CONTENTS

July - August 2010

Features machinerylubrication.com
Features in Detail
4 As I See It
Strategies to Extend Oil Drain Intervals
and Reduce Lubricant Consumption
When you look at the true cost of an oil change and the
associated risks, there is an abundance of financial and
business motivation to maximize, or at least optimize, the
oil change interval.

8 Viewpoint
Take a Plant Safety Approach
to Your Lubrication Efforts
Human error incidents can be minimized through a
combination of awareness and consistent reinforcement.

10 The Exponent
Understanding the Social Psychology
of Reliability Management
Drew Troyer examines some common mistakes made in
managing plant personnel.

14 Cover Story 26 Hydraulics at Work

Pizza Plant Goes All In Hose vs. Tube: Whats the Best Call
Janes Dough Foods, a division of Donatos, shuffled the deck and turned to bio- for Hydraulic Equipment?
based lubricants for its production facility in Ohio. MLs Paul V. Arnold provides the Hydraulic hoses and tubes are not interchangeable. They
details in this in-depth case study. (Pictured above: Greg Wilkett and Tom Krouse) are different tools for different jobs.

28 From the Field

52 64 How Do You Know if
Youre Using the Right Hydraulic Oil?
Stephen Sumerlin provides tips to help you select the
right oil for the equipment and application.

52 Oil Analysis
A New Technique for Filter Debris Analysis
A new method has been developed to recover filtered
debris particles efficiently, productively and economically.
56 56 Lubricant Storage
Pennsylvania Power Plant
Gives Oil Storage Room a Makeover
Elrama Generating Station has revamped its facilities
and practices for lubrication storage and handling.

64 Contamination Control
Five of the Most Common Filter Cart Mistakes
While most plants use filter carts, many dont use them in
Editorial Features Departments the most effective way.
2 Editors column 33 Reliable Plant 2010 24 Product News
66 Back Page Basics
4 As I See It 52 Oil Analysis 30 Product Supermarket
8 Viewpoint 56 Lubricant Storage 32 Product Spotlight Telltale Signs and Tips
10 The Exponent 62 Certification News 50 Crossword Puzzler to Tame Machinery Vibration
26 Hydraulics at Work 64 Contam Control 60 Web Preview Jeremy Wright explores causes, effects and characteris-
28 From the Field 66 Back Page Basics tics of vibration, and offers some prevention ideas.

