple spur gears that mesh together. They
can handle more chemically active lubricants
without the risk of corrosion or chemical degra-
dation to the gear surface. These gears often
have a more defined pitch line, which makes
the building of a lubricating film easier.

Press and Calender Sections

During the paper manufacturing process,

www.machinerylubrication.com | November - December 2017 | 39

 IN THE TRENCHES
By the Paper Machine Oils
Lubricants used in paper
Numbers: machines are specially formulated
to handle the rigors of the applica-
tion. These oils tend to have high
4,390 paper levels of additives to combat water
manufacturing contamination and support the loads
in working zones. The lubricants
facilities are generally consist of antioxidants, rust
inhibitors and anti-wear additives.
currently oper- In certain cases, they may also have
ating in the detergent additives to help prevent
buildup on machine surfaces due to
United States, the breakdown of the oil.
according to Viscosity is the most important
physical property of a lubricant
the American and must be properly selected for
the application. Paper machine
Forest & Paper lubricants typically have a viscosity
Association of more than 150 centistokes (cSt).
This viscosity allows the oil to be
pumped but still provides a thick
enough lubricating film to protect
the bearings. If the viscosity is too
low, the lubricated components will
suffer accelerated wear and have a
shorter lifespan. Conversely, if the
viscosity is too high, additional
power is needed to pump the lubri-
cant. Temperatures may also run
higher due to viscous drag.
Demulsibility is another critical
lubricant property to consider. The
oil must be able to readily separate
from any water picked up during
its journey through the system.
The lubricant should also be able to
transport this water to the reservoir
or a settling tank, where it sheds the
water and continues its way through
the lubrication circuit.
Contamination Control Automatic Lubrication
Filters should be employed on
every paper machine circulating
system. Without the ability to remove
contaminants, the oil and machine
surfaces will degrade rapidly. Many
paper mills choose filters with a
focus on smaller particles, such as 10
microns or less, as they often cause
the greatest damage. The selected oil
must also be able to pass through
40 | November - December 2017 | www.machinerylubrication.com
the filters at all expected operating
temperatures. This is largely a func-
tion of the viscosity and viscosity
index. Moreover, as oil flows through
the filter, the additives must remain
in the oil and not be stripped by the
filter. Paper machine oils require
many additives, so look for lubricants
that are filterable and retain their
additives during the process.
Usage Considerations
The intended use of the finished
paper product can also be a factor in
lubricant selection. In cases where
the paper is used for food packaging
or hygiene products, food-grade
lubricants may be required. This
will limit your lubricant options
as well as the additives that can be
used. Mandatory compliance with
the Food Safety Modernization
Act (FSMA) has made this issue
even more important. Be sure to
ask your internal FSMA champion
what the best course of action is for
minimizing any incidental contact
of the lubricant with the product.
Grease Lubrication
Depending on the paper
machine’s design, some bearings
may be lubricated with grease. There
are specific greases formulated for
these applications as well. They typi-
cally utilize a higher viscosity base
oil (above 220 cSt), have high water
resistance and are white so as not
to impact the color of the finished
product if any grease would happen
to fall onto the paper during its trip
through the machine.
Although certain paper machines
may be greased one point at a time
by a lube tech, others are tied into
large, centralized greasing systems.
These systems dispense grease from
a central reservoir to every point
using injectors. The injectors set the
volume applied at each point. When
automatic greasing systems are
employed, the lines and each injector
must be inspected to verify that they
are working properly.
Oil Changes
With large volumes of oil at
stake, many mills choose to change
their paper machine oil based on
its condition rather than taking a
time-based approach. This allows
them not only to get the most life
out of their oil but also to track
and trend variables like wear debris
and contamination. Normal oil
analysis test slates can be used to
examine the particle count, water
content, viscosity, additives and wear
metals. Other tests, such as varnish
potential, foam tendency and demul-
sibility, should also be conducted
periodically to look for a breakdown
of the base oil or any changes in the
oil’s physical properties.
Lubricant Selection
Selecting the right lubricant
for any application can be chal-
lenging. The same is true for
paper machines. As this industry
continues to evolve, the lubricants
used in these machines will as well.
However, by following the simple
practice of keeping lubricants clean,
cool and dry, you can ensure the
best possible life for your lubricants
and machines. ML
About the Author
Wes Cash is the director of
technical services for Noria Corpora-
tion. He serves as a senior technical
consultant for Lubrication Program
Development projects and as a senior
instructor for Noria’s Oil Analysis II
and Machinery Lubrication I and II
training courses. Wes holds a Machine
Lubrication Technician (MLT)
Level II certification and a Machine
Lubricant Analyst (MLA) Level III
certification through the International
Council for Machinery Lubrication
(ICML). Contact Wes at wcash@
noria.com to learn how Noria can
help you implement best practices for
lubricating machines at your facility.

Introducing the new Flexxpump 1500, a high-per-
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Over 90% of rotating equipment failure at startup is
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LUDECA
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LE’s FM Approved® fire-resistant Firesafe PoE
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The Original Gurtech™ Grease Coupler: No hands, no
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Big Gator Tools
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sales@bgtools.com
The MiniLab 53 is the next generation onsite oil
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delivers comprehensive onsite oil analysis, providing
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reduce costs for equipment operators and maintainers.
Spectro Scientific Inc.
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UE Systems’ new 4Cast Remote Ultrasound Bearing
Monitoring System operates 24/7/365. Stored data
and sound samples are sent to a host computer when
user defined alarms are breached to help determine
cause and action.
UE Systems, Inc.
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800-223-1325
info@uesystems.com
Translucent new oil is visually assumed to be clean,
but many times contains more contamination than the
existing oil being replaced. Find out why, plus the crit-
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Summit Ultima Series rotary screw compressor
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800.749.5823 – 903.534.8021
| November - December 2017 | 41
 TEST YOUR KNOWLEDGE
This month, Machinery Lubrication continues its “Test Your Knowledge” section in which we focus on a group of questions from Noria’s
Practice Exam for Level I Machine Lubrication 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.

Stay Connected With Noria

1. Anti-wear and extreme-pressure additives function by:

A) Reacting within the bulk oil to form wear protecting chemicals.
B) Are used in the same oil formulations.
C) Reacting with the iron surface due to frictional heat to reduce surface damage.
D) Stopping the wear reaction pathway.
E) Altering the surface tension of the oil.
Follow us on Twitter
https://twitter.com/NoriaCorp

2. Which hardware is the best for sampling pressurized

lines above 500 psi?
A) A long dead-leg of piping with a plug at the end
B) A pressure-regulating valve or a helical coil connected to a minimess valve
C) A capped drain plug
D) A minimess valve located on an elbow
E) A minimess valve located on a straight length of pipe

Like us on Facebook
3. Upper and lower alarm limits are generally needed http://www.facebook.com/noriacorp
on which oil analysis test results?
A) Acid number
B) Base number
C) Viscosity
D) Flash point
E) RPVOT

new (reference) oil.

Connect with us on LinkedIn

and RPVOT, lower limits are generally monitored by comparing them to the values of
https://www.linkedin.com/company
monitored by comparing it to the AN value of new oil. For the base number, flash point
/noria-corporation
in some cases component failure. For acid number (AN), the upper limit is normally
other hand, a lower viscosity may not be able to carry the load, which causes wear and
leads to churning as well as high temperature and its associated problems. On the
nents run on the correct oil film. Viscosity that is higher than the system requirements
Viscosity upper and lower alarm limits are needed to ensure that lubricated compo-
3. C

These two methods help control (reduce) the pressure to safely collect samples.
2. B

abrasive wear. Therefore, the correct answer is C.

high frictional heat from a low shear-strength film that protects against adhesive and
Anti-wear and extreme-pressure additives react with a component’s surface due to

Continue learning with us on

1. C
ANSWERS
YouTube
http://www.youtube.com/user/noriacorp

42 | November - December 2017 | www.machinerylubrication.com

 BOOKSTORE
Welcome to Machinery Lubrication’s Bookstore, designed to spotlight lubrication-
related books. For a complete listing of books of interest to lubrication professionals, check out the Bookstore at store.noria.com.

Reliable Plant Introduction

2017 Conference to Lubrication
Proceedings Fundamentals
Format: CD Training Video
Publisher: Noria Corporation Format: DVD
If you missed the learning Publisher: Noria Corporation
sessions at Reliable Plant Having a solid grasp of the
2017, you can still get the fundamentals of lubricants
conference proceedings on and lubrication is at the core of
CD-ROM. It includes the papers and presentations in any world-class lubrication program. This 37-minute
PDF format from nearly every educational session. The video will help you understand lubricant functions,
real-world case studies at Reliable Plant 2017 were full the differences between common lubricant types,
Use the Correct Oil of practical, experience-based information and tools for their advantages and disadvantages, as well as what
Poster lubrication and reliability programs. makes them perform or fail.

Chemistry and Root Cause

Technology of Analysis —
Lubricants — Fourth Edition
3rd Edition Authors: Robert, Kenneth
Authors: R.M. Mortier, M.F. and Mark Latino
Fox and S.T. Orszulik This 279-page edition
This updated and revised explains how to identify,
third edition describes the understand and prevent
chemical components that contribute to the formu- chronic problems that
lation of liquid lubricants and includes a discussion hinder the attainment of organizational goals using
of lubricant technology for specific applications. It is root cause analysis (RCA). Outlining steps to teach
Home Sweet Home of particular relevance for those in industry who are you how to automate the RCA process, the infor-
Poster involved with lubricant additives, formulation and mation in this book can improve the reliability of
testing, as well as those who are concerned with the your plant assets and save your company precious
use and specification of lubricants. time and money.

Machinery Lubrication I Study Pack

• • Flash Card Pack
• • 125-question Practice Exam
• • How to Take a Multiple-Choice Exam
• • Machinery Lubrication Reference Guide
•• Oil Analysis Basics
• • The Practical Handbook of
Machinery Lubrication
Keep Our
Machines Clean See page 53 for the next scheduled training class.
Poster

www.machinerylubrication.com | November - December 2017 | 43

 Alejandro Meza | Noria Corporation
31%
of lubrication professionals do
not know when a food-grade
lubricant is required, according
to a recent survey at
MachineryLubrication.com
44 | November - December 2017 |
PERSPECTIVE Food-grade Lubricants
Selecting Lubricants for
Pharmaceutical Facilities
Over the past few years, there
has been an increasing interest in
the use of food-grade lubricants
for machines operating in the
pharmaceutical industry. While these lubri-
cants can be beneficial, several other factors
must be considered.
Modern machinery used in the produc-
tion of pharmaceuticals generally requires
minimal or even no lubrication, particularly
in sections of the production line where
the product or its packaging is processed.
However, other machines with chains or
moving components near the production
line may need lubrication, and the lubricant
recommended by the equipment manufac-
turer might not always be classified as H1
food grade or certified according to the ISO
21469 standard. In these cases, it must be
determined whether the machinery should
be lubricated with conventional lubricants or
if there are specific requirements for selecting
an appropriate lubricant.
Lubricant Requirements
Lubricant selection should begin by
considering the lubrication needs of the
component or machine in terms of the load,
speed, viscosity and application method. Once
these parameters have been defined, additional
requirements must be taken into account,
such as food-grade properties. While the use
of food-grade lubricants is widely accepted in
pharmaceutical facilities, these H1-registered or
www.machinerylubrication.com
 PERSPECTIVE

ISO 21469-certified products are primarily intended for This last statement allows for the use of food-grade
food-processing plants and applications in which there lubricants in exposed areas of the machine. However,
is incidental contact with food. this should be addressed and documented properly. The
The U.S. Federal Drug Administration (FDA) FDA also permits the use of lubricants in a manufac-
provides regulations and good practice recommen- turing facility or in isolated machine sections when there
dations regarding pharmaceutical manufacturing is no risk of contact with the pharmaceutical product or
equ ipment a nd its packaging.
lubricants within When a lubricant is
t he C o d e of needed in an area that
Federal Regulations IT MUST BE DETERMINED WHETHER THE is exposed to the drug
(CFR). In 21 CFR MACHINERY SHOULD BE LUBRICATED WITH product, the poten-
211.65, it states: tial impact should be
“Equipment shall CONVENTIONAL LUBRICANTS OR IF THERE ARE analyzed to ensure it will
be constructed so SPECIFIC REQUIREMENTS FOR SELECTING AN not be detrimental to the
that surfaces that product’s intended fitness
contact compo- APPROPRIATE LUBRICANT. for use. This requirement
nents, in-process is stricter than the crite-
materials, or drug rion for food-processing
products shall not be reactive, additive, or absorptive machines, which allows a maximum lubricant contam-
so as to alter the safety, identity, strength, quality, or ination of 10 parts per million.
purity of the drug product beyond the official or other In general, sealed-for-life or non-lubricated
established requirements.” components should be the first choice for machinery
The document further stipulates: “Any substances components. Food-grade lubricants are a good option
required for operation, such as lubricants or coolants, for isolated production machine components that need
shall not come into contact with components, drug lubrication. Of course, proper cleaning and sanitizing
product containers, closures, in-process materials, or practices will be required after the application of lubri-
cants within the production area.
drug products so as to alter the safety, identity, strength,
quality, or purity of the drug product beyond the official
or other established requirements.”
Lubrication-related Requirements
In CFR 21.211, the FDA provides guidance
From this information, it can be concluded that
regarding lubrication practices and machine main-
machine operation should be free of lubricants in
tenance used in the manufacturing, processing and
sections or components where exposure to a pharma- packing of pharmaceuticals. It emphasizes the impor-
Helpful Resources ceutical product or its packaging may occur. Keep tance of maintaining clean equipment and establishing
For more information on this sub- in mind this regulation does not specify that lubri- written procedures, including lubrication procedures.
ject, visit the following websites: cants should not be applied in machinery utilized for If a lubricant change or lubrication issue could impact
NSF International pharmaceutical production, but rather that lubricants product quality, written records are required to be kept
www.nsf.org
U.S. Federal Drug Administration
should not come in contact with the drug product. relating to the affected product batch. However, routine
www.fda.gov Moreover, while lubrication routes would not be maintenance such as lubrication does not have specific
U.S. Government Publishing expected in equipment sections that are exposed to record-keeping requirements.
Office the product or its packaging, it is possible to lubricate
www.ecfr.gov
isolated machine sections. Lubricant Selection
The FDA’s Good Manufacturing Practice Guidance For effective lubricant selection in pharmaceutical
for Active Pharmaceutical Ingredients offers additional facilities, one of the first steps should be to classify
information on lubricants used in the manufacturing machines by the application. For support services
process: “Any substances associated with the operation equipment not located in the production area and that
of equipment, such as lubricants, heating fluids or cool- have no potential contact with production machinery
ants, should not contact intermediates or APIs (Active or the product/packaging, it is possible to use H2 lubri-
Pharmaceutical Ingredients) so as to alter the quality of cants, which are not intended for food-grade (incidental
APIs or intermediates beyond the official or other estab- contact) applications. These types of machines would
lished specifications. Any deviations from this practice include pumps, compressors, gearboxes and hydraulic
should be evaluated to ensure that there are no detri- systems involved in the supply of water, compressed
mental effects on the material’s fitness for use. Wherever gases and energy. Most lubricants (non-H1) in the
possible, food-grade lubricants and oils should be used.” market fulfill H2 requirements, while only a limited

46 | November - December 2017 | www.machinerylubrication.com

number have a formal H2 registration. If a compressed air line for
production machines requires lubrication, an H1 lubricant would be
a good choice.
Machines or machine components that are situated in the produc-
tion area but with a physical barrier blocking exposure to the locations
where products and packages are processed have no formal require-
ments for lubricant selection. However, food-grade lubricants may
be preferred to maximize safe maintenance practices related to the
production machines.
For components like sliding ways, chains or conveyors that have
the potential to contact drug products or packaging, further analysis
is recommended to identify the components’ true lubrication needs.
Determine whether these pieces must be lubricated, and if so, what
lubricant type, application method and frequency would be suitable.
For instance, a chain can be lubricated with oil, grease or dry spray.
Clean-room applications may demand the sterilization of tools and
machine components. If lubrication is needed, it may be necessary
to use not only food-grade quality but lubricants previously steril-
ized through thermal treatment (autoclave) or gamma irradiation. In
these cases, lubricant selection should include additional performance
requirements such as high oxidation, chemical or radiation resistance.
Special storage and handling procedures may also be required.
Whenever possible, switch to sealed-for-life or non-lubricated
components to eliminate lubrication tasks as well as potential lubri-
cant contact. Typically, the pharmaceutical industry utilizes relatively
smaller machines and components than other sectors. The equipment
also tends to operate in controlled environments. These favorable
conditions facilitate the conversion to a sealed-for-life or non-lubricated
asset. This recommendation is intended for production areas, but it can
also be beneficial if implemented across the facility.
In certain circumstances, an ISO 21469-certified lubricant may
be preferred over a lubricant registered as H1 food grade. While both
classifications involve food-grade lubricants for incidental contact with
products, the ISO certification “reviews the level of quality control
applied to the formulation, manufacturing, distribution and storage
of the lubricant to ensure it complies with the highest standards of
hygiene.” Both classifications are managed by NSF International.
Finally, be sure to follow the established protocols for change
management and keep a record of all lubricant conditions, analysis, deci-
sions and actions taken. For official recommendations and regulation
interpretations, contact the appropriate federal organization. The FDA’s
Division of Drug Information may also offer further assistance. ML

About the Author

Alejandro Meza is a senior technical consultant with Noria
Corporation. He has more than 20 years of experience in the lubricant
industry, technical services, quality assurance, training, consulting and
development in the United States, Brazil, Mexico and the Americas
region. Contact Alejandro at ameza@noria.com to learn how Noria
can help you select the right lubricants for your application.
www.Beckman.com/particle
© 2017 Beckman Coulter, Inc. Beckman Coulter, the
stylized logo, and the Beckman Coulter product
and service names used herein are trademarks or
registered trademarks of Beckman Coulter, Inc. in
the United States and other countries.

www.machinerylubrication.com | November - December 2017 | 47

 ASK THE EXPERTS
“What are the top three characteristics you look for when
considering an oil analysis laboratory (i.e., turnaround
time, price, quality, capabilities, etc.)?”
Selecting an oil analysis
laboratory can be daunting
if you don’t know where to
begin. Once you make the
decision to initialize an oil analysis
program at your plant or to find a
quality lab other than the one offered
by your oil supplier, there are several
important factors to consider. The
following three attributes will be key
to building a successful relationship
with your oil analysis lab.
Quality of Testing
Many laboratories struggle to
meet their customers’ expecta-
tions because of mishaps in testing
procedures. A quality lab will make
efforts to follow ASTM or ISO test
procedures in order to maintain the
utmost accuracy in analysis interpre-
tation. Be sure to find out whether
there will be any deviations to the
standardized test procedures, which
“Can you offer any advice on selecting desiccant breathers
for gearboxes in the mining industry?
Which factor plays more
of a role in breather
selection: the sump head-
space above the oil level,
ambient conditions like high
humidity or a dusty environ-
ment, the machine type (mobile
unit or fixed installation), the type
of oil and its application, or the
oil’s cleanliness requirement?”
48 | November - December 2017 | www.machinerylubrication.com
should be followed for all types of
testing instruments. Also, do not be
afraid to ask questions.
Data Interpretation
An oil analysis report is not
intended to be just a sheet of paper
with raw data results. These tests
can be quite complicated, so it may
not be easy to determine an obvious
concern, let alone an inconspic-
uous or unusual one. The best oil
analysis reports come complete
with a full analysis interpretation
summary. This should not be
computer-generated but tailored
by a specialist. The report should
also have graphs that show trend
data, along with a comparison
to the baseline, as well as critical
and cautionary limits. Finally, the
report should feature a layout that
is easy to understand.
Desiccant breathers are great
contamination control accessories
for machines that would other-
wise be breathing in dirty, wet
air. These devices allow for the air
being ingressed by the machine to
be cleaned of particulate matter
and also dried to help control the
amount of water in the oil. This
becomes very important in critical
Customer Service
The services an oil analysis labo-
ratory offers should go beyond those
relating simply to the oil samples.
The individual in charge of receiving
the reports at the plant should be in
frequent communication with those
who interpret data at the lab to
collaborate on possible explanations
for data anomalies and to obtain
expert advice on determining the
best course of action. The laboratory
should also offer a hotline to provide
quality customer service whenever
you need it.
Please note that price is not
included in this list, as you should
expect the cost of laboratory services
to remain competitive. Also, in
regard to price, it is important to
keep in mind that a single machine
failure that is avoided through oil
analysis can justify an entire year or
more of the oil analysis program.
machinery as well as those that are
in harsh environments where the
oil may become contaminated and
break down quickly.
These breathers have a partic-
ulate filter phase and a moisture
absorption phase. Both of these
phases are essential not only for
the health of the lubricant but also
for the health of the machinery.
 ML

Considering all of these variables will
provide the most effective way to select a
desiccant breather. While a number of options
are available, some are better suited for certain
situations. Remember, it is far better to provide
more protection than needed rather than to
skimp on quality in order to save money. ML
If you have a question for one of Noria’s
experts, email it to editor@noria.com.