Machinery Lubrication www.machinerylubrication.com July - August 2010 1

EDITOR
ML Wins, VW Gets Athletic,
and a VP Worth Checking Out
PAUL V. ARNOLD
NORIA CORPORATION
I get to chat with you through this column
just six times a year, so theres usually a
ton of information that I wish to
share/discuss/pontificate about and a
limited amount of opportunity, time and
space to do so. Therefore, Im devoting this
issues column to clearing my memory bank
and scattershooting on several topics.
Honored by an Honor
We at Noria are in the knowledge-dissem-
ination business, not the trophy-gathering
business, but its always nice to be recog-
nized by your peers for outstanding or
enterprising work. As such, I and the
Machinery Lubrication magazine team were
humbled recently to have won an award for
editorial excellence in the 32nd annual
American Society for Business Publication
Editors competition.
More than 2,000 entries, from editorial
products published in 2009, were considered
for awards in this years ASBPE contest. After
five months of judging, only a small fraction
of entries were cited for honors. The judges
selected my cover story on lubrication and
reliability excellence at Texas Instruments
(Texas Instruments: Pure and Reliable,
July/August 2009 issue) as a winner in the
case history category.
This is the second time in the last three
years that Machinery Lubrication was recog-
nized in the ASBPE competition. Over the last
five years, Noria media products have won 21
awards for editorial and design excellence.
Crafting Industrial
Athletes
Industrial companies expect their
machinery to run at peak performance
without unscheduled slowdown or break-
down throughout the course of the work
2 July - August 2010
day. Shouldnt they expect the same from
the people who work with those machines?
Volkswagen now does. The car manufac-
turer made headlines this spring by
announcing that workers hired for its new
assembly plant in Chattanooga, Tenn., were
being put through a fitness program, on
top of the normal job training, with the
goal of creating industrial athletes who
could achieve peak performance without
unscheduled slowdown or breakdown
throughout the course of the work day.
According to company wellness-
disability specialist Marsha Wood, exercises
in the two-hour daily workout sessions are
linked to movements that plant workers will
do every day and include stretching, cardio-
vascular strength, endurance and physical
strength (grip, push and pull).
Volkswagen Chattanooga spokesman
Scott Wilson says the companys class-
room, hands-on and fitness training is all
focused on getting each and every one of
us, no matter what our job is at the plant,
prepared to show up and perform at the
highest level of professional excellence.
It goes back to a column I wrote recently.
Whether youre talking about the industrial
machine or the human machine, you truly
do get out of it only what you put into it.
Catch a Rising Star
Nissan received a lot of press in late May
when it began construction on a manufac-
turing facility in Smyrna, Tenn., that will
produce the lithium-ion batteries that
power the Nissan LEAF zero-emission
vehicle. The all-electric LEAF will be
produced at Nissans vehicle assembly
facility in Smyrna beginning in 2012.
Taking center stage and commenting at
the groundbreaking ceremony were Nissan
president/CEO Carlos Ghosn, Tennessee
www.machinerylubrication.com
Governor Phil Bredesen and Mark Swenson,
Nissan North Americas vice president of
manufacturing engineering and vehicle
production engineering. Swenson, a true
rising star in the auto sector, will provide
the opening keynote address on August 31
at Norias RELIABLE PLANT 2010 confer-
ence and exhibition in Nashville.
Swensons keynote speech, titled From
Adversity to Competitive Advantage: Nissan
Turns Over a New LEAF, will surely be among
the high points of the three-day event (visit
http://conference.reliableplant.com for more
info and to register). Ive already received
requests from media outlets to cover the
Nissan VPs address.
On a side note, Nissan LEAF and battery
production will create up to 1,300 jobs
when the plants are operating at full
capacity. The battery plant, 1.3 million
square feet when its completed, will be
capable of producing 200,000 advanced-
technology batteries annually. It will be
located adjacent to the vehicle assembly
plant, which will be retooled to accommo-
date LEAF production and will be capable
of producing 150,000 electric cars annually.
And, Furthermore ...
Is it just me or do you think that the
whole BP catastrophe could have been
solved right away by putting a bunch of
Machinery Lubrication readers in a room
and letting them hash out some ideas? Im
totally serious. ... ICMLs Suzy Jamieson
does so much for the lubrication profes-
sion. Be sure to say thanks when you see
her at the RELIABLE PLANT conference. ...
The MachineryLubrication.com Web site is
on pace to draw more than 1 million visi-
tors this year.
- Paul V. Arnold, editor-in-chief
Machinery Lubrication
AS I SEE IT
Strategies to Extend Drain
Intervals and Reduce
JIM FITCH
NORIA CORPORATION Lubricant Consumption
T he reasons that lubricants age and need to be replaced periodically
are well known. It is true that many of the factors that influence
lubricant consumption and oil change intervals are not within the
realm of control of most users. However, there are far more control-
lable factors that many user organizations fail to capitalize on in
reducing both costs and risks associated with relubrication.
According to one report, the true cost of an oil change can
exceed 40 times the cost of the oil itself. In fact, there are many
hidden costs and unknown risks that are encountered during relu-
brication that must be considered. Lets look at some of the risks in
doing a simple oil change:
Introducing a wrong, mixed or incompatible oil
Introducing a contaminated oil
Introducing a lubricant that degraded in storage (severe additive
stratification is a common example)
Introducing a defective oil (blend or formulation related)
Disturbing sediment and sludge during the oil change (this is
known as the fish bowl effect and can lead to subsequent oil-
way blockage and starvation)
Dislodging sludge and deposits, causing leakage (disturbed oil
clotting)
Dry restarts, dirty oil restarts (before filter can restore cleanliness)
Human agency failures during or directly after an oil change
(over-charging, under-charging, failure to open/close valves,
dead-heading pumps, etc.)
When you look collectively at the true cost of an oil change and the
associated risks, there is an abundance of financial and business moti-
vation to maximize, or at least optimize, the oil change interval. When
well implemented, this can translate to sharply reduced oil consump-
tion, lower maintenance costs and greater machine reliability.
Lets begin by examining the need for an oil change. Oil doesnt
last forever; it ages in ways similar to the human body. By exposing a
lubricant to the elements within a machine (heat, air, water, glycol,
particulates, shear, etc.), irreparable damage is often done. Additives
can extend a lubricants life, but they cant prevent degradation and
4 July - August 2010 www.machinerylubrication.com
aging altogether. Lubricating oils need to be changed for the
following reasons:
1) There is a current or impending loss of the lubricants perform-
ance (friction control, wear control, deposit control, corrosion
control, etc.).
2) The lubricant has become a carrier of one or more harmful and
non-removable contaminants (sludge, glycol, bacteria, acids, etc.).
3) There is fear that the lubricant might need to be changed (due
to one or both of the first two reasons) without a convenient
means to confirm.
The following are several common and a few not-so-common
methods for reducing lubricant consumption and extending drain
intervals. Not all of these methods have practical application in every
case where lubricants are used. However, in those cases where
extended drain intervals have the greatest potential benefit, a strategy
for success relating to the methods can usually be constructed.
Select Lubricants with Enhanced
Performance and Durable Service Life
There are a great many differences in the durability of lubricants
when exposed to machine operating conditions. Therefore, one
simplistic strategy is to select lubricants with robust formulations
that resist degradation in the target application. The use of high-
purity mineral oils, oxidatively stable synthetics, enhanced
antioxidant systems, better demulsifiers, robust over-base additives
and long-life dispersants can substantially extend service life of the
lubricant. Additionally, select lubricants for the applications for
which they were formulated. For instance, a high-performance
motor oil might exhibit superior performance in a diesel engine, but
it might fail rapidly when used in a hydraulic system.
Reduce the Density of Critical
Exposures that Stress Additives
and Harm Base Oils
Most additives deplete at a rate proportional to the density of
exposure to a range of contaminants and operating conditions.
Machinery Lubrication
Water, dirt, metal particles, soot, heat, acids and
air are all contaminants that put stress on addi-
tives and lead to their depletion. Additive
depletion is the usual precursor to base oil failure,
impaired machine performance and eventual
machine failure. The following are examples of
how to reduce exposure density:
Increase the volume of oil used. The greater
the oil volume, the more total amount of
additive protection there is and the more
diluted contaminants become. Contaminant
dilution reduces the severity of the stress (acti-
vation energy in the case of heat) on both
additives and base oil. However, increasing oil
volume is not a practical option in many
applications.
Maintain vigilant contamination control.
Keeping oils cooler, cleaner, dryer and well-
protected can substantially extend service life.
This is done by restricting contaminant ingres-
sion and rapid removal (filtration, coolers,
separators, etc.). It is important to not only
reduce the density of these contaminants but
also the longevity of exposure.
Limit exposures to pro-oxidants. Free radicals, PUBLISHER
hydroperoxides and other oil oxidation by- Mike Ramsey - mramsey@noria.com
products accelerate the additive depletion
GROUP PUBLISHER
rate (antioxidants) once new oil is added. In Brett OKelley - bretto@noria.com
many cases, it is important to flush these pro-
oxidants from a machine before new oil is EDITOR-IN-CHIEF
added. Oil analysis can alert users to the need Paul V. Arnold - parnold@noria.com
to perform a flush during an oil change.
SENIOR EDITORS
Jim Fitch - jfitch@noria.com
Restore Depleted Additives Drew Troyer - dtroyer@noria.com
Mark Barnes - mbarnes@noria.com
Depleted additives can be restored in a couple
of different ways for the purpose of extending the TECHNICAL WRITERS
oil change interval and to avoid the wasteful Jeremy Wright - jwright@noria.com
Stephen Sumerlin - ssumerlin@noria.com
disposal of otherwise healthy oil. These are the
two options available to users organizations:
CREATIVE DIRECTOR
Ryan Kiker - rkiker@noria.com
Additive reconstruction is the practice of
giving certain depleting additives a booster
GRAPHIC ARTIST
shot. Additive reconstruction involves intro- Kam Stinnett - kstinnett@noria.com
ducing an additive concentrate to circulating
in-service oil. Only certain additives can be ADVERTISING SALES
reconstructed with suitable success, and the Brett OKelley - bretto@noria.com
Phone: 800-597-5460, ext. 112
practice is usually only applied to machines
with large oil volumes (e.g., turbine oil, PRODUCTION MANAGER
compressor lubricants and hydraulic fluids). Rhonda Johnson - rjohnson@noria.com
CORRESPONDENCE
You may address articles, case studies,
special requests and other correspondence to:
Paul V. Arnold - Editor-in-chief
MACHINERY LUBRICATION
Noria Corporation
P.O. Box 87 Fort Atkinson, WI 53538
Phone: 920-568-9768 Fax: 920-568-9769
E-mail address: parnold@noria.com
SUBSCRIBER SERVICES: The publisher reserves the right to accept or reject any
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related correspondence to: Noria Corporation, P.O. Box 47702, Plymouth, MN
55447. 800-869-6882 or Fax: 866-658-6156.
MACHINERY LUBRICATION USPS #021-695 is published bimonthly by Noria
Corporation, 1328 E. 43rd Court, Tulsa, OK 74105. Periodical postage paid at
Tulsa, OK and additional mailing offices.
Copyright 2010 Noria Corporation. Noria, Machinery Lubrication and asso-
ciated logos are trademarks of Noria Corporation. All rights reserved.
Reproduction in whole or in part in any form or medium without express written
permission of Noria Corporation is prohibited. Machinery Lubrication is an
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reserves the right, with respect to submissions, to revise, republish and authorize
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POSTMASTER: Send address changes and form 3579 to Machinery
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Award Winner, 2008 and 2010
VOLUME 10 - NUMBER 4
 AS I SEE IT
Further, it should only be done after laboratory testing has
confirmed that a lubricant has: 1) not experienced irreparable
harm, 2) there are no threatening contaminants that cant be
easily removed (glycol, for instance), and 3) the use of an addi-
tive supplement has been determined not to impair
performance of other lubricant properties.
When it is inconvenient or risky to do an oil change, one option
is to perform a bleed-and-feed partial oil change. This involves
draining a portion (say one-third) of the oil volume, immedi-
ately followed by the introduction of new oil. The drained oil
removes some of the contaminants, and the new oil dilutes the
remaining contaminants and brings in fresh additive.
Optimize the Timing
of Lubricant Changes
A vast amount of lubricant is wasted each year due to prema-
ture and unnecessary oil changes. In fact, the life expectancy of a
lubricant cannot be accurately predicted due to the numerous
factors that both induce aging and resist aging. No lubrication
expert or computer program can forecast the need for an oil
change. Therefore, users are faced with either changing the oil
well in advance of any expected end-of-life oil condition (a
wasteful and risky practice) or to periodically analyze the oil to
monitor the advancing end of life (a far better practice).
6 July - August 2010 www.machinerylubrication.com
Analyzing the oil using routine oil analysis is a far more practical
and reliable alternative.
Lower Leakage
Of course, leakage doesnt actually trigger the need for an oil
change, but it certainly does result in unnecessary oil consumption
through repeated addition of make-up oil. Fortunately, healthy,
uncontaminated oil can have an amazing positive impact on
reducing oil leakage. Likewise, leakage is often associated with exces-
sive contaminant ingression, which, of course, shortens oil life. All
told, there are many opportunities to reduce oil change frequency
and the associated costs and risks. All of these involve some form of
intervention, transforming past practices to oil-life-extending new
practices. Precision lubrication is about selecting the correct inter-
vention action(s) to systematically achieve the intended objective at
the lowest possible cost and risk to the organization. In this case,
lower oil consumption by extending oil drain intervals.
About the Author
Jim Fitch has a wealth of in the trenches experience in lubrication, oil
analysis, tribology and machinery failure investigations. Over the past two
decades, he has presented hundreds of lectures on these subjects. Jim has
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 director and 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.
Machinery Lubrication
VIEWPOINT
Take a Plant Safety
Approach to Your
MARK BARNES
NORIA CORPORATION
Lubrication Efforts
L ike most of the Noria technical team, I spend a considerable
amount of time visiting many different types of plants. From
pharmaceuticals to mining, food production to steel making, tire
making to roof shingles, Ive seen most of what the United States
manufacturing base has to offer. But while the challenges and
equipment used are many and varied, my day in the plant always
starts the same way: a walk through the front gate after signing in
with security. And, thats where youll see the most striking simi-
larity between these very diverse plants. The signage at the front
gate usually states something like: We have worked X man days
with a lost-time accident. Work safe.
If you stop to think about, do we really need to be reminded
about safety every day? Isnt it enough to be told once a year in a
short safety class that, yes, safety is indeed important and some-
thing that should be considered above everything else? The
answer, of course, is a resounding NO! Having a daily reminder in
the form of signage at the front gate, awareness posters
throughout the plant and a safety notice at the machine are an
important tool in avoiding complacency the most common
cause of workplace accidents.
In other areas of plant life, complacency also is one of the
leading causes of failure to succeed. This includes lubrication. Like
other maintenance tasks, lubrication often is performed poorly due
to one or more of a combination of factors, the most common of
which are lack of training and lack of procedure (see my Viewpoint
column in the July/August 2009 issue of Machinery Lubrication
magazine, www.machinerylubrication.com). But even where good
procedures and well-trained people are in place, mistakes do still
happen, usually due to complacency.
So, how can we avoid complacency in lubrication? Just like
safety, accidental human error resulting in poor lubrication can be
minimized through a combination of awareness and consistent re-
enforcement of the mission and vision. What better way to do this
than through signage, metrics and awareness notices.
Achieving Awareness on Three Levels
Taking our lesson from safety, lubrication awareness needs to
take three basic forms. The first is to provide awareness of
the importance of lubrication at a macroscopic level. This is
8 July - August 2010 www.machinerylubrication.com
equivalent to the lost time notification at the front gate. For
lubrication, there are several macroscopic metrics we can use, but
the most effective is overall lubrication effectiveness, or OLE
(read Drew Troyers column on this important subject at
www.machinerylubrication.com/Read/363/lubrication-metric).
Taken as the product of lubrication preventive maintenance
compliance, lubricant quality compliance and contamination
control compliance, OLE serves as a metric to identify the effec-
tiveness of current lubrication performance in mitigating the
causative factors of lubrication-related failure:
failure to do lubrication tasks on time,
failure to keep contaminants out of the machine, and
failure to keep lubricant in good health.
Just like the lost-time notification is intended to inspire us to
exceed previous safety records, publishing OLE in the form of a
monthly graphical analysis serves to inspire those who can influ-
ence the outcome of lubrication to constantly strive for excellence.
At the shop-floor level, safety often is proclaimed through a series
of awareness posters sometimes featuring photos of family members
of co-workers to help stress the point that safety affects everyone and
is everyones responsibility. For lubrication, a similar approach can
be taken. For example, a simple awareness poster showing the effects
of over-greasing on a bearing or a laminated poster showing the
different colors assigned to each lubricant in the plant helps to rein-
force the importance of precision lubrication and dispel the myth
that oil is oil, grease is grease, and the more the better.
At the machine level, pinch points or locations where safety
hazards exist are usually identified with signage. While useful for all
employees, safety hazard labels are most important for new
employees and those least experienced with a specific machine. For
lubrication, the same holds true. At each point of application, a
simple color-coded label identifying the correct lubricant, or a more
elaborate schema including the correct quantity of grease to apply,
easily can be developed. The same applies to lubrication inspec-
tions. Simple annotated photographs showing various points on
the plant and what the desired state should be during inspection
serve to help reinforce best practice and encourage precision. The
approach is often referred to as the visual plant.
Machinery Lubrication
Standardized Work Plans
In addition to labels, metrics and awareness
posters, safety also is made a priority through the
use of standardized work plans which provide (or
should provide) specific details about a task and
the associated hazards. For lubrication, the same
holds true. Lubrication instructions need to
provide specific details and guidelines that are
simple and easy to understand, but contain
specific details for how to perform the task
according to prescribed best practice.
Training and Reinforcement
Finally, no safety program would be complete
without formal and informal safety training. Even
though an employee may have been through safety
training during his or her initial hiring, safety is
reinforced through regular routine, formal training
as well as informal reinforcement at the start of a
crew meeting or other group gathering. For lubri-
cation, the same approach also applies. Both
formal and less formal awareness sessions should
be held with those that can influence the outcome
of lubrication to help insure that the need for preci-
sion and the consequences of imprecise practices
Machinery Lubrication
are brought to the forefront. Often, picking a
specific topic (e.g. the importance of proper oil
sampling or the effects of contaminants on
element bearings) is a good way to stay focused on
an area where perhaps preferred practices are
starting to lapse.
Just like safety and the various ways we help to
insure that we minimize the number of lost-time
accidents, think about how we also can apply a
similar approach to help insure you strive toward
lubrication excellence. As always, this is my
opinion; Im interested in yours.
About the Author
As a skilled educator and consultant in the areas of
oil analysis and machinery lubrication, Mark Barnes
has helped numerous clients develop effective
machinery lubrication programs and troubleshoot
complex lubrication problems through precision lubri-
cation and oil analysis. As chief technical officer of
Noria Corporation, Mark and his team work on proj-
ects in the areas of: plant audits and gap analysis,
machinery lubrication and oil analysis program design,
lube PM rationalization and redesign, lubricant storage
and handling, contamination control system design
and lubrication, and mechanical failure investigations.
Contact Mark at mbarnes@noria.com.
www.machinerylubrication.com July - August 2010 9
THE EXPONENT