Find us online at
klsummit.com

Solid particulate contaminants can lead to

machinery failure mechanisms such as three-
body abrasive wear. Moisture contamination
can result in adhesive failure mechanisms
and increase the rate at which lubricants
break down.
Oil by nature is hygroscopic, which means
it will absorb moisture readily from any source,
including from humidity in the air. By utilizing
a desiccant breather, you can reduce the
amount of moisture in the air that is entering
the system.
The headspace is important to keep in
mind, as it can help determine the amount
of “breathing” that will occur inside the
machine. Therefore, it is imperative to under-
stand how much the headspace can fluctuate.
For instance, the headspace in a splash-lubri-
cated gearbox will fluctuate less than that of
a hydraulic system reservoir where there are
large volumetric changes within the sump. This Customer
volumetric flow rate must be within the breath-
er’s capabilities, or it may cause a vacuum or
Service
pressurization condition inside the component. is not dead.
The environment in which the machine
operates should be considered as well. For
severe environments, such as those with water
spray and large amounts of dirt, select a desic-
cant breather that can handle the expected
amounts of contamination. For the most severe Great Products. Great Service.
environments, you might choose a breather Whether it’s fixing an issue, finding the right application,
with a check valve or bladder assembly to help the right product, oil analysis, cross-over, compatibility,
prolong the desiccant’s life. or any other need, we’re here to support our customers.
The cleanliness level required by the
machine must also be taken into account when
determining the desired desiccant quality. Of ( 800.749.5823
Klüber Lubrication NA LP
course, the more critical machines should Summit products are made in U.S.
receive the most attention.

www.machinerylubrication.com | November - December 2017 | 49

 Bryan Johnson
TRAINING AND CERTIFICATION
Online Tools Can Simplify
the Certification Process
Professional certification based on the
demonstration of knowledge through
formal testing is a key element in
lubrication and oil analysis programs.
However, identifying the requirements for certi-
fication testing is often not as straightforward.
Fortunately, online tools can help make the process
easier. For example, the International Council for
Machinery Lubrication (ICML) maintains a useful
website – www.lubecouncil.org – to assist individ-
uals with their certification needs.
Language Flexibility
One powerful function of the ICML website
is its flexibility in viewing content in 11 different
languages, specifically Chinese, Dutch, English,
French, German, Russian, Italian, Japanese,
Korean, Portuguese and Spanish. The organiza-
tion’s certification exams are available in these
same languages. While the website’s default
is English, non-English speakers can select a
language from the pulldown menu or by clicking
the appropriate flag on the righthand side of the
home page.
Schedule Exams
Of course, the first step in achieving certi-
fication is to complete the necessary training.
Most individuals prefer to schedule a certifica-
tion exam immediately after training has been
completed so the course information will still be
fresh in their minds. ICML exam sessions typi-
cally are scheduled for the afternoon or morning
following the training.
Training providers can often supply infor-
mation on related certification exams. If the
50 | November - December 2017 | www.machinerylubrication.com
certification information isn’t included as part of
the training offering or it’s not possible to take the
exam immediately after the training, an exam can
still be self-scheduled through the ICML website
at a later date. Individuals who do not wish to
self-register can also send an email to ICML and
request scheduling assistance.
When scheduling an exam, be sure to allow
ample time for testing. ICML does not limit an
exam sitting to a single test. Any of its certification
tests can be taken at each exam sitting. The exam
session calendar feature on the organization’s
website displays upcoming test sites throughout
the world. Certification candidates are welcome
to enroll at any of these published locations. An
option also allows you to find nearby exams by
entering your location in the search field. In
addition, ICML can arrange for a private exam
session. This will require sending an email to
registration@lubecouncil.org.
Extend Certifications
It’s only natural that job duties and require-
ments may change as professional skills and
competencies increase. The next logical career
step is to extend your certification by enrolling
in additional training and then following up
with the next higher tier test. ICML certifica-
tions and training are offered in three distinct
tracks and at progressively higher levels for
Machine Lubricant Analyst (MLA), Machine
Lubrication Technician (MLT) and Laboratory
Lubricant Analyst (LLA). The ICML website
describes the associated competencies for each of
these certifications, including their requirements
and the knowledge base needed. This informa-
Lubrication Programs
tion can be found under the “Certifications and
Exams” menu tab.
Successfully completing a higher tier
certification is one way to extend an ICML
certification for an additional three years. The
other option is to recertify. Recertification
requirements are based on a point system. Main-
taining employment as a lubrication professional
will earn points to recertify, but this information
must still be registered. If you would like to
extend your certification or if your certification
has lapsed, the ICML staff can help. Contact
them via email at admin@lubecouncil.org.
Search the List
of Certified Professionals
ICML maintains a listing of all individuals
who hold active certifications. This list can be
accessed by navigating from the home page using
the “Certified Professionals” menu tab. Certified
individuals are listed alphabetically along with
their company, country and all certifications
currently held. As employment situations change,
it is recommended that individuals review their
information and provide ICML with corrections
or updates when appropriate.
Reap the Full Benefits
of Certification
A certification is a valuable industry-based
acknowledgement of a highly desirable skill set. It
is useful for employers and employees alike. ICML’s
website and other online tools can help both compa-
nies and certification candidates achieve the full
benefits of certification. Be sure to take advantage
of them in your certification journey. ML

Recent Recipients of ICML Certifications
Abdelgadir Zienelabdin Glaleldin
Gergawe, MLA II
Amjed Amin Abdelgalil Mustafa,
MLA II
3M
Elliot Brandenburg, MLT I
Randall Albrecht, MLT I
Abbvie
Angel Rojas Reyes, MLT I
Juan Jimenez Nunez, MLT I
Marilyn Goyco de Vera, MLT I
Mervin Rivera Vazquez, MLT I
Advanced Technology
Services
Brandon Keeney, MLT I
Aker
Fredrik Sirevaag, MLA I
Henrik Neudecker, MLA I
Aleris Rolled Products
Eric Gray, MLA I
Alliant Energy
Don Singer, MLT I
Jay Schnelle, MLT I
Altec Industries
Bradley Vinson, MLT I
Aluminum Products
Ali Saeed Al Mesbah, MLA I
Americas Styrenics
Craig Jacobs, MLT I
Anglo American
Tobias Francois Johannes van
Rhyn, MLA II
Arauco
Gonzalo Garcia Roque, MLA II
ArcelorMittal
Kevin Polacec, MLT I
Ascend Performance
Materials
Aaron Chatraw, MLT I
Austin Langfeldt, MLT I
Cory Steigerwald, MLT I
Derrick McDaniel, MLT I
Francis Szymanski, MLT I
Guy Lowery, MLT I
James Stinson, MLT I
Kraig Hall, MLA I
Luis Silva, MLT I
Mark Cottingham, MLT I
Rubin ODonovan III, MLT I
Salvador Quezada, MLT I
Shane Odom, MLT I
William Brazell, MLT I
Ash Grove Cement
Brandon Marple, MLT I
The International Council for Machinery Lubrication (ICML) continues to provide skill certi-
fication testing for professionals in the areas of oil analysis and machinery lubrication.
The organization offers three certifications: Machine Lubricant Analyst (MLA), Machine
Lubrication Technician (MLT) and Laboratory Lubricant Analyst (LLA). ICML congratu-
lates the following individuals who recently achieved certified status in one of the three
certification areas.
Dorthy Whited, MLT I
Scott Dierks, MLT I
Shaun Finlinson, MLT I
ATI Metals
Artie Host, MLT I
Brian Keeney, MLT I
James Dodge, MLT I
Jason Waggoner, MLT I
Jeffry Sitton, MLT I
Jeremy Gerhardt, MLT I
Joe McKinney, MLT I
Joseph Longtin, MLT I
Kevin Dixon, MLT I
Lucas Lindstrom, MLT I
Ron Freitas, MLT I
Atlantic LNG Company of
Trinidad & Tobago
Jerome Watson, MLT I
Axiall Corp.
Christopher Pourciau, MLA I
Barrick
James Syme, MLA III
BASF
Azlee Bin Anis, MLA II
BHP Billiton
Nathan Baxter, MLA II
Bintulu Port
Awang Raisudin Bin Awang
Saifudin, MLA I
Boise Paper
Craig Manley, MLT I
C&W Services
Orrin McCarty Jr., MLT I
Cameco
Deanna Exley, MLA I
Canfor Pulp Limited
Jeffrey Kiss, MLA I
Caraustar Industries
Bryan Hawkins, MLT I
Matthew Fisher, MLT I
Cargill
Justen Brown, MLT I
Kelsie Perkins, MLT I
Kevin Lloyd, MLT I
Terry Oyster, MLT I
Carmacks
Cynthia Bouchard-Gagne, MLT I
Catalyst Paper
Michael Mayer, MLT I
CertainTeed Gypsum
Jacob Williams, MLT I
Larry Larson, MLT I
Cervecera de Puerto Rico
Francisco Hernandez, MLA I
Chevron
Brian Noble, MLT I
Charles Davis, MLT I
Daniel Delaughter, MLT I
Derek Mallette, MLT I
Derrick Ross, MLT I
Greg Fleming, MLT I
Jeremy Henry, MLT I
Joel Woods, MLT I
Joseph Crawford, MLT I
Robert Grogan, MLT I
Timothy Presley, MLT I
Val DeLancey, MLT I
China Aluminum
Ming Cai, MLT I
Qingyu Ma, MLT I
Yuan Li, MLT I
China Nuclear Power Co.
Kezhen Wang, MLT I
China Petroleum
Hao Zhang, MLT I
Coca-Cola
Carlos Santiago, MLA I
CRE Philippines
Joy Lomugdang, MLA II
Dong-A System
Seung Gyu Kim, MLT I
DSME
Sung Bum Hong, MLT I
DuPont
Cody Welch, MLA II
EcoElectrica
Luis Ramos, MLA I
Eco-Services
Ryan Powell, MLA II
Elantas
William Hellmuth, MLT I & MLA I
Energy Development Corp.
Robert Aguilar, MLA II
Entergy
Gregory Vest, MLA I
Entidad Binacional Yacyreta
Horacio Martinez, MLA II
Excel Contractors
Kim Panepinto, MLT I
Exelon Corp.
Joseph Bendyk, MLA II
Lucas Zimmerman, MLA I
FCF Minerals Corp.
CERTIFICATION NEWS
Erickson Gerald D. Lubat, MLA II
Flint Hills Resources
Fred Viano Jr., MLT I
Fluid Life Corp.
Adam Kuebel, MLA I
Fortescue Metals Group
Christopher Gibbons, MLA II
Fuchs
Omar Romero, MLT I
GCI
Jesse Merritt, MLT I
Joseph Bond, MLT I
Need to take
General Electric an exam?
Ben Payton, MLT I ICML regularly holds
Billy Maners, MLT I
Calvin Robinson, MLT I exam sessions throughout
Curtiss Crowe, MLT I the United States and the
Ed Potts, MLT I
world. Upcoming dates
Greg Lamb, MLT I
Jason Brown, MLT I and locations for ICML
Mary Jo Cherney, MLT I exams can be found at
Michael Kunz, MLT I
Rodney Lewis, MLT I
www.lubecouncil.org.
Steve Hall, MLT I
Timothy Koeninger, MLT I
William Bishop, MLT I
General Mills
Jessie Tatum, MLT I
ICML Certifications
Georgia-Pacific
Adam Albright, MLA I
AJ Robertson, MLT I LLA I
Andrew Linn, MLT I L aboratory Lubricant
Andrew Meredith, MLA II
Anindya Patra, MLA I
A nalyst Level I
Christopher Ey, MLT I
Corey Hinrichs, MLT I MLA I
Cory Hank, MLT I M achine Lubricant
Dax Bolin, MLT I
A nalyst Level I
Dennis Toms, MLT I
Dianne Van Valkenburgh, MLT I
Emmett Scott, MLT I MLA II
Frank Branch, MLT I
Geoffrey McCall, MLT I
M achine Lubricant
A nalyst Level II
Jane Olson, MLT I
Jarreau Jackson, MLT I
Jason Wood, MLT I
Jay Gardner, MLA I
MLA III
M achine Lubricant
Jeremy Davis, MLT I
Joe Fitzgerald, MLT I A nalyst Level III
John Fitzgerald, MLT I
Kadee Patterson, MLT I
Keith Flynt, MLT I MLT I
Kimberly Long, MLT I M achine Lubrication
Matt Woodward, MLT I Technician Level I
Michael Ford Sr., MLT I
Michael Musgrove, MLT I
Michael Webb, MLT I MLT II
Oliver George, MLT I M achine Lubrication
Technician Level II
CERTIFICATION NEWS
Robert Rush Jr., MLT I
Solomon Chikere, MLA I
Stacy Taylor, MLT I
Timmy Pullin, MLT I
Georgia Power
Chris O’Neal, MLT I
Glencore
Juan Alonso Pizarro Delgado,
MLA II
GN Power Mariveles
Joanna Marie Obien, MLA II
Harley Davidson Motor Co.
Charles Lechmaier, MLA I
Hecla Mining Co.
Alan Blenitz, MLT I
Austin Kuhl, MLT I
Daryl Kuk, MLT I
Elizabeth Floyd, MLT I
Joshua Setzer, MLT I
Ryan Roomsburg, MLA I
Travis Johnson, MLT I
Honeywell
Keith Martiny, MLT I
Kevin Day, MLT I
Hormel Foods Corp.
Kevin Stinnett, MLT I
Shane Soppe, MLT I
Hyundai-Steel
Young Seup Kim, MLT I
International Paper
Gary Kuper, MLT I
Matthew Gagne, MLT I
Invicta
Kevin Hughes, MLA I
Kine Grov, MLA I
Robert Roed, MLA I
John Bourgeois, MLA II
ISL
Jack Davey, MLT I
Jeremy Peters, MLT I
John Deere
Bonnie Wulfekuhle, MLA II
Johnsonville Sausage
Timothy Winter, MLA II
Kellogg Brown & Root
Jordan Vicknair, MLT I
52 | November - December 2017 |
Kimberly Clark
David Middleton, MLT I
Korea Hydro & Nuclear Power
Byong Woo Cheon, MLT I
Hyun Ju Lim, MLT I
Jin Goo Huh, MLT I
Laboratorio Dr. Lantos
Andres B. Lantos, MLA II
LafargeHolcim
Eric Prena, MLA I
Hunter Rousseau, MLT I
Mitchell Friedman, MLA II
Lake Lubes
Ahmed Abdelrhman
Yousif Mohmed, MLA III
Land O Lakes
Colin Scanlan, MLT I
Lion Co.
Kent Palmer, MLT I
Lion Copolymer
Matthew Watson, MLT I
Longyuan (Beijing) Wind
Power
Ce Yang, MLT I
Lopez Foods
Jim Jackson, MLA I
Malakoff Corp.
Ahmad Zariff Bin Hadderi, MLA II
Amirullah Bin Amran, MLA II
Mohd Fairuz Bin Ahmad, MLA II
Shaza Amirah Mohd Nasir, MLA II
Umair Haqqan Aminurrahman,
MLA II
Mallinckrodt Pharmaceuticals
Virgil Sutton, MLT I & MLA I
Michelin
Alan Davies, MLA II
Mosaic Co.
Ari Dromberg, MLA I
Donnavan Baker, MLA I
Gord Whitney, MLA I
Joshua Howe, MLA I
Kyana Main, MLA I
Mike Fries, MLA I
Neil Spearing, MLA I
Tyler Deschambeault, MLA I
Warren Grona, MLA I
www.machinerylubrication.com
National Oilwell Varco
Stian Haukalid Jensen, MLA I
Nestle
Michael Lueth, MLT I
Noranda Alumina
Christopher “Brent” Hazelwood,
MLT I
Oelcheck
Dominik Bohnert, MLA II
Florian Wenning, MLA II
Marcel Giehl, MLA II
Matthias Assmann, MLA II
Raphael Hartmann, MLA II
Olein Recovery
Yolanda Rivas, MLA I
Packaging Corp. of America
Clifton Shove, MLT I
Lee Moulton, MLA I
Neil Heeney, MLA I
Robert Sullivan, MLT I
Wade Ralston, MLA I
PetroChoice
Allen Kleven, MLT I
Dan Doherty, MLT I
Ronny Holum, MLT I
Petroknowledge
Razfaliza Binti Roslan, MLA III
Petrolab Services
Andre Tambajong, MLA III
Petronas
Alias Bin Kadir, MLA II
Julian Jues, MLA II
Khairul Hazwan Bin Abdul
Rahman, MLA II
Mohammad Iqhwan Alimi Mohd
Yunus, MLA II
Mohd Fauzi Bin Mamat, MLT I
Muhammad Fadhil Abdul Latif,
MLA II
Muhammad Hafiz Bin Muhammad
Yunus, MLA I
Muhammad Husni Bin Mohammad
Sani, MLA III
Petroquimica
Matias Campos, MLA II
Plant Reliability Engineering
Limited (PRELIM)
Deon Harrison, MLT I
Duncan Webb, MLA II
Joshua Merchant, MLT I
Platte River Power Authority
Wes Ridinger, MLA II
Prairie State Generating Co.
Mark Leonhardt, MLT I
Qingdao Technological
University
Jing Wang, MLT I
Renewable Energy Group
Mark Crochet, MLT I
Trenton DuBois, MLT I
RelaDyne
Colin Istre, MLA II
Coty Thibodeaux, MLT I
Kristen Hebert, MLT I
Nicholas Morgan, MLA I
Travis Parker, MLT II
Rio Tinto
Ashley Pritchard, MLA II
Craig Neumann, MLA II
David Thomson, MLA II
Felipe Chaves, MLA II
Ryan Smith, MLA II
Rochelle Foods
Dean Walker, MLT I
Sarawak Shell Berhad
Devendran Raghavan, MLA III
Saudi Aramco
Ahmed Al Kubaish, MLA I
Ali Habib Al-Homoud, MLA I
Ammar Abdullah Abuassonoon,
MLA I
Francesco Chimenti, MLA I
Mohammed Fahad Aljama, MLA I
Muhammad Malik, MLA I
Om Prakash, MLA I
Ronny Rusli, MLA I
Zyad Ali Al-Ahmadi, MLA I
Semeq
Jorge Luiz Pinheiro Jr., MLA II
SGI
Albert Havelka, MLA II
Shandong Alchemy
Petrochemical
Wei Yan, MLT I
Shell
Shawn Williams, MLA II
Shell Trinidad and Tobago
Clint Jaggernauth, MLT I
Shermco Industries
Brian Dircks, MLT I
Cody Young, MLT I
Steve Swiech, MLT I
Sociedad Minera Cerro Verde
Sergio Muniz Madueno, MLA II
Soltrak
Eduardo Tapia Melgar, MLA I
Jose Alberto Bernui Vilchez, MLA I
Southern Co.
Christopher Harrison, MLA II
Gavin Love, MLA I
Southern Peru Copper Corp.
Martin Ahmed Cary Valdivia,
MLA II
Southwire
Matthew Ellis, MLA II & MLT I
Specialty Granules
Barry Collier, MLT I
Square Oil
Flemming Nielsen, MLA I
Timken Co.
Travis Selvick, MLT I
Tremack Holdings
Kenneth Chen Kit Ken, MLT I
UPM
Shane Nelson, MLT I
U.S. Army
Alberto Banda, LLA I
Valmet
Paul Merry, MLA III
Westlake Chemical Co.
Caleb Redmond, MLT I
Jarren Cornner, MLT I
Matthew Grabert, MLT I
Matthew McPhate, MLT I
Weyerhaeuser
Chris Brokopp, MLA III
Wolf Creek Nuclear
Operating Corp.
Matthew Kirk, MLA II
Xintian China Oil Co.
Guowei Du, MLT I
Global Training Calendar

November ADVANCED OIL ANALYSIS December

EIbar, Spain • November 21 – 23, 2017
MACHINERY LUBRICATION I MACHINERY LUBRICATION II
Guangzhou, Guangdong Province, China ESSENTIALS OF MACHINERY LUBRICATION Alexandria, Egypt • December 10 – 13, 2017
• November 14 – 16, 2017 Kolkata, India • November 23 – 25, 2017
MACHINERY LUBRICATION II
PRACTICAL OIL ANALYSIS OIL ANALYSIS III
Montreal, Canada • December 12 – 14, 2017
Dhaka, Bangladesh • November 20 – 22, 2017 Johannesburg, South Africa • November 27 – 30, 2017
MACHINERY LUBRICATION II ADVANCED MACHINERY LUBRICATION OIL ANALYSIS I/MACHINERY LUBRICATION I
Kingston, Jamaica • November 21 – 23, 2017 Mumbai, India • November 27 – 29, 2017 Bangkok, Thailand • December 12 – 15, 2017

OIL ANALYSIS II ADVANCED OIL ANALYSIS OIL ANALYSIS II

Jakarta, Indonesia • November 21 – 24, 2017 Mumbai, India • November 30 – 2, 2017 Guangzhou, Guangdong Province, China • December 13 – 15, 2017

ICML certification testing is available for most of the courses listed.

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

www.machinerylubrication.com | November - December 2017 | 53

 Devin Jarrett | Noria Corporation
BACK PAGE BASICS Greases

4 Grease Tests for Centralized

Lubrication Systems

“
When designing a centralized lubrication
system, which comes first: the system or
the grease selection? Most people begin
with the system and then find a grease that
The best is suitable for it. However, the best approach is to start with
approach is to a grease that serves the needs of the machine and then
start with the design a lubrication system that works with the lubricant.
grease and then What’s in a Grease?
design a system Before considering which tests should be performed
to help select the right grease, a basic understanding of
that works with grease formulation is needed. During Noria’s training
the lubricant.” courses, the class is often asked, “What is grease?”
Typical responses include “really thick oil,” “a paste-like
lubricant,” etc. According to ASTM D288, grease is
defined as “a solid-to-semifluid product of dispersion of a
thickening agent in a liquid lubricant. Other ingredients
imparting special properties may be included.”
Basically, a grease is comprised of three parts: the base
oil, additives and a thickener. The base oil may constitute
between 70 to 95 percent of the grease. It provides the
grease’s viscosity and film thickness, and is the founda-
tion upon which the grease is built. A mineral, synthetic
or vegetable-based oil may be used in a grease. The oil
type is selected based on the desired properties needed
for the application.