Understanding the
Social Psychology of
DREW TROYER
Reliability Management
A s a reliability engineer and MBA, I concluded early in my career
that managing reliability in a manufacturing plant is approxi-
mately 80 percent engineering and 20 percent business
management. Boy, was I wrong. With experience over time, my
views have changed dramatically. I think its about 20 percent
engineering, 30 percent business management and 50 percent
social psychology. Sure, a plant is an electromechanical thing (engi-
neering) thats built to create shareholder value (business
management). But its run by groups of people the social psycho-
logical piece of the pie. In fact, I may be grossly underestimating the
people side of the equation.
As a consultant, I hear it again and again we cant get the
people part figured out. Lets explore some common mistakes we
make managing our people.
What Gets Rewarded Gets Done
Early in my career, I taught a course on contamination control
for hydraulic systems to an angry group of mechanics. I didnt
understand why they were angry. Its pretty simple: If you control
contaminants in a hydraulic system, pumps last longer, seals last
longer and valves dont jam or fail near as often. It wasnt until a
break that a master mechanic enlightened me that the guys werent
directing their anger at me, nor did they disagree with the technical
message I was delivering. The problem was that I was talking about
Conscious
Drivers: Competence Drivers:
Crisis Measurement
Effort/Organizational Resistance
taking away their boats, cabins, vacations, etc. It hit me like a load
of bricks; for many mechanics, overtime represents a good chunk of
their total pay.
For overtime to occur, somethings got to break. Weve been
extrinsically rewarding failure with overtime for decades. If we dont
replace the overtime pay opportunity with a reliability-based
opportunity thats the equivalent or better, were not looking after
the WIFMs (whats in it for me) of our people. In fact, were rein-
forcing the behaviors that lead to failure. Moreover, if a mechanic
comes in on overtime and fixes a machine in the middle of the
night, we intrinsically reward him by lavishing praise on him for
getting us back up and running. When was the last time you plant
managers lavished praise on a team member for changing a filter,
performing an inspection, completing a laser alignment, etc.?
Weve heard that what gets measured gets done. In truth, its
what gets rewarded that gets done.
Here are some other common reward mistakes:
1) Operators get an unscheduled break when the manufacturing
process fails.
2) Production managers receive a bonus for hitting production
goals, even if it creates inventory for which theres no demand.
3) Equipment design and procurement teams receive a bonus and
recognition for getting functional, fast and cheap, even when it
increases the life-cycle cost of ownership.
4) Purchasing teams are rewarded for cutting costs, even if it
results in large transitional costs (e.g. changing lube suppliers)
or reduced material quality (e.g. increased dimensional vari-

Culture Shock
Profitability Peer Pressure ability in bottles).
Aspiration Sustained
Management 5) Sales teams are rewarded for selling product even if it produces
Support
a loss due to manufacturability problems (e.g. packaging solu-
Effort/Organizationa

Conscious Loss oof Success

Incompetence
co pe
p e ce Innocence
Innoceence tions that require plenty of manual intervention).
There are many other examples. The key is to create reward
Unconscious Incompetence Unconscious Competence
systems that drive the right kinds of behaviors. These systems must
Old Business as Usual New Business as Usual include the extrinsic drivers (money, benefits, etc.) and intrinsic
IIgnorance
Igno
Iggno
nora
ranc
rancee is
nc is Bli
B
Bliss
liliss
ss S
Seco
Se
Second
econdd N
Nature
atur
at
tur
uree drivers (recognition and atta-boys, feeling like a part of a team,
etc.). I also believe they should be based on a balanced scorecard of
Timee
Tim individual, team and organization goals. Above all, they must drive
Figure 1. The Journey to the New Business as Usual behaviors that promote reliability and value creation for the firm.