54 | November - December 2017 | www.machinerylubrication.com


Additives are employed to impart
new properties or to suppress or
enhance existing properties of the
base oil. They can make up between
0 to 10 percent of the grease and
typically offer protection to rotating
equipment during startup and
shutdown. Additives can also help
protect against rust and corrosion.
The thickener is critical, as it is
the vessel that delivers the base oil
and additives to the equipment.
It can represent between 3 to 30
percent of the grease. There are
many types of thickeners, but most
fit into two categories: simple soap
or complex soap. Other thickeners,
such as polyurea, clay and silica, do
not fall into these categories but also
act as thickening agents in specialty
grease formulations.
Selecting a Grease
Now that you have a better
understanding of how grease is
formulated, let’s look at four tests
that can reveal how the grease’s
ingredients will interact inside a
lubrication system. The first prop-
erty to consider is the base oil’s
apparent viscosity.
1. Apparent
Viscosity Test
Viscosity is the most important
property of any lubricant. To
determine the required base oil
viscosity, you must identify the
optimal viscosity for each system
component you plan to lubricate.
A grease’s base oil viscosity is noted
on its product data sheet. Once
you have established the required
viscosity, test the grease to find its
apparent viscosity. This relates to
mobility of a grease moving through
lines and components of a central-
ized lubrication system. Apparent
viscosity involves the collective
influence of the base oil, additives
and thickener. The ASTM D1092
standard test is ideal for measuring
the apparent viscosity of lubricating
ML
50%
greases. It can help predict pressure conditions. You must know if the
drops in a centralized lubrication grease will be able to handle the
system under a steady flow and at a intended loads and for how long
constant temperature. The results of before it begins to fail. The ASTM
this test are reported in centipoise. D1831 structural stability test
method utilizes a penetrometer of lubrication professionals use
centralized lubrication systems at
2. Cone test of unworked grease. The same their plant, based on a recent survey
Penetration Test grease is then worked in a standard at MachineryLubrication.com
You also will need to determine roll stability device for two hours
the required consistency or NLGI at a temperature between 20 to
grade of the grease. A general starting 35 degrees C (68 to 95 degrees F).
point is the expected operating The grease is then put through the
temperature and speed factor. Other penetrometer test again. The differ-
variables that can impact the required ence between the two tests is used
consistency include the bearing type, to measure the effect of low shear
thickener type, base oil viscosity and stability of the oil in the grease.
base oil type.
A cone penetration test (ASTM 4. Ventability Test
D217) is frequently employed to gauge The final test relates specifi-
a grease’s consistency. It utilizes a cally to matching the grease to the
weighted cone to penetrate a block of lubrication system’s design and
grease, with four standards of testing the size of tubing to be utilized.
the grease’s consistency: undisturbed, Depending on how far the grease
worked, prolonged worked and block. will be pumped, the tubing size can
The focus of this article will be on the
undisturbed and worked tests.
An undisturbed penetration test
provides information on the grease’s
consistency during storage conditions.
Worked penetration tests reveal what
the consistency of the grease will be
while inside a machine or component.
This is imperative with centralized
grease systems, as the grease may
be in “storage conditions” for a
prolonged period before it reaches
the component. Storage conditions
apply to grease both while it is in a
drum or other storage container and
in supply lines.
Among the factors to keep in
mind when planning a supply-line
path are the temperature exposures,
vertical paths, and the time it takes for
the grease to enter the supply line and
reach its destination. These factors
can cause the base oil and thickener
to separate, leading to oil starvation
in the equipment.
3. Structural Stability Test
Next, assess how stable the grease
will be as it is subjected to operating
www.machinerylubrication.com | November - December 2017 | 55
BACK PAGE BASICS

significantly impact the system’s
cost. A ventability test will identify
the supply-line diameter required for
a specific grease. It can also assist in
determining whether the grease can
be used in a centralized lubrication
system and whether grease valves and
injectors will function properly. The
test pressurizes grease to 1,800 psi in
a 25-foot coil. After the grease has
stabilized at 1,800 psi, a relief valve
is opened and the pressure gauge
is read after 30 seconds. Matching
this pressure reading to a supply-
line reference chart will provide the
diameter needed.
Also, when choosing a supply
line, be sure to select an appro-
priate material. Some metals, such
as copper and galvanized steel,
can have severe effects on the
grease’s composition.
It should also be noted that when
grease is subjected to certain condi-
tions under pressure, it can undergo
what is called cake-lock. This occurs
when the grease thickener’s movement
is restricted, leading to a block in the
line or component. The base oil may
still flow, but the thickener will not.
Without the thickener, the base oil
may not reach the working zones of the
components, thus creating lubricant
starvation. All three parts of a grease
(the base oil, additives and thickener)
can contribute to cake-lock, and no
single element can increase or decrease
the possibility of the condition.
With the results of these tests,
you should now have the necessary
information to make an informed
decision. Consider your budget for
a centralized system when making
your grease selection but design the
system around the grease. Avoid
common mistakes such as having
a supply-line diameter that is too
small or too large, using too much
or too little pressure to push grease
through the supply lines, and sacri-
ficing essential grease properties just
so the lubricant can flow through
the system.
Now, if you are asked which
comes first when designing a
centralized lubrication system, the
system or the grease, you’ll know
the right answer. ML
About the Author
Devin Jarrett is the program
manager at Noria Corporation. He
holds a Machine Lubrication Tech-
nician (MLT) Level I certification
through the International Council
for Machinery Lubrication (ICML).
Contact Devin at djarrett@noria.com.

Machinery Lubrication Statement of Ownership 2017

1. Publication Title: Machinery Lubrication
2. Publication Number: 021-695
3. Filing Date: September 29, 2017
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9. Full Names and Complete Mailing Addresses of Publisher,
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Tulsa, OK 74105
Editor: Jason Sowards, Noria Corporation, 1328 E. 43rd Ct.,
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the name and address of the corporation immediately followed
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13. Publication Title: Machinery Lubrication
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Outside County Nonrequested Copies Stated on PS Form
Subscriptions stated on PS Form 3541: 14,375 (2) In-County 3541: 9,348 (2) In-County Nonrequested Copies Stated on PS
Paid/Requested Mail Subscriptions stated on PS Form 3541: 0
Form 3541: 0 (3) Nonrequested Copies Distributed Through
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the USPS by Other Classes of Mail: 0 (4) Nonrequested Copies
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Outside USPS®: 0 (4) Requested Copies Distributed by Other Distributed Outside the Mail: 75 e. Total Nonrequested
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Outside County Nonrequested Copies Stated on PS Form
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the USPS by Other Classes of Mail: 0 (4) Nonrequested Copies 17. Publication of Statement of Ownership for a Requester
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18. Signature and Title of Editor, Publisher, Business Manager,
Requested Circulation: 59.7%
Machinery Lubrication Statement of Ownership 2017 (cont.) or Owner: Mike Ramsey, September 29, 2017. I certify that all
No. Copies of Single Issue Published Nearest to Filing Date information furnished on this form is true and complete. I
a. Total Number of Copies (Net press run): 26,875 b. understand that anyone who furnishes false or misleading
Legitimate Paid and/or Requested Distribution (By Mail and
information on this form or who omits material or information
Outside the Mail) (1) Outside County Paid/Requested Mail
requested on the form may be subject to criminal sanctions
Subscriptions stated on PS Form 3541: 16,817 (2) In-County
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(3) Sales Through Dealers and Carriers, Street Vendors, (including civil penalties).

56 | November - December 2017 | www.machinerylubrication.com

 THE

HUB
Attached Oil Level
Sight Glass

Recessed Oil
Sampling Port

Attached
Quick Connect

Attached
BS&W Bowl

The Hub of Lubricant Monitoring

The Hub is a multiport adapter for equipment with limited or inaccessi-
ble port locations. It allows you to connect all the tools you need in one
location. The Hub has four lateral ports which allow you to install oil level
sight glasses, BS&W bowls, drain valves, quick connects for filter carts,
etc. It also features a recessed high-flow oil sample port that can tackle
all your sampling needs.

For more information visit Luneta.com | 888-742-2021

Go to noria.com/quicktips/ for more videos.
TRAINING GUIDE
TRAINING
THAT
WORKS

Using Education as a
Catalyst for Change
How Noria Transformed Its Training
Model to Revolutionize the Industry
Learn More on Page 4. >>

Industrial Lubrication Fundamentals | Machinery Lubrication | Oil Analysis

 WHY CHOOSE NORIA?
The Difference is in the Details
It’s been said that the only constant thing is change. At Noria, we realize change is vital for a
company to thrive and sustain for the future. Positive change is impacted through a variety of
means, but one important vehicle for change is education.

We are the Source. We Have Been Down

Noria is the global authority in machinery
lubrication and oil analysis. Each year, we train
thousands of professionals worldwide – and in
more than 10 different languages – on innovative
plant reliability measures through excellence in
machine lubrication. Our training encompasses
all types of mechanized industries.
We Share Your Passion.
Noria continues to pursue a mission of inspiring
change through education by providing
customers with the tools, resources and
expertise to achieve the tremendous, untapped
potential that lubrication excellence has to offer.
This Road Before.
Noria’s team of experts combines a wide
variety of industry experience in reliability,
engineering and lubrication excellence to
provide world-class training and expertise.
Whether you need industry education,
technical consulting, failure investigation or
program/analysis development, our experts
can help you.
Along with extensive experience, Noria’s
team relies on a large network of industry
leaders to stay current with
industry technologies, trends
and client needs. Our team
works hard to bring the best
services and highest level of
expertise to each client.

2
 TABLE OF
We Work Together with You.
CONTENTS
Time is money, and your time is valuable. To
accommodate our customers, Noria offers a
variety of training options that includes online Using Education as a Catalyst for Change 4
and private training. We can also customize
course curriculum and training to achieve your Your Learning Path 6
desired results.
Industrial Lubrication Fundamentals 8
We Implement Change
that Endures. Machinery Lubrication I 10
The difference is in the details. Noria’s courses
are designed to align with the needs of adult Machinery Lubrication II 12
learners, as determined by expert staff that
includes an adult-learning specialist, an
instructional designer and multiple graphic Oil Analysis II 14
artists and video/multimedia developers.
Training sessions are goal-oriented, relevant Oil Analysis III 16
and practical. Interactive opportunities are
incorporated when possible to maximize
knowledge retention and understanding. Noria Services 18

Online Learning 20
We Want You to Succeed.
All course material – from beginner to Onsite Training 21
advanced – is task-based and immediately
applicable in the workplace. Students receive
preventive maintenance tips and learn why Reliability Skills Series 22
every strategy is important. Knowledge is
powerful and when our workforce becomes Registration Page 23
empowered with excellent lubrication
methods, the results are a safer, more efficient
and more reliable industry.

We Guarantee Satisfaction.
Noria proudly stands behind our training
courses. If you’re not satisfied with the
information and insights you gain at these
events, we will refund 100% of your paid
registration fee.