10 July - August 2010 www.machinerylubrication.com Machinery Lubrication

 THE EXPONENT
Whos Watching the Bottom Line?
Large organizations are grouped into functional subsets by
necessity. Unfortunately, these groups interpret the mission based
upon their context of the world and drive forward based upon this
interpretation, creating functional action plans, key performance
indicators, reward systems, etc. Lets use physics to illustrate the
point. Think of a functional group in the organization as a vector, a
force that has direction and magnitude. If a different functional
group interprets the mission in such a way that sends them on a
vector that has the same magnitude but is 180 degrees opposite to
the first group, the physical resultant is nullified. This happens all
the time. In many cases, its worse than just negating the efforts of
another function.
In some cases, the vectors collide to destroy value. For example,
the sales organization makes commitments to deliver a product
that has no chance of being profitable because the manufacturing
lot size is too small, or the process of creating or packaging the
product cant be automated, etc. Design engineers and equipment
specialists build and install plant equipment thats cheap up front
but has high life-cycle costs. There are many other examples along
the value stream of the organization. Now theres an important
concept value stream.
Organizations are created to create value. Our most funda-
mental performance metric, return on net assets (RONA)/return on
capital employed (ROCE), is a value-based metric. Stock analysts
call it a measure of management effectiveness. It, more than any
other KPI, determines whether or not people want to buy or sell
your stock. It is also the basis for economic value added (EVA)
calculations, which drive executive bonuses, stock options, etc.
If maximizing value is so important, why then do most func-
tional groups in the organization focus their efforts on revenue
maximization or cost minimization. Whos watching the bottom
line? Sure, revenue and costs are a part of the value equation, but
increasing revenue or decreasing costs can and often does
destroy value. I think its because value is so difficult to measure,
particularly at the functional level, where the functional group only
contributes a part of the value equation. However, if we dont get
our functional teams working for (not against) each other, we stand
little chance of creating lasting value. The winners figure out how to
minimize the silo effect.
A New Business as Usual
Using physics metaphorically again, organizations experience
psychological inertia. A body at rest remains at rest. To create
movement, we must increase propelling force or decrease imped-
ance. In other words, people and particularly groups of people
resist change.
As a consulting reliability engineer, I observe practices. If I see a
bad practice and ask why its done that way, the most common
response is, Its how weve always done it. Likewise, when I
observe a good practice and ask the same question, I get the same
response: Its how weve always done it. Its business as usual.
12 July - August 2010 www.machinerylubrication.com
The key to successfully changing an organization is to replace the
old, failed business as usual with a new business as usual that
works to achieve the goal. The problem, typically, is our approach.
In the book Learning to Fly by Chris Collison and Geoff Parcell,
the authors clearly illustrate why change usually fails. Organizations
undergo a predictable change process. They have a current prac-
tice, the current business as usual, a state which Collison and
Parcell call unconscious incompetence (see Figure 1). Were
lousy, but unaware; ignorance is bliss. A manager reads an article,
speaks to a colleague, attends a seminar or in some other way
discovers that theres a better way conscious incompetence.
Now we have a gap that needs to be closed. So a program is put
in place to close the gap. This new business process, which has the
organization in a state of conscious competence, takes much
energy for the organization and is very uncomfortable. Remember,
psychological inertia.
Frequently, the change agent who put the program in place to
start with bails out and moves on to the next big thing. Without
relentless leadership support, the organization, which is resisting
the change, will predictably drift back to its old practice, back to its
comfort zone. To succeed, we must achieve a state of unconscious
competence, where doing it right is second nature. This requires a
combination of mechanical support mechanisms like procedures
and training, enforcement of the new practices, and plenty of
encouragement and coddling.
Dont underestimate the importance of this concept. Most new
initiatives fail because we fail to recognize the impact of psycholog-
ical inertia. Making matters worse, if we fail to execute a business
process change initiative, the next time we try it, the organization
collectively responds that we tried that and it didnt work here,
making it harder to implement the second time around (think TPM,
lean manufacturing, etc.).
It Is All About the People
In this column, Ive touched on three important social psycho-
logical aspects of reliability management. There are many more.
E-mail me if youd like to discuss these factors specifically as they
relate to your organization. Also, ping me if you want to see more
on the social psychology of reliability management. Its a fasci-
nating subject.
In the immortal words of Kurt Vonnegut, If only it werent for
the people, the (expletive removed) people always getting
tangled up with the machinery. If it werent for them, Earth would
be an engineers paradise. It is all about the people.
About the Author
Drew D. Troyer is a champion of effective reliability management and
passionate about helping companies find hidden profits inside their plants. As
a highly sought consultant to Fortune 500 manufacturing firms, award-
winning columnist and teacher, he understands both management
expectations and plant-floor realities. Drew is a Certified Reliability Engineer
(CRE), a Certified Maintenance and Reliability Professional (CMRP), and
chairs the standards committee of the Society for Maintenance and Reliability
Professionals (SMRP). Contact him at drew.troyer@sigma-reliability.com.
Machinery Lubrication
COVER STORY

14 July - August 2010 www.machinerylubrication.com Machinery Lubrication

Pizza Plant Goes All In
Janes Dough Foods, a Division of Donatos, Shuffles the Deck
and Turns to Bio-Based Lubricants for Ohio Production Facility
BY PAUL V. ARNOLD

T heres opportunity in poker. ... If Horace Greeley were alive today, his advice wouldnt be Go West, young man, and
grow up with the country. Instead, hed point to that deck of cards on the table and say, Shuffle up and deal.
Lou Krieger, professional poker player and best-selling author on poker strategy

Did you hear the one about the pizza guy who cleaned up after placing an all in bet in a factory version of draw poker?
The guy is sitting with a strong hand, by all accounts trip Queens with an Ace-Nine kicker. Stand pat, and the odds say hes
got the pot. But with ice water in his veins, he tosses in the Ace-Nine and rakes in two fresh cards from the dealer. Twin deuces.
Full house. He goes all in. He gets the call, and the chip pile grows. Flip em over ... ka-ching.
The smart approach may be if its not broke, dont fix it, but thats not what were all about. Were
about its not broke, but lets make it better, says Greg Wilkett, the pizza guy in this analogy, whose
business card reads vice president of manufacturing at Janes Dough Foods, a pizza and dough producer
in Columbus, Ohio, and the baking division of the Donatos family of pizza restaurants and
retail/grocery brands.
The data indicated that it would be better. Its not blind faith. Its a calculated move.
Tom Krouse, Donatos president of expansion brands, chimes in: You were more nervous than
you were letting on.
If so, thats one heck of a bluff.
Wilkett had the cards falling his way when he ditched the petroleum-based lubricants at Janes
Dough Foods 50,000-square-foot plant in the fall of 2009 in favor of synthetic lubes. Over a four-
month period following the conversion, the advantages were apparent a reduction in downtime
and the elimination of catastrophic failures.
But he didnt stand pat. In early 2010, he dumped the synthetics and wound up
strengthening his hand with bio-based lubricants. As a result, the house is full. Record
uptime is allowing the plant to fill an increasing number of orders and raise capacity
utilization into uncharted territory. More than two million pizzas and nearly 15.5
million pounds of dough (both all-time highs) will be made this year.
Good move? You bet.

Dealing With Downtime

The Columbus plant traditionally had been solid in its mainte-
nance practices and performance. While normally staffed by a

Machinery Lubrication www.machinerylubrication.com July - August 2010 15

 COVER STORY
Vice president of manufacturing Gregg Wilkett is a
proponent of really good pizza and bio-based lubricants.
The Columbus plant is on pace to produce 2.3 million
topped pizzas this year.
A Slice of Life in Columbus
Company: Donatos, headquartered in Columbus,
Ohio, consists of Donatos Pizza, a 180-restaurant
chain and marketer of retail/grocery pizza products,
and Janes Dough Foods, a manufacturer of pizza
and dough products. The company had annual sales
exceeding $10 million in 2009 and forecasts nearly
$20 million in sales for 2010.
Plant: Janes Dough Foods in Columbus. The facility,
which opened in 1996 and expanded in 2006, is
rated as Superior by the American Institute of
Baking.
Size: Approximately 50,000 square feet.
Plant employment: The site employs 68 workers,
including six in maintenance (one manager, five
hourly technicians).
Products: The plant produced 1.5 million topped
pizzas in 2009 and is slated to produce 2.3 million in
2010. All total, it produced 10.7 million pounds of
dough in 2009 and is forecasted to make 15.4 million
pounds in 10. Current capacity is 5 million pizzas
and 26 million pounds of dough.
FYI: CEO Jim Grote started Donatos in 1963 while a
student at Ohio State University. He bought a
Columbus pizzeria for $1,300. ... Janes Dough
Foods is named after Donatos president and COO
Jane Abell, the daughter of Jim Grote.
16 July - August 2010
Freshly cut shells move down the production line at the
Janes Dough Foods plant in Columbus.
small number of maintenance depart-
ment employees, it had knowledgeable
veterans in manager Kevin Rine (hired in
1996) and multi-craft technicians Steve
Van Horn (1988), Kim Siv (1990) and
Homer Ashcraft (2001); talented
newcomers Doug Morrison and Derek
Zwirner were added in 2008. The crew
utilized progressive tactics for preven-
tive and predictive maintenance.
Lubrication-based PMs had long been
driven by data (run time) and schedule
(sanitation cycles). PdM followed an
inside/outside approach, with plant
maintenance handling the sampling
piece of oil analysis, and contractors
tackling the laboratory end of that, as
well as vibration analysis and infrared
thermography.
As a result, unplanned downtime
constituted 11 percent of the work day, an
adequate total considering the extreme
temperatures to which key machinery
components were exposed the dough
proofing system operates at more than
100 degrees Fahrenheit and the tunnel
www.machinerylubrication.com
freezer registers minus-175. That environ-
ment, though, had a tendency to trump
maintenances best efforts.
Our maintenance record has always
been what I would consider good, says
Wilkett. We really did have a pretty
good preventive and predictive program.
But we were having major breakdowns
two or three catastrophic ones where we
broke shafts because bearings seized and
gears broke. If you go down because of a
part you cant readily buy and replace,
you may be down for four days.
If pizzas arent being produced,
orders arent filled. Increased uptime
became essential as a boom in sales
required epic productivity.
The maintenance and manufacturing
team traced the root cause of the failures
to the petroleum-based oils and greases
lubricating those critical components.
We had to have lubricants that
could hold up in those temperatures,
says Wilkett.
The plant knew when to hold em and
knew when to fold em.
Machinery Lubrication
 COVER STORY
Maintenance technician Steve Van Horn
greases machinery during a PM route.
Bearings get a workout in the pizza
plant. The tunnel freezer operates
at minus-175 degrees Fahrenheit.
Leaders at Janes Dough Foods
feel that the benefits of bio-based
lubes are clear.
Synthetics Suit Plant Needs
As stated earlier, the next hand that Wilkett and his Janes
Dough colleagues played was synthetic lubricants, beginning in
September 2009.
We acknowledge that better lubrication not only ties into our
preventive maintenance and predictive maintenance programs, but
it also ties in to better operating procedures and policies standard
operating procedures which allow us to gain consistency, says
Wilkett. To run a facility effectively every day, you have to look at
everything ... including your lubricants.
The plant drained its equipment and sumps, purged its inven-
tory, and replaced it all with synthetic oils and greases.
The benefits were immediate and dramatic. Gearboxes and
bearings on the oven and freezer lines werent failing. Run time
moved to previously unreachable levels. The amp draw for the
proofer ovens variable frequency drives dropped nearly 20 percent
(from an average of 34 amps down to around 28).
We used thermal cameras and imaging to see what kind of heat
buildup we were getting, says Wilkett. We knew that the bearings
Consistently Excellent Pizzas Start at the Columbus Plant
While Donatos has been making pizzas since
1963, it didnt have a central manufacturing plant
until 1992. Enter the site and business now known as
Janes Dough Foods. Company executives, particu-
larly founder/CEO Jim Grote, felt development of
such a facility was long overdue.
Jim is a stickler. He is consumed with the consis-
Jim Grote tency of the product, says Tom Santor, Donatos
executive director of marketing and public relations. In the early years, he
used to work like 100 hours a week. He didnt want to leave because
he thought the pizza might be made differently. As we expanded, he
vowed to put together a pizza making system. To round this system out, we
18 July - August 2010 www.machinerylubrication.com
were getting better lubricated. We had a real good baseline with the
synthetics over a 4.5-month period.
Thats when Janes Dough Foods raised the ante. In February 2010,
the synthetics were removed and replaced by bio-based lubricants.
A Royal Flush and Fill
Some may think that Wilkett was gambling with house money
(or not playing with a full deck) when he decided to switch the
known for the unknown. He disagrees with that sentiment,
characterizing the decision as a safe bet and bio-lubricants as a
known, mature industrial lubrication option.
Bio-lubricants are one of the more advanced areas of environ-
mental technologies for manufacturing facilities, he says. These
are high-quality lubricants that perform just like a synthetic.
Bio-based oils were indeed around before the development of
petroleum-based oils in the 19th century. They have become the
subject of renewed interest with the advent of bio-fuels, the unex-
pected supply of foreign petroleum and the push for green
products.
manufacture our dough at a single site. Its the same flour, the same water,
the same temperature, the same yeast. Everything is exactly the same.
The company believes that high levels of consistency and quality make
a difference in a very crowded, competitive marketplace.
Consistency is not the sexiest word in the world, but our customers
recognize it, says Tom Krouse, president of expansion brands. We
have everything in place the team, the facility and the capabilities to
manufacture a product that is consistently excellent. There is a gap in
the mass-produced pizza market for quality. The industry is kind of
designed around speed first and quality second. Fortunately, the culture
of this company is about quality. Quality comes first, and then we add
speed to it.
Machinery Lubrication
 COVER STORY

time before the eventual switch. And, Wilkett and corporate

Here are Some of the Cards Up the management had a strong green background Wilkett as a
Columbus Pizza Plants Sleeve degreed environmental engineer who worked in that capacity at
According to Renewable Lubricants BPL Food-Grade Bio-Penetrating Pillsbury in the late 1990s; and chief executive officer Jim Grote
Inc. (RLI), the supplier of bio-based Lubricant (NSF H1, H2), for close- as an owner of a Ohio-based butanol production company
products to Janes Dough Foods, the tolerant areas in order to lubricate (former chief operating officer Tom Grote now runs that busi-
following oils and greases are among and prevent corrosion ness). To top it off, Tom Grote introduced Janes Dough leaders
those used at the Columbus, Ohio, plant. RLI Bio-Food Grade Extreme-Pressure to colleagues at Renewable Lubricants, a local manufacturer and
RLI Bio-Food Grade Gear Oils (ISO Grease (NLGI #0, #1, #2), high supplier of bio-based lubes, leading to an exchange of dialogue
32-460), for gear drives and right- temperature, for food processing and and information.
angle gear drives packaging machinery When it came down to it, switching lubricants was the right call
RLI Bio-Food Grade General-Purpose To learn more about these and other at the right time for the right size and type of company.
Lubricant (SAE 20; NSK H1, H2, H3), products, visit the Renewable Lubricants We are in a unique situation, and it was as if the stars aligned
for various applications Web site at www.renewablelube.com. when this came along, says Wilkett. We are small enough in our
capacity to make this happen. If we had been running at 94 percent
According to a 2008 report from the United Soybean Board, capacity, Im not sure we would have done a carte blanche change.
bio-lubricants can be generally defined as friction- and wear- But when you are running at 30 percent capacity, you can still treat
reducing fluids and semi-solids based on biodegradable and this like an innovation center. Lets figure all this stuff out before we
renewable materials. Bio-lubricants do not need to be composed get to 90 percent.
entirely of vegetable oil basestocks. They can be products derived The companies that I came from were expanding every year.
from renewable oils, such as the fatty acids from fats and oils, They were adding on to the building because they were constantly
reacted with synthetic alcohols or polyols to produce esters that running out of capacity. They had co-packers packing. Im not sure
can be considered bio-lubricants. that smart people would pull the trigger on a project like this if they
We more than knew what we were getting into, Wilkett says. were at 98 percent capacity.
For production and corporate image purposes, the company Donatos is also privately held and, as a result (according to
had been investigating the application of bio-lubricants for some plant leaders), can be faster and more flexible than publicly traded,
red-tape-laden firms. This was tantamount in the all in decision
six months ago.
Do you know how long that conversion would have taken at a
blue-chip, Fortune 500 company? says Wilkett. A conversion
from petroleum to synthetic or from synthetic to bio-based would
have taken years. That would have been test-bedded and beta
sited to death. We didnt do any of that. We did it in 11 days. We
flushed all of the machines and converted the entire facility. We
went with Renewable Lubricants bio-based products for the bear-
ings, gearboxes, even the spray lubricants that we use every day. We
went all in.
Raising the Metrics
Production equipment at the Janes Dough plant has not
skipped a beat since the flop to bio-based oils and greases. As with
the synthetics, there have been no catastrophic failures, no bearing
or gearbox failures, no issues whatsoever.
Run time, oil life and component life are obliterating the old
standards. Components that typically went 500 hours or 1,000
hours between oil changes are hitting 2,000 and 3,000 hours, and
they still havent been changed.
We do oil analysis, and we do see some degradation, says
Wilkett. After 2,000 hours in the proofer, we are starting to see
degradation. We are getting more particulate in the oil. But it is not
at the level where we need to change the oil.
How long can in-service lubricants go? The maintenance crew
doesnt know.
We are in the run time between failure extension mode, he
says. What that means to us is, we are letting things fail so that we
know how long we can run them. I am either happy to report or, for
this program, unhappy to report that we dont know when its
going to fail because we cant make one fail. We dont know what
the baseline is because we havent had a failure. We have a large
gearbox; it runs with an 80-horsepower motor. It has more than
2,000 hours on it, and we havent changed the lubricant. Typically,
the PM cycle on that was 1,000 hours, so we are double the typical
PM cycle. Its still not making noise. We use stethoscopes, infrared
cameras, etc. theres nothing to report. Ill call you when we have
a failure, but I dont know when that will be.
This uncertainty has led to the urge to perform maintenance
when none is truly needed.
Wilkett says, The technicians had to get over the fear. They
would remark, Are you sure you dont want to change that oil? Do
you know that gearbox costs $21,000? Then you get into the
mirage mode Did you hear that noise? Does that feel hot to you?
when everything is fine. You try to talk yourself out of caving in.
Stacking Up Chips, and Pizzas
Bio-based lubricants are roughly twice the cost to purchase as
petroleum-based products (they are comparable in price to
 COVER STORY

synthetics), but a host of factors make them

a better overall deal for Janes Dough Foods.
The cost is minor, says Wilkett. Failure
of high-dollar components, the downtime
associated with it, the frustration for your
associates that is the real cost of having a
poor lubrication program. If you can get
expanded run time between stoppages and
you can eliminate your catastrophic or
unplanned failures, those are advantages.
Downtime has dropped to a mere 4
percent. Right the first time quality is at
99.8 percent. Case fill is at 100 percent for
2010. And, because production is humming,
and existing and new customers are happy,
capacity will double this year.
There are other benefits, too.
First, theres the time and cost associated
with the proper disposal or reclamation of
petroleum products and items (sorbents,
shop rags, etc.) that have come in contact
with them. On a related note, Wilkett says
that because the bio-lubes are deemed non-
hazardous, the regulatory requirements are
less complex and less costly from an admin-
istrative perspective. The conversion away Bio-based lubricants have helped drop the plants
from petroleum-based lubricants is one downtime to a mere 4 percent.
reason why the plant hopes to be landfill-
free by the end of 2010. The plant has a close relationship with manufac-
Second, because the bio-lubes have a much turing and packaging programs at Western
wider temperature range than the petroleum Michigan University and other colleges. We feel
products, the facility has been able to consolidate that we can attract these Western Michigan
its supply down to just three gearbox lubricants University students to work with us following
(for low, medium and high temperatures), two graduation, says Wilkett. We can attract the
spray lubricants (for chains, conveyors, etc.) and best talent because we have this philosophy and
two greases (for low and high temperatures). we have these programs.
For the gearboxes, its just straight weight; its Thinking for a moment, he lays all of his cards
not based on viscosity, he says. Technicians on the table. I think its a pretty cool story when
normally like to have seven viscosities of grease you can do something for the environment and
and 14 viscosities of lubricant, and they want to the community and have social responsibility and
have seven different spray cans with different at the same time create better reliability in your
colored lubricants. But its not needed anymore. facility. How do you beat that?
It would be like hauling around a tool box with 30
wrenches when you only need three of them. A Winning Hand
Third, the public sees Janes Dough Foods and This article closes with another quote from
Donatos more and more as a green business. poker maven Lou Krieger:
Research shows that an increasing percentage of I believe in poker the way I believe in the
U.S. consumers prefer to buy from environmen- American Dream. Poker is good for you. It enriches
tally conscious companies. Consumers are the soul, sharpens the intellect, heals the spirit and,
looking to make the right choices in everything, when played well, nourishes the wallet.
including what consumer goods to buy from I think if Lou knew the plant floor the same
responsible companies, says Krouse. way he knows the casino floor, he would say,
Fourth, the next generation of industrial Well played, Donatos and Janes Dough Foods.
leaders place value in the companys green side. Well played.