For dates, complete course description or to enroll, visit Noria.com/train or call 1-800-597-5460 3
 Using Education as a
Catalyst for Change
Transforming the Industry through Training

-Natalie Blythe Noria Corporation

The only
“
“The only thing that is constant is change,” said Heraclitus
of Ephesus.
This statement has never been truer than today.
According to a recent study by the Manufacturing Insti-
tute, more than 75% of manufacturers experienced a thing that is
constant is
moderate or serious shortage of qualified applicants for
skilled and highly skilled production positions. The study also
found that this skills shortage costs manufacturers up to 11%
of net earnings. To combat this, the Manufacturing Institute
reported that manufacturers invest approximately $1,000 in
training per employee each year (“Out of Inventory” 2-10).
change
But what drove this change in education?
“The change came from requests by companies with a reli- looking for knowledgeable employees or competent employees,”
ability focus and industry professionals who needed to get their says Chris Christenson, director of education at Noria.
teams to correctly apply lubrication in the facility. At the corpo- “The focus for each organization varies with the different
rate level, organizations need training to impact the business, roles within the facility, but it can be hard to pinpoint because
but the question comes down to whether an organization is the requirements are driven by each organization,” he says.
44

“Some companies do want technicians
to have certification as a prerequisite
for a job. At this level, there’s already
been a pre-awareness for the knowl-
edge, and that education is the impetus
for change.”
Christenson has a lengthy history as
an educator and instructional course
designer. Prior to joining Noria, he was
the senior learning manager at the
University of Phoenix, leading training
facilitation, deployment of operational
programs and diagnosis and coaching of
staff and leadership for three territories.
Before that, he served as the campus
college chair for the University of Phoenix
and computer graphics chair for the
Career Education Corporation.
Having been at Noria for five years,
Christenson has thrown himself into
revamping the training program. “For the
first two years, my time was spent getting
our content into a logical flow and
working with our instructors on stan-
dardizing their approach,” he says.
Prior to Christenson’s arrival, Noria’s
training courses needed the addition of
interactive experiences which lead to
applied learning. This approach greatly
increases comprehension and retention.
With this focus on the student’s experi-
ence, Noria’s courses are aligned with the
needs of adult learners – a concept which
is gaining momentum within the ever-
evolving workplace.
With adult learners, their learning
styles are different than traditional
students, and the training approach and
delivery needs to reflect that. Adult
learners, defined as a person who is older
than 25 and involved in forms of learning,
are typically employed full-time, looking
to enhance their professional lives
through education and use their personal
experience as a resource (Pappas).
Keeping adult learners in mind, Noria
divided its training model into three
“
facets. First, the trainings are designed
for utilizing the student’s experience to
unlock new knowledge. Then, the train-
Through
ings help the students internalize the new
concepts by relating it to their individual
knowledge,
experiences. Lastly, students gain confir-
mation of the training’s importance
we want to
through in-class discussions.
“It’s important to have a time where
spark that
participants reflect, talk about their
experiences and have the instructor
need for
record those experiences on a board.
That way, every time someone references
change and
his/her experience, the class can go back
to that issue and discuss it,” Christenson with our
says. “It’s a slight position change from
telling someone what is good to showing hands-on
them what is good, and being able to
show change is powerful.” courses, we
Noria’s model supports evidence
from a recent study that showed how want to
adult learners need to make the connec-
tion from the curriculum and program show you
content to workplace performance and
career development to promote contin- how to make
that change.
uous learning behaviors (Yoo and
Huang, 2013).
“By using the adult learning approach,
we can break down the mindset of ‘We
do it this way because this is the way veterans transition into the next phase
we’ve always done it’ and show how of their career, and possibly retirement,”
education is catalyst for change,” Chris- Christenson says. In response, he
tenson says.
believes companies are starting to realize
With its continual focus on evolving
the need to change their reliability
and improving their courses, Noria is also
approach from reactive to proactive.
prepared to aid facilities experiencing
“When bringing in a new workforce, you
generational changes in its workforce,
particularly since the maintenance and want to ensure they are learning good,
reliability industry is on the cusp of its structured processes rather than what
own “Great Crew Change,” a term passed through the grapevine.”
recently used during the 2016 downturn Christenson’s ultimate goal is for
in the oil and gas industry that referred Noria to be the world-renowned source
to the large workforce generation gap for applied knowledge. “Through knowl-
and subsequent talent shortage. edge, we want to spark that need for
“In five to 10 years, a lot of institu- change and with our hands-on courses,
tional knowledge – from veteran we want to show you how to make
employees – will be leaving as these that change.”
5
 FIND YOUR PERFECT FIT
Something For Everyone
Noria’s course plan is versatile. From beginners to experienced technicians and engineers, we can
help you no matter what stage you are currently. Follow the entire course track, progressing from
beginner to the expert level, or pick and choose according to your specific needs and interests.

The course progression shown is recommended but not

required. To determine the best course for you, contact
us at 918-392-5063 or email training@noria.com.

6 800.597.5460 | Noria.com
Basic To Most Advanced
Noria’s courses are built from the same foundational concepts, layering more detailed explorations
or specialized topics in higher level coursework. The chart below gives a glimpse into which topics
are emphasized in each course as well as how technically detailed the information is. Topic areas
are classified from the most basic (♦) to the most advanced (♦ ♦ ♦ ♦).

Industrial Machinery Machinery

Topic Area Lubrication
Fundamentals Lubrication I Lubrication II
Oil Analysis II Oil Analysis III

Maintenance Strategies ♦ ♦♦♦♦ ♦ ♦ ♦

Lubrication Concepts ♦♦ ♦♦♦♦ ♦ ♦ ♦♦♦♦

Fundamentals of
♦ ♦♦ ♦♦ ♦ ♦♦♦♦
Machine Wear

Lubricant Selection ♦ ♦♦ ♦♦♦♦ ♦ ♦

Reception and Storage ♦♦♦ ♦♦ ♦♦♦♦ N/A N/A

Handling and Application ♦♦♦♦ ♦♦♦ ♦♦♦ ♦ ♦

Contamination Control ♦♦ ♦♦ ♦♦♦♦ ♦♦♦♦ ♦

Lubricant Analysis ♦ ♦ ♦♦ ♦♦♦♦ ♦♦♦♦

Wear Debris Analysis N/A N/A N/A ♦♦♦♦ ♦♦♦♦

Oil Analysis Program N/A N/A N/A ♦♦ ♦♦♦♦

Environmental Disposal ♦♦♦♦ ♦♦ ♦ N/A N/A

MLT I and
Certification Preparation N/A MLT II MLA II MLA III
MLA I
Private Public, Private Public, Private Public, Private Public, Private
Availability
Classroom Classroom & Online Classroom Classroom Classroom

Topic Area Scale From 1-4 ♦

For dates, complete course description

description, or
or to
to enroll,
enroll visit Noria.com/train or call 1-800-597-5460 7
 Bridging The Gap Training Options

INDUSTRIAL
• ONSITE

LUBRICATION FUNDAMENTALS
Course Topics
Lay the Groundwork for Future
Contributions • Receiving and Inspecting
Every job has a specialized skillset rooted in its New Lubricants
foundation. Industrial Lubrication Fundamentals
• Maintaining Lubricant
is the starting point for individuals with all levels
of mechanical or maintenance experience. This Containers, Machines and
essential course provides strong techniques Lubricant Storage Areas
and perspective for those with some lubrication • Maintaining Lube
knowledge, while presenting sound practical
Room Inventory
material and instructions for those starting their
journey in the field. • Removing Contaminants from
Based on extensive collaboration between Noria and New Oils with Filter Carts or
plant reliability professionals, the skillset for basic Installed Systems
lubrication excellence provides students with the most • Protecting Lubricant Integrity
useful, up-to-date information. This course presents
through Contamination Control
materials in a task-based context, so students receive
a well-rounded experience by engaging in interactive • Transporting and
exercises, discussing case studies and gaining Applying Lubricants
confidence through hands-on examples.
• Conducting Field Inspections
on Machines
Who Should Attend?
As an entry-level course, Industrial Lubrication • Excluding and Removing
Fundamentals is designed for individuals with little Contaminants from Lubricated
to no technical background, who are responsible for Machines
lubrication tasks. Attendee job titles may include
• Sampling Lubricants
lubrication technicians, maintenance technicians,
millwrights, mechanics, oilers, machine operators, • Importance of Safety, Leak and
multicraft technicians, etc. Spill Response, and Disposal of
Hazardous Materials
• Modifying Machinery for
Contamination Control, Safety
and Reliability Improvement
Want to learn more about
this course? Download • Understanding the Communication
our brochure or visit and Administrative Tasks
Noria.com/train. Necessary for Your Role

8 800.597.5460 | Noria.com
 Take This Course If You Are Responsible For:
• Electric Motors • Gas/Steam Turbines • Paper Machines
• Compressors • Gearboxes • Process Pumps
• Diesel Engines • Hydraulic Systems • Rolling Mills
• Final Drives • Hydrostatic Transmissions • Blowers/Fans

Training That Benefits Topics Include:

Your Entire Facility • Conducting inspections
Training is an ongoing process; not just a one-time
event. We realize the need for constant training • Oil changes
and made this course easy to take back with you. • Electric motor bearing regreasing
Upon taking this course, you will receive 90-day
access to Noria’s video-based procedures used • Installation of external oil level indicators,
in the course. Each video procedure comes with valves, quick connectors and more
a printable job aid to ensure you can take the • Oil sampling
training with you as you head out to the plant floor.
With access to our world-class procedures, you • Using top-up containers
can refresh and review the content learned in the
course anytime and anywhere. • Oil filtration using a dedicated filter cart

Noria produced instantly usable knowledge,

which will definitely result in changes in the way
we handle lubricants and lubrication systems.
– Joe Kelly, Maintenance Engineer, Akzo Nobel

For dates, complete course description or to enroll, visit Noria.com/train or call 1-800-597-5460 9
 Technical Knowledge Starts with a Solid Foundation
Training Options
MACHINERY • Public

LUBRICATION I
• Online
• Onsite

Course Topics
Learn the Crucial Elements of
Maintenance, Lubricant Selection • How Lubrication Affects
and Filtration Machine Reliability
Early on, Noria's experts and instructional designers • Lubrication Fundamentals
recognized an industry-wide need to establish
• Additives, Base Oils and
an effective blueprint for a best-practice-based
lubrication program. Machinery Lubrication I (ML I) Grease Thickeners
provides the essentials of proper lubricant application • Lubricant Performance Properties
while instilling proven industry methods for selecting,
storing, filtering and testing lubricants for improved • Additive Functions
machine reliability. Through ML I, you will move beyond • Food-grade and Environmentally
the dated methods of vague, non-specific lubrication friendly Lubricants
procedures to understand what to do and why there is
a right way to do it. • Grease and Oil Lubrication
By completing the course, you will leave ML I with a Methods
solid understanding of the crucial relationship between • Lubricants and Fluids for Journal/
lubricant health and machine reliability, as well as Rolling-Element Bearings, Gears,
understand how doing simple tasks or inspections Automotive, Compressors, Steam/
right will significantly extend machine life and cut
Gas Turbines, Hydraulics
costs. You will also gain better understanding of oil
analysis, allowing you to align your efforts with those • Contamination Control
of maintenance professionals or oil analysis experts.
• Oil Drains, Flushing and Reservoir
Management
• Storing/Handling Lubricants

Want to learn more
about this course?
Download our brochure
or visit Noria.com/train.
Get Certified
Machinery Lubrication I prepares
students for ICML Level I MLT
certification. Certification testing
is available the Friday following
the training. Register for your
exam at LubeCouncil.org.