22 July - August 2010 www.machinerylubrication.com Machinery Lubrication

PRODUCT NEWS

Mist and Fume Control Wireless Shaft Alignment

The OILMISER Vapor Guard (OVG) is
designed for rotating, lubricated machinery such
as gearboxes and bearing housings. The OVG has
a central diffuser post inside a sealed
containment chamber. Migrating
vapors are dispersed inside the
containment chamber, where they
condense back into liquid oil. The
condensate runs down the diffuser
post and inside walls of the
containment chamber and collects
at the bottom. The recovered and
uncontaminated lube oil is then
channeled back into the machinery.
Alignment Supplies released its newest Easy-Laser product, the E710. The E710
continues on the development path of the Easy-Laser E-Series products, which all
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Alignment Supplies Inc.
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800-997-4467

JLM Systems Limited

www.oilmiser.com Square Infrared Window
888-736-8645 IRISS Inc. expanded its product line of Custom Application Products (CAP)
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The KPL-24 Grease Lubricator from shape or size. IRISS can take a panel,
Yamada America is a 24-volt DC-powered machine guard or
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24 July - August 2010 www.machinerylubrication.com Machinery Lubrication

 Fluorescent Oil Dye Portable FTIR Analyzer
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800-562-8483

Machinery Lubrication www.machinerylubrication.com July - August 2010 25

HYDRAULICS AT WORK
Hose vs. Tube:
Whats the Best Call for
BRENDAN CASEY
Hydraulic Equipment?
W hat do lifting chains, bladder-type accumulators and
hydraulic hoses all have in common? Well, they typically
have only one mode of failure and thats catastrophic. One
minute theyre working as they should, and the next thing you
know, theyve gone to hell.
Oh, sure, hoses can leak from around their ferrules and show
obvious signs of abrasion, both of which are early warning signs
that a change-out would be prudent. But even under these condi-
tions, estimating their remaining service life is virtually
impossible.
The Trouble with Hose
Beyond the fact that their service life is finite and difficult to
estimate, other disadvantages of hydraulic hoses when compared
to tubes include:
They expand and stretch under pressure. This flexing requires
extra volume and adds to machine cycle time.
They typically have a limited operating temperature range.
Their requirement for regular replacement makes them a source
of contaminant ingression.
They are expensive.
Despite the above disadvantages, hoses are a necessary feature
of most hydraulic systems. This is because the alternative
conductor tubes cannot be used where:
There is limited space (particularly in mobile hydraulics).
There is relative movement between machine components and
superstructure.
Noise and vibration need to be suppressed.
However, hose is often substituted for tube when its not neces-
sary. This is because a hose assembly can usually be fabricated
much faster than a tube assembly. And, the additional labor cost
required to fabricate and install a tube can make hose appear to be
the cheaper solution.
But this belies the fact that the same hose may need to be
replaced many times over the life of the machine. This false
economy is similar to buying the machine itself on initial capital
outlay alone without considering its total life-of-ownership cost.
26 July - August 2010 www.machinerylubrication.com
Tube is Cool
Hydraulic tubing has some compelling advantages of its own.
One of these is its superior heat transfer, especially if its painted.
One aspect of heat transfer is thermal radiation. The total radi-
ation from an object is the sum of its reflection, emissivity and
transmission of heat through the object.
When hydraulic tubing is painted, it reduces its reflectance and
increases its emissivity, enabling better heat rejection, as this case study
published in Hydraulics and Pneumatics magazine1 illustrates:
An industrial hydraulic installation was originally designed to
operate at 1,200 psi and at a maximum operating temperature of
120 degrees Fahrenheit (49 degrees Celsius). Zinc dichromate-
coated steel tube distributes fluid from the 600-liter reservoir to the
various stations around the plant. Over the years, the system had
been added to (without any increase in installed cooling capacity)
to the point where it was now overheating in the summer months.
Because the system operated satisfactorily for 10 months out of
the year, management did not want to spend the money necessary
to upgrade the cooling system. So, one of the maintenance guys on
staff who was familiar with the thermal radiation theory described
earlier suggested painting the hydraulic systems tubing.
Before proceeding, the maintenance team did a test. Team
members applied electrical tape to two of the hydraulic tubes, and
using an infrared camera, they measured the difference in temperature
between the taped and untaped areas. They found the taped areas on
the tubes were 7 degrees F (4 degrees C) cooler than the untaped areas.
This gave the maintenance team the confidence to proceed with
the idea. Because the rest of the hydraulic system was painted flat
white, the tubing was painted the same color.
And, the result? A week and 12 cans of spray paint later, the
system was running 10 degrees F (5.5 degrees C) cooler. This might
not sound like much, but the end result meant that the hydraulic
system could now operate through the two hottest months of the
year without overheating. It also meant that the need to increase
installed cooling capacity was at least deferred, if not eliminated.
Managing Hose Replacement
Despite the superior reliability of tubing, for reasons already
explained, hoses are a necessary feature of most hydraulic
machines. And unlike tubing, hoses are a maintenance item, one
Machinery Lubrication
which usually gives no warning of impending failure. So in a condi-
tion-based maintenance environment, how can you proactively
manage the replacement of hydraulic hoses? Well, there are two
considerations which should be foremost in your mind: the down-
time cost of in-service hose failures, and NOT treating all hoses
equally. Consider this example:
A couple of years ago, I worked with a mining client whose ad-hoc
replacement of hoses which failed in service on hydraulic shovels had
resulted in machine availability falling to as low as 65 percent.
In this companys case, when a multi-million-dollar shovel stops,
so does a multi-million-dollar fleet of haul trucks. Downtime is a
major cost. So, it implemented a hydraulic hose replacement
program. This involved changing out every hose on the machine
every 18 months.
Whenever a shovel was down for planned maintenance, a portion
of the hoses were changed out, beginning with the oldest first. The
plan worked. Machine availability was soon back above 90 percent.
Of course, large-diameter, multi-spiral hydraulic hoses arent
cheap. However, hose expense paled to insignificance when
compared to the cost of the downtime it prevented. By any
economic measure, the hose replacement program was a great
success. But, it did have a fundamental flaw. It was treating all
hoses the same. And, it was highly unlikely that each hose on the
machine was equally responsible for an equal proportion of the in-
service failures and downtime.
Machinery Lubrication www.machinerylubrication.com
I advised this company to study the historical data. I also stated that
it should expect to find that a relatively small percentage of hoses were
responsible for the majority of the in-service failures and downtime. In
fact, the available data revealed that less than 20 percent of the hoses
on the machine were responsible for nearly 90 percent of the failures.
Armed with this information, the hose replacement program was opti-
mized to reduce unnecessary hose change-outs.
The Final Selection
Hydraulic hoses and tubes are not interchangeable. They are
different tools for different jobs. The benefits of hose which
make it a necessary feature of most hydraulic machines come at a
cost. It has a finite service life and usually gives no warning of
failure. This makes it a difficult maintenance item to manage. For
these reasons, hose should only be used where tubing cannot.
Reference:
1. Hays, D., Little Things Mean a lot In Manufacturing, Hydraulics &
Pneumatics magazine, May 2009, pp 38-41.
About the Author
Brendan Casey has more than 20 years experience in the maintenance,
repair and overhaul of mobile and industrial hydraulic equipment.
For more information on reducing the operating cost and increasing
the uptime of your hydraulic equipment, visit his Web site,
www.HydraulicSupermarket.com.
July - August 2010 27
FROM THE FIELD

How Do You Know

if Youre Using the
STEPHEN SUMERLIN
NORIA CORPORATION Right Hydraulic Oil?
A synthetic fluid is a manmade chain of molecules that are
F or most lubricated machines, there are many options when it
comes to lubricant selection. Just because a machine will run
with a particular product doesnt mean that product is optimum for
precisely arranged to provide excellent fluid stability, lubricity and
other performance-enhancing characteristics. These fluids are great
the application. Most lubricant misspecifications dont lead to choices where high or low temperatures are present and/or high
sudden and catastrophic failure; rather, a misspecification shortens pressures are required. There are some disadvantages to these
the average life of the lubricated components and, thus, goes unno- fluids, including high cost, toxicity and potential incompatibility
ticed. With hydraulics, there are two primary considerations the with certain seal materials.
viscosity grade and the hydraulic oil type (AW or R&O). These speci- A petroleum fluid is a more common fluid and is made from
fications are typically determined by the type of hydraulic pump refining crude to a desired level to achieve better lubricant perform-
employed in the system, the operating temperature and the systems ance with the inclusion of additives, which range from anti-wear
operating pressure. Selecting the best product for your system (AW), rust and oxidation inhibitors (RO) and viscosity index (VI)
requires that you collect and utilize all available information. improvers. These fluids offer a lower-cost alternative to synthetics
and can be very comparable in performance when certain additive
Hydraulic Fluid packages are included. Water-based fluids are the least common of
Hydraulic fluid has many roles in the smooth operation of a well- the fluid types. These fluids are typically needed where there is a
balanced and designed system. These roles range from a heat transfer high probability of fire. They are more expensive than petroleum
medium, a power transfer medium and a lubrication medium. The but less expensive than synthetics. While they offer good protection
chemical makeup of a hydraulic fluid can take many forms when for fire, they do lack on wear protection abilities.
selecting it for specific applications. It can range from full synthetic
(to handle drastic temperature and pressure swings) to water-based Pumps and Viscosity Requirements
fluids (used in applications where there is a risk of fire). There are three major design types of pumps used in hydraulic
systems: vane, piston and gear (internal and external), and each of
these pump designs are deployed for certain performance tasks and
Pump Type Temp C/F max. Pressure bar/psi Viscosity ISO VG operations. Each pump type must be treated on a case-by-case
Gear 70/158 34.5/500 32-68 basis for lubricant selection.
60/140 34.5/500 15-32 Vane: The design of a vane pump is exactly what its name
Vane 70/158 34.5/500 15-22 depicts. Inside the pump, there are rotors with slots mounted to a
70/158 69/1,000 22-46 shaft that is spinning eccentrically to a cam ring. As the rotors and
60/140 69/1,000 15-32 vanes spin within the ring, the vanes become worn due to the
40/104 69/1,000 10-15 internal contact between the two contacting surfaces. For this
Piston 70/158 34.5/500 15-22 reason, these pumps are typically more expensive to maintain, but
70/158 172.5/2,500 22-46 they are very good at maintaining steady flow. Vane pumps typically
60/140 172.5/2,500 32-46 require a viscosity range of 14 to 160 centistokes (cSt) at operating
40/104 172.5/2,500 15-22 temperatures.
70/158 293/4,250 46-68 Piston: Piston pumps are your typical middle-of-the-road
60/140 293/4,250 22-46 hydraulic pump, and are more durable in design and operation
40/104 293/4,250 15-22 than a vane pump; they can produce much higher operating pres-
sures, up to 6,000 psi. The typical viscosity range for piston pumps
Figure 1. Viscosity Selection for Hydraulic Fluids is 15 to 160 cSt at operating temperatures.

28 July - August 2010 www.machinerylubrication.com Machinery Lubrication

 Application-Based Selection
Application-based selection techniques are the reality checks to
make sure all of the time spent selecting the proper viscosity, addi-
tives, etc., was not wasted by simply ignoring the applications
requirements and operating conditions. Just following OEM speci-
fications will not be enough to ensure that the correct hydraulic oil
is selected; these are typically for best-case scenarios. Ignoring
these reality checks will most often still lead to failures down the
road. They may not be as rapid as selecting the wrong viscosity, but
they will eventually happen; therefore, application and operating
factors should be taken seriously.

About the Author

Stephen Sumerlin is a technical consultant with Noria Corporation,
working on Lubrication Process Design Phase II projects for clients. He is a
mechanical engineer and a certified Level I Machine Lubrication Technician
(MLT) through the International Council for Machinery Lubrication.
Contact Stephen at ssumerlin@noria.com.

Figure 2. Example of a Hydraulic System

From Page 50
Gear: Gear pumps are typically the most inefficient of the three
pump types, but are more agreeable with larger amounts of
contamination. Gear pumps operate by pressurizing the fluid
between the trapped air volume of the meshing teeth of a gear set
and the inside wall of the gear housing, then expelling that fluid.
There are two main types of gear pumps, internal and external.
Internal gear pumps offer a wide range of viscosity choices, the
highest of which can be up to 2,200 cSt. This type offers good
efficiency and quiet operation, and can produce pressures from
3,000 to 3,500 psi.
External gear pumps are less efficient than there counterpart,
but have some advantages. They offer ease of maintenance,
steady flow, and are less expensive to buy and repair. As with
the internal gear pump, this variety can produce pressures
ranging from 3,000 to 3,500 psi, but the viscosity range is
limited to 300 cSt.

Machinery Lubrication www.machinerylubrication.com July - August 2010 29

PRODUCT SUPERMARKET
A new full-color 104-page catalog is available on
Oil-Rites lubrication equipment, featuring PurgeX
Centralized Lubrication Systems. Complete turnkey
systems are available for immediate delivery, liquid
or grease delivery, air or electric motor-operated.
The catalog also features an entire line of level
gauges, lubricators, valves, vent plugs and filters.
www.oilrite.com 920-682-6173
MEMOLUB Lubrication Systems Precise,
Reliable. Lube up to 12 points with the reusable
MEMOLUB. Available in 3 sizes and 4 power
options, MEMOLUB uses low-cost replaceable lube
cartridges with customer-specified grease or oil.
PLI, LLC
www.memolub.com 800-635-8170
sales@memolub.com
In addition to particle counting and automatic
type of wear classification into non-metallic,
cutting, fatigue, sliding, fibers, water droplets
offering images and trending, the new SpectroLNF
Q200 also reports dynamic viscosity.
Spectro Inc.
www.SpectroInc.com 978-431-1120
sales@SpectroInc.com
30 July - August 2010
PAID ADVERTISING SECTION
Summit Syngear FG Series Gear Oils are a full
synthetic, formulated for gear systems used in the
food service, beverage and packaging industries.
They are NSF registered H1, ISO 21469 certified,
Kosher approved and CFIA accepted.
Summit Industrial Products
www.klsummit.com 800-749-5823
info@klsummit.com
Quickly monitor the remaining useful life of
lubricants. The RULER provides an easy on-site
method for monitoring antioxidants and identi-
fying problems like lube oil varnish. Maximize
lubricant life with the RULER.
Fluitec
www.fluitec.com 888-557-9575
info@fluitec.com
An EP grease for extended, heavy-duty service, LEs
Almagard Vari-Purpose Lubricant stays put even in
severe conditions. It lengthens intervals, will not
harden with age, and extends bearing life by up to
threefold.
Lubrication Engineers Inc.
www.le-inc.com 800-537-7683
Webleads@le-inc.com
www.machinerylubrication.com
CONTROL WATER CONTAMINATION. Remove
100% free water and 95% dissolved water with C.C.
JENSEN Desorbers. Proven, effective and reliable.
Suitable for oil systems with small or large volumes.
Guaranteed performance. Contact us today for
information or purchase.
C.C. Jensen Inc.
www.ccjensen.com 800-221-1430
ccjensen@ccjensen.com
Simple and cost-effective, LEs Clear Grease Gun
will make an immediate impact on your reliability
efforts. No more mistakes or cross-contamination.
Be confident in knowing you are using the right
grease, time after time.
Lubrication Engineers Inc.
www.cleargreaseguns.com 800-537-7683
Webleads@le-inc.com
This DVD includes instructive videos and
animations to give viewers a better understanding
of electric motor bearings and how to lubricate
them properly.
Noria Corporation
www.noria.com/secure 800-597-5460
Machinery Lubrication
 Easy Vac Inc. provides the right tool for an
important job! Vampire fluid sampling pumps ...
small, hand-operated vacuum pumps accept any
size sampling tube (with an OD of 3/16 inch to
5/16 inch) without changing fittings. Super
Clean sampling containers, tubing and acces-
sories are also available.
Easy Vac Inc.
www.easyvac.com 865-691-7510
REMOVE VARNISH, PARTICLES AND WATER.
Three problems, one solution. C.C. JENSEN is
focused on supplying highly efficient and reliable
offline filters and filter carts. Guaranteed
performance. Contact us today for more informa-
tion or to purchase.
C.C. Jensen Inc.
www.ccjensen.com 800-221-1430
ccjensen@ccjensen.com
Because viscosity measurement should be
simple, CANNON is excited to introduce the
SimpleVIS portable viscometer. Everything is
included to get you started, minus your sample and
solvent. Contact us for more information.
Cannon Instrument Company
www.cannoninstrument.com 800-676-6232
sales@cannoninstrument.com
Machinery Lubrication
Des-Case Extreme Duty breathers have been
designed to take contamination control to a whole
new level, standing up to a wide variety of applica-
tions in challenging environments. They attack the
cause of contamination, keeping dirt and water
where it belongs out of your equipment.
Des-Case Corporation
www.descase.com 615-672-8800
sales@descase.com
Keep your hands free and your lubricant spot-on
with perma automatic lubricators. Preloaded with
premium LE lubricants, they provide continuous,
precise application. The result: reliability, efficiency,
safety and savings.
Lubrication Engineers Inc.
www.le-inc.com 800-537-7683
Webleads@le-inc.com
Best Practices for Lubricant Storage and Handling
video-based training provides procedures you can
implement right away for managing lubricants, from
delivery to dispensing to filling the machine. Preview at
Noria.com.
Noria Corporation
www.noria.com
800-597-5460
www.machinerylubrication.com
Inolex Chemical Company synthesizes premium
ester base oils for high-performance lubricant applica-
tions such as chain formulations for oven temperatures
up to 550C. HX-1 food grade oils for baking chains
are available.
Inolex Chemical Company
www.inolex.com
1-800-521-9891
lubeinfo@inolex.com
In this information-packed course, youll discover
how to build a world-class lubrication program and
put an end to your lubrication frustrations.
Noria Corporation
www.noria.com 800-597-5460
Harvards filter systems are designed and built
with quality materials and craftsmanship to provide
years of trouble-free service. Filter elements for
viscosity ranges from fuels to gear oils (ISO 1000).
Customers report clean fluids to ISO 13/12/8 in
operation. Contaminant capacity per element is
about four pounds. The product has demonstrated
the ability to remove one gallon of water from oil.
Harvard Corporation
www.harvardcorp.com 800-523-1327
July - August 2010 31
PRODUCT SPOTLIGHT