10 800.597.5460 | Noria.com
 Through our Machinery Lubrication training,
IKEC initiated a lubrication program that saves
them $2 million each year in annual losses.
noria.com/serv/customers

Take This Course If You Are Responsible For:

• Lubrication procurement • Procedure/quality-control implementation
• Equipment maintenance • Identifying cost-saving methods
• Ensuring equipment readiness and uptime • Operations planning
• Efficiency initiatives/design • Equipment reliability

Don't Forget Your Study Packet

Designed for both ICML Level I MLT and Level I MLA certification,
the Level I MLT/MLA Study Packet includes:
Flash Card Pack - 385 flash cards designed in preparation for
ICML Level I MLT certification.
125-Question Practice Exam - A great assessment tool, this
multiple-choice practice test is preparation for ICML Level I
MLT certification. It is licensed for use by one person.
How to Take a Multiple-Choice Exam - This book let contains
advice from professionals who have passed ICML certification
exams as well as helpful hints to prepare the night before the exam, steps to take before
entering the exam room; techniques for time management during the exam, and advice for
handling diverse types of questions.
Machinery Lubrication Reference Guide - Packed with useful checklists, look-up tables,
charts and illustrations, this reference guide is designed to make information easily
accessible where you need it. Also doubles as a handy, on-the-job reference tool!
Oil Analysis Basics - With 90+ illustrations, figures and look-up tables, this book presents
the fundamentals of oil analysis for machinery condition monitoring in an easy-to-
understand format. The book covers everything from how to take a proper oil sample to
how to select a test slate for your applications.
The Practical Handbook of Machinery Lubrication - Noria’s all-time bestseller, this book
contains useful, actionable information that is ready for immediate use. The book contains
understandable explanations of how lubricants work, what they’re made of and how they break
down. Covering topics ranging from engine lubricants to industrial oils and hydraulic fluids, The
Practical Handbook of Machinery Lubrication is page-turner that will stay on the shelf.

Add the Study Packet to your course registration, or visit us at store.noria.com.

For dates, complete course description or to enroll, visit Noria.com/train or call 1-800-597-5460 11
 Advanced Training in Lubrication Excellence
Training Options
MACHINERY • Public

LUBRICATION II
• Online
• Onsite

Course Topics
Take Charge of Your
Lubrication Program • Lubrication Preventive
Maintenance Optimization
Machinery Lubrication II (ML II) covers advanced
and Design
lubrication topics like lubricant selection,
troubleshooting, predictive maintenance and more. • Troubleshooting Lubrication
Designed for maintenance professionals with a Problems
solid understanding of the benefits and potential
in excellent lubrication practices, this course builds • Lubrication and Oil
upon their knowledge and provides an in-depth Analysis Metrics
look into the world of lubrication. • Oil Drains, Flushing and
Built as a continuation of ML I, the ML II course Reservoir Management
prompts you to analyze machines for wear
symptoms and select lubricants and additives to • Accessorizing New Equipment
counteract or prevent damage. for Lubrication Excellence
Through ML II, you will be able to distinguish the • Lubricating Grease and Oil
appropriate lubricants and additives for every Application
application in your facility, guide staff in conducting
basic maintenance and analyze machine/fluid
• Advanced Lubrication Techniques
indicators for potential problems. These tools will • Base Oils
enable you to make comprehensive improvements
in the workplace, resulting in key savings of time, • Viscosity and Viscosity Index
money, storage space and training resources. • Oxidation and
Thermal Stability
• Air Release and Foam Control
• Lubricant Degradation
• Lubricant Selection
and Consolidation

Want to learn more
about this course?
Download our brochure
or visit Noria.com/train.
Get Certified
Machinery Lubrication II prepares
students for ICML Level II MLT
certification. Certification testing
is available the Friday following
the training. Register for your
exam at LubeCouncil.org.

12 800.597.5460 | Noria.com
 Take This Course If You Are Responsible For:
• Lubrication procurement • Troubleshooting equipment
• Equipment maintenance design/process/material

• Systems operation/management • Equipment reliability

• Checking meters/recording instruments • Production management

• Mechanical inspections • Procedure/quality-control implementation

• Controlling lubricant contamination • Identifying cost-saving methods

Get Certified
Certification testing is the Friday following your training and conducted by
the International Council for Machinery Lubrication.

Which Certifications?
Completion of Machinery Lubrication I and Machinery Lubrication II will
prepare you for Level I Machine Lubrication Technician (MLT) and Level II
Machine Lubrication Technician (MLT) ICML certification exams.

For more information What Is ICML?

or to register for a The International Council for Machinery Lubrication (ICML) is a vendor-neutral,
certification exam, visit not-for-profit organization founded to facilitate the growth and development
LubeCouncil.org. of machine lubrication as a technical field of endeavor. In addition to other
activities, ICML offers skill certification testing for individuals in the fields of
machine condition monitoring, lubrication and oil analysis.

...the information I learned can

improve our hydraulic systems by 40%.
-Vernon Player, PDM Tech, International Paper

For dates, complete course description or to enroll, visit Noria.com/train or call 1-800-597-5460 13
 Developing Verified Data
Training Options

OIL ANALYSIS II • Public

• Onsite

Course Topics
Uncover the Finer Aspects of
• Lubricant Health Monitoring
Contamination Control and
Comprehensive Oil Analysis • Oil Analysis Fundamentals
Oil Analysis II (OA II) approaches lubrication • Oil Sampling – The Very
excellence through the critical information to be Best Practices
gleaned from oil analysis. By starting this course, you
• Fluid Properties Analysis
will understand the basic analysis procedures from
ML I, and learn how to combine and apply these for • Contamination Control and
more advanced strategies in conducting impactful Proactive Maintenance
predictive maintenance.
• Fault Detection and Wear
In OA II, you will gain everything needed to properly
Particle Analysis
sample, monitor health and detect additive, thermal
and particle factors that degrade lubricants via on- • Instrument-free Onsite Tests
site tests and lab analysis. Taking knowledge from an
• Interactive Case Studies
oil analysis lab report, you will develop a proactive
line of defense against failures, factoring lab findings
Workshop
into your own onsite analyses for more precise, timely • Test Results and Oil Analysis
maintenance. Report Interpretation
By reviewing case studies, reading and interpreting oil
analysis reports and participating in group problem-
solving exercises, you will delve into the best practices
of oil sampling, learn the fundamentals for conducting Practice In Class
effective fluid analysis and become adept in analyzing
lubrication systems for optimal efficiency and savings, Oil Analysis II includes practice
ensuring that machine/fluid health, lubrication oil analysis reports and individual
procedures and objectives reflect the ideal for the and group participation in
plant, its personnel and the bottom line. problem-solving exercises.

Get Certified
Oil Analysis II prepares students
for ICML Level II MLA certification.
Certification testing is available
Want to learn more
the Friday following the training.
about this course?
Register for your exam at
Download our brochure
LubeCouncil.org.
or visit Noria.com/train.

14 800.597.5460 | Noria.com
 This is an outstanding course in understanding
the desired state and use of oil and how to
determine the best practices. I wish I would
have taken it a year and a half ago.
– Derik Williams, Engineer, US Army CERDEC

Take This Course If You Are Responsible For:

• Resource management
• Equipment maintenance
• Systems operation/management
• Lubricant health and cleanliness targets
• Mechanical inspections
• Diagnostics and equipment troubleshooting
• Efficiency initiatives/design
• Quality-control implementation
• Operations planning
• Sensor selections/installation
• Lubrication program effectiveness
• Choosing test slates

Don't Forget Your Study Packet

The Level II MLA Certification Study Packet is
designed to prepare students for ICML Level
II MLA certification. The packet includes:
Level II MLA Flash Cards - 440+ flash
cards designed in preparation for the ICML
Level II MLA certification exam.
Oil Analysis Basics - With 90+ illustrations,
figures and look-up tables, this book
presents the fundamentals of oil analysis
for machinery condition monitoring in
an easy-to-understand format. The book
covers everything from how to take a
proper oil sample to how to select a test
slate for your applications.
Wear Debris Analysis - With 70+
illustrations, figures and tables, this book
offers a practical look at wear debris and
wear particle analysis in many forms.
Machinery Oil Analysis - This unique,
in-depth analysis presents the entire practice of oil analysis as a condition monitoring tool for
machines. The book also describes the what, when, where and how-to for machinery lubrication
concepts, machinery failure and maintenance concepts, machinery failure modes, oil sampling and
testing, plus statistical analysis and data interpretation.

Add the Study Packet to your course registration, or visit us at store.noria.com.

For dates, complete course description or to enroll, visit Noria.com/train or call 1-800-597-5460 15
 Master Advanced Analysis
Training Options

OIL ANALYSIS III • Public

• Onsite

Course Topics
Take the Next Steps in Transforming
Your Oil Analysis • Understanding and Analyzing
Designed as a more in-depth look into this Machine Wear
specialized field, Oil Analysis III (OA III) gives you • Integrating Oil Analysis with
the tools and education to develop, implement Vibration Analysis
and sustain a first-rate, comprehensive oil analysis
program. Merging the machine lubrication and • Fluid Properties Analysis
oil analysis focuses of course prerequisites, OA III • Additive Depletion
trains you to diagnose problems like contamination,
corrosion and additive depletion – even with limited • Contamination Analysis
test results or difficult machines. • Grease Analysis
Through this course, you will compare detection
• Onsite Oil Analysis Options
and cost benefits/drawbacks for any type of lab
test to select the most precise option for your • Designing an Oil Analysis
needs. You will be able to gather extensive data on Program
a lubrication program, make informed decisions
and maintain the program as a major company • Cost/Benefit Analysis
asset. You will also gain strategies for applying
your data and analysis to build strong proposals for
improvement projects and calculate accurate return
on investment predictions. Practice In Class
By completing OA III, you will attain the highest
level of expertise and join the elite ranks of others Oil Analysis III includes practice
who create or assess new oil analysis programs oil analysis reports and individual
within any industrial workplace. and group participation in
problem-solving exercises.

Want to learn more
about this course?
Download our brochure
or visit Noria.com/train.
Get Certified
Oil Analysis III prepares
students for ICML Level III MLA
certification. Certification testing
is available the Friday following
the training. Register for your
exam at LubeCouncil.org.

16 800.597.5460 | Noria.com
 I was amazed of the information that’s
out there, and the techniques or tests
that can be taken for oil analyses.
-Reuben Clowdis, Lubrication Tech Huber Engineered Woods, LLC

Take This Course If You Are Responsible For:

• Systems operation/management • Troubleshooting equipment
• Operations design/process/material

• Equipment maintenance • Efficient utilization design

• Testing samples and interpreting results • Procedure/quality-control implementation

• Mechanical inspections • Cost/benefit analysis

• Diagnostics • Quality-control analysis

Suggested Reading
Machinery Oil Analysis Methods, Automation & Benefits - This
book uniquely presents the entire practice of oil analysis as a
condition monitoring tool for machines.
Wear Particle Atlas - A guide to wear particle analysis, this guide
contains photographs of typical wear particles found in used
lubricating oil, illustrative case histories and operational procedures
for wear debris analysis.
You can purchase these books online at Store.Noria.com.

Avoid Costly Mistakes And Reap The Benefits Of Good Oil Sampling
A small misstep when installing sampling
ports, performing oil sampling or choosing
lubricants can translate into expensive
problems. For most facilities, these mistakes
are only apparent after problems arise or
through expert analysis. For example, a large
steel mill installed 1,200 new sampling ports
and, after gathering strange data on multiple
occasions, learned they had been
placed in the wrong locations.
Another Noria customer had been conducting
oil analysis for years but was still unable
to detect bearing failures that shut down
production. The company discovered that
the tests being conducted could only
identify degraded or wrong lubricants – not
impending failure.
Successful oil sampling requires know-how.
Improper sampling port placement, running
the wrong tests, poorly collected samples
and more can compromise accuracy or even
eliminate valuable information. Noria can
lend you the expertise to avoid these costly
mistakes so you can reap the full benefits of
good oil sampling.

For dates, complete course description

description, or
or to
to enroll,
enroll visit Noria.com/train or call 1-800-597-5460 17
 Services & Solutions
Lubrication Program Development
Noria’s Lubrication Development Program (LPD) is a comprehensive lubrication overhaul of your
facility. Starting with a 540-point assessment of your existing lubrication practices and materials,
we use our findings to detail your “roadmap” to lubrication excellence. After developing a custom
lubrication program, Noria experts then deliver detailed instructions for maintenance routes, hardware
modifications, lubricant types and procedures. We also make recommendations for redesigning your
lubricant storage area to preserve lubricant quality and maximize space.

Prevent Mechanical Failure,

Train Personnel And
Maximize Efficiency
In One Program.

WORKFORCE
SOLUTIONS
For facilities needing to tap into Noria’s network of skilled lubrication
and oil analysis professionals, Workforce Solutions is the lubrication
labor outsourcing division of Noria Corporation. We place skilled
personnel at your facilities on a full-time or short-term basis to
manage your lubrication program and/or execute aspects of
machinery lubrication and oil analysis for more details visit:

Noria.com/serve/workforce-solutions

18 800.597.5460 | Noria.com
 Education & Training
To achieve plant-wide lubrication
excellence, Noria can train all
personnel – from those with no
technical background to those with
specialized roles. Noria offers five
nationally recognized courses on machinery
lubrication and oil analysis, with four of these
containing certification preparation for more
details visit:

Noria.com/train

Technical Consulting
Lubrication-enabled reliability is Noria’s core mission; we
supply answers and advice for any reliability issue about
lubrication. Over the years, Noria technical consultants
have provided expert witnessing and forensic
investigations, laboratory studies, benchmarking and
specialized troubleshooting on a variety of machine
parts and systems.

For More Information,

Call 800-597-5460

Failure Investigation
Machine and lubricant failures-those are words no one
likes, but there is a solution. Noria’s network of expert
investigators covers a multitude of industries and
applications. Our technical consulting team has decades
of experience in root cause analysis, tribological
studies, lubricant analysis, debris/wear particle
identification, metallography and more. Our
failure investigators will provide the answers and
solutions to quickly and efficiently identify the
cause to ensure a complete and permanent fix.

For dates, complete course description or to enroll, visit Noria.com/train or call 1-800-597-5460 19
 Master Advanced Analysis
Available Courses
ONLINE LEARNING • Machinery Lubrication I
• Machinery Lubrication II

We realize schedules get hectic. That’s why Noria

Key Features
offers two of its most popular courses, Machinery
Lubrication I and Machinery Lubrication II, online. • 125-question pre-and post-
With our online learning, you receive: assessments
• Flexible Certification Preparation: Gain the right • Knowledge checks for each
understanding and steps for excellent condition-based section to evaluate your
maintenance, prepare for a certification test and do it understanding. Know what
all on your own time – whenever it is best for you. to work on before moving
• Onboarding: Use this training for onboarding new forward.
employees or to get your team up to speed quickly,
efficiently and in alignment with your company culture, • Step-by-step interactive
skills requirements and performance expectations.
demonstrations of common
lubricant analysis tests
• Self-paced: Log in anywhere, anytime on your
customized schedule for one year. Play, pause, rewind • Meets the training
and replay as often as needed. Learn while maintaining requirements for the ICML MLA
plant and operational schedules. ADA-compliant closed and MLT Level I certifications
captioning is available. • SCORM compliant, tablet ready
• Pre-/Post-assessment Quizzes: Track your • Includes closed captioning
knowledge and understanding through each section
with quizzes designed to show your progress and
areas that may require further attention..

For more information, visit Noria.com/train

or call 918-392-5063
Why Train Online?
Affordable: Reduce training
costs and improve productivity.
Flexible: Anytime, anywhere.
Online training enables your
team to learn at their own pace.
Easy To Use: Noria’s simple
click-and-watch training method
is easy for anyone to use.
Course Manual: Downloadable
PDF manual for future reference.

20 800.597.5460 | Noria.com
ENTERPRISE ONLINE LEARNING
Private Onsite Training
Bring online machinery lubrication and reliable skills training to your entire company through Enterprise Online
Learning. Our team works closely with you to create a learning plan that meets your short- and long-term goals.
Noria can host training content on your learning management system (LMS) or provide a private, easy-to-
use learning portal for your team. Noria’s online learning solutions provide the following features:

• Monitor learning progress • Prepare for industry certification

• Train on your team’s schedule • Reduce travel expenses
• Integrate machinery lubrication reliability to • Onboard new employees faster
your training portfolio • Improve efficiencies and reduce costly errors
• Verify skills • Train your entire workforce

All modules are compliant with all training industry standards, and we can successfully implement the following
reporting formats: AICC, SCORM 1.2 and xAPI (Tin Can). If you don’t have an LMS, ask us about a no-hassle,
branded solution for your organization.

Available Courses
BRING NORIA • Industrial Lubrication
Fundamentals

TRAINING TO YOU • Machinery Lubrication I & II

• Oil Analysis II & III

Private Onsite Training

Looking for a personalized training plan for your facility? Noria offers onsite training to meet
your company’s schedules, goals and budget needs. Additionally, Noria can customize any of
its courses based on your specific needs.
By providing onsite training, Noria helps employers avoid travel time/costs. This option also
allows for personalized training with examples from onsite equipment. Many of our customers
have utilized this option to rotate groups of employees through consecutive one-day trainings
and to bring personnel from multiple plants to one onsite training.
Whether you have 15 people or 500, Noria is committed to providing options that will have the
smallest impact on your production.

For more information, visit Noria.com/train or call 918-392-5063.

For dates, complete course description

description, or
or to
to enroll,
enroll visit Noria.com/train or call 1-800-597-5460 21
 RELIABILITY SKILLS SERIES
Reliability Skills Series Online
Need fundamental and best-practice training for everyone in
your facility? Noria’s Reliability Skills Series provides online
lessons to help your facility rise to the top.
How to Use a Grease Gun delves into best practices for using
a grease gun. Although it’s one of the most widely used tools
for machinery lubrication, few are properly trained to use it.
When used or loaded improperly, the grease gun becomes a
safety risk to both the lubrication technician and machine.
How to Grease a Motor Bearing gives plant personnel an overview of the
best practices for lubricating electric motor bearings. Use this evergreen
course to train operators, lubrication technicians, mechanics, electricians
and maintenance personnel for years to come.
Introduction to Lubrication Fundamentals presents a solid foundation of
the basics of industrial lubricants and tribology, including oil and grease
properties, additives, synthetics, mineral oils, lubricant oxidation and
other important topics.
Best Practices for Oil Sampling shows you how to design and implement a
world-class oil sampling program that will deliver better results and help you
focus on improving equipment reliability.
Best Practices for Lubricant Storage and
Handling provides procedures to apply
right away. From delivery to dispensing to
filling the machine, you will learn the best
practices for new oil storage and handling.
Lubrication Basics for Machinery
Operators Offers basic lubrication
training, including how to recognize
the early signs of lubrication-related
problems, grease gun basics and
safety, checking oil levels, cleaning and
inspecting machinery, oil leak inspections
and more.

Add this online series to your course

registration or visit store.noria.com.

22 800.597.5460 | Noria.com
REGISTRATION
HOW TO REGISTER
ONLINE FAX (3-4 days processing) PHONE MAIL (3-4 weeks processing)

FORM
Noria.com/training 918-746-0925 800-597-5460 Noria Training
or 1328 E. 43rd Court
918-749-1400 Tulsa, OK 74105

PLEASE PRINT CLEARLY

Last Name First Name Middle Initial

Job Title Organization/Business Name

Mailing Address

City State/Province Postal Code/ZIP Country

Phone Fax

Email (required)

Note: The mailing address is where all mailed correspondence about this registration will be sent. The email address is how Noria communicates important program details to you.

PLEASE REGISTER ME FOR THE FOLLOWING COURSE(S): COURSE DATE LOCATION

q Machinery Lubrication I $1,295
q Optional: Study Packet - Level I MLT / Level I MLA
Price includes shipping to a U.S. address
$295

q Machinery Lubrication II $1,295

q Oil Analysis II $1,295

q Optional: Study Packet – Level II MLA $310

Price includes shipping to a U.S. address

q Oil Analysis III $1,295

Note: Payment is due before the course. Total Amount Due $___________________

q Check is enclosed. (Allow 3-4 weeks for processing.) Please make checks CANCELLATIONS AND SUBSTITUTIONS If you cannot attend the
payable to Noria Corporation in U.S. dollars drawn on a U.S. bank. course, a colleague can attend in your place. Registrations canceled
q I authorize Noria Corporation to charge $__________________ to my: at any time prior to 10 days before the course are not subject to
fees. Cancellations after 10 days are subject to a $75 service charge.
q VISA q MasterCard q AMEX q Discover Or, your registration fee can be transferred to another program of
your choice to be taken within 12 months. For more information, visit
Noria.com/train/registration.
Card Number Expiration Date
CERTIFICATION EXAMS Certification testing is offered by the
International Council for Machinery Lubrication the morning following
Signature
a training course at the same hotel. Please contact ICML to register
for the certification exam or register online at LubeCouncil.org.
Print name as it appears on credit card bill
SATISFACTION GUARANTEE Noria proudly stands behind our
training courses. If you’re not satisfied with the information and
q Our purchase order is attached. P.O. Number insights you gain at these events, we’ll refund 100% of your paid
registration fee.

Register online at Noria.com/training or call 800-597-5460

 1328 East 43rd Court
Tulsa, OK 74105
Noria.com

TRAINING THAT WORKS

Find the training that works for you. Noria’s machinery lubrication and oil analysis training courses offer something for all
levels of expertise, from beginners to experienced technicians and engineers. Enroll today to learn precision lubrication skills
for maximizing machine reliability. For dates and locations, check out Noria.com/train.

ONLINE • ONSITE • PUBLIC COURSES | 800-597-5460 | Noria.com/train