SYSTEM 24 Lubricators Foam Lubricant Applicator

SYSTEM 24 single-point automatic lubricators from SKF provide Correctly relubricating open gears and rack & pinion systems is
timely and accurate hands-off solutions to deliver the proper pre- now easier with the advanced open cellular polyurethane foam appli-
set amount of lubricant when needed for bearings in industrial cator from PLI. The low-density foam pinion holds in 90 percent of
machinery. The product line includes cost-effective gas-driven feed the lubricant volume, thereby avoiding hardening that can happen
versions and newly introduced electromechanical- with conventional felt pinions. This saturation provides a proper
driven systems engineered for reusability. All
lubricant film to ensure uniform coverage of equipment wear points.
perform reliably on a 24-hour basis without
The applicator is available as standard straight and helical pinions
manual intervention and can resolve issues
and has operating speeds up to 20 feet per second. This product,
typically associated with hard-to-access or
when used with the MEMOLUB lubricator, provides a complete auto-
potentially hazardous lube points. All
SYSTEM 24 lubricators feature flexible and matic lubrication system. MEMOLUB lubricators are available in
adjustable dispense settings ranging up to 12 three sizes and use low-cost pre-filled replaceable cartridges.
months and transparent lubricant containers
for visual inspection of dispense rate. They are
filled with SKF high-quality lubricant.

SKF USA Inc.

www.skfusa.com
800-440-4753

PLI LLC
www.memolub.com
800-635-8170

Single-point Jack Luber perma Automatic Lubricators

ATS Electro-Lubes newest single-point lubricator is the 125cc (4- LE carries a full line of perma automatic single-point lubricators,
ounce) Jack Luber. It joins the companys family of single-use Original including electrochemical and electromechanical units, which deliver
Electro-Lubers and the refillable, motor-driven Ultimate and Titan Series lubricant at the right time, in the right place, in the right amount.
offerings. The Jack Luber operates on a programmable timer to release These products replace the need for routine manual lubrication,
exact quantities of lubrication when needed. It thus lowering labor costs. They are commonly used on roller and
can be mounted directly on a bearing or sliding bearings, chains, motors,
mounted as far as 20 feet away from the lube open gears, and conveyors. LE perma
point. It is weatherproof and can operate in lubricators come filled with industry-
temperatures from minus-40 to plus-60 degrees proven greases, including: Monolec
Celsius (-40 to 140 Fahrenheit). The product is Multiplex Lubricant (4622), Monolec
reusable by unscrewing the empty grease Industrial Lubricant (4701), Almasol
cartridge and replacing it with a new one, High Temperature Lubricant (1251),
prefilled with the grease of your choice. It can Almasol Syntemp Lubricant (9901),
operate on a replaceable battery Almaplex Industrial Lubricant (1275),
pack or be configured to run on Almaplex Ultra-Syn Lubricant (1299),
AC or DC power. Almagard Vari-Purpose Lubricant
(3751 & 3752) and Quinplex H1
ATS Electro-Lube International Inc. Food Machinery Lubricant (4024).
www.atselectrolube.com
800-663-8141 Lubrication Engineers Inc.
www.le-inc.com
800-537-7683

32 July - August 2010 www.machinerylubrication.com Machinery Lubrication

 INCLUDES 3-DAY
Noria Training Coupon
See Page 3 for Details.

Visit conference.reliableplant.com or call 800-597-5460

ONE BADGE. THREE CONFERENCES. Opening Keynote Session

Mark Swenson
VP for vehicle production
and manufacturing
engineering,
Nissan North America
Voices of Experience PLUS Lubrication, Reliability
Presented by practicing professionals for professionals, including:
and Lean Case Studies From:
Kevin Desrosiers Samuel Bethea Claudia Faye Eric Bigelow Energizer Battery Cargill
engineer, director of N.A. reliability engineer, lean industrial
Alabama Power Temple-Inland
Anheuser-Busch maintenance and Alcoa engineer and
InBev reliability, continuous
Eli Lilly Raytheon
Campbell Soup improvement expert, Goodyear Xerox
Yamaha Motor Frito-Lay MillerCoors
 Welcome to Reliable Plant 2010

How Youll Benefit From

3 Co-Located Conferences Attending and Implementing
What You Learn
The three co-located events at Reliable Plant 2010 supply
the tactics and solutions for substantial advances in plant Secure answers and ideas to address specific
issues and needs at your plant
performance and profitability.
Acquire new skills you can immediately apply on
The leading conference devoted exclusively the job
to using effective lubrication practices to get Go home with the best tools and processes to
the most from a plants physical equipment implement and sustain a successful plant
assets. These unique presentations, delivered by subject matter experts and suc- reliability program
cessful lubrication practitioners, demonstrate how to achieve the efficiencies and
financial benefits of a proper, proactive lubrication program.
Company Advantages
Spotlights the winning strategies and best
practices that drive reliability results to the More time operating less downtime
bottom line. Industry experts deliver com- More output per hour yield
pelling, practical learning sessions, with particular focus on case studies where
Higher first-pass quality fewer rejects
the use of effective reliability strategies has led to measurable economic and pro-
ductivity benefits. Help develop a new generation of leaders
Teams leave with a common vision and
Identifies and examines the specific tools needed to quickly improve understanding
a plants total productivity, profitability, and safety and environ-
Low maintenance costs organizations
mental performance. Case studies reveal how best-in-class
with the highest reliability have the lowest
companies use lean tools to improve the reliability and performance of their mechan-
maintenance costs
ical assets and overall operations.

OUTSTANDING! Weve already seen a

Table of Contents HUGE RETURN on our INVESTMENT
Opening Keynote ....................................................................................3 in attending this conference and weve
Whats Included ......................................................................................3 only just begun to implement the
Conference Schedule ..............................................................................3
STRATEGIES we learned.
Certification ............................................................................................4 - Glenn Moore,
Pre-Conference Workshops ....................................................................5 Alcoa Mill Products
Lubrication Excellence Sessions..............................................................6
Reliability World Sessions ....................................................................10
Lean Manufacturing Sessions ..............................................................13
Exhibitor List..........................................................................................15
Take Home the Tools Game ..................................................................15
Hotel and Travel ....................................................................................16
Conference Fees....................................................................................16
Registration Form ..................................................................................17

For complete conference and expo information

2 and updates, visit conference.reliableplant.com
 Real Strategies.
Measurable Results.

Opening Keynote Session Conference Schedule

From Adversity to Competitive Advantage: MONDAY, AUGUST 30
Nissan Turns Over a New LEAF Sponsored by:
7:00 am 6:00 pm Registration at the Nashville
Mark Swenson, vice president for Convention Center
manufacturing engineering and vehicle 8:00 am 4:30 pm Pre-Conference Workshops
production engineering, Nissan North America 5:30 pm 8:30 pm Certification Testing (ICML)
Tuesday, August 31, 8:00 am
Mark Swenson, vice president of engineer- TUESDAY, AUGUST 31
ing at Nissan North America, knows something
7:00 am 6:00 pm Registration at the Nashville
about responding to a crisis. Mark had just
been promoted to the Nissan leadership team Convention Center
in the late 1990s when the company sal- 7:30 am 8:00 am Continental Breakfast
vaged its future by forming an alliance with 8:00 am 9:20 am Opening Keynote Session
Frances Renault. Mark will share his obser- 9:30 am 10:50 am Exhibit Hall Grand Opening
vations on how that crisis molded the
11:00 am 11:50 am Conference Sessions
company that Nissan became and how the
experience in handling adversity has given the 12:00 pm 1:20 pm Lunch in Exhibit Hall
company a competitive advantage during the current economic 1:30 pm 5:20 pm Conference Sessions
downturn. Nissan has a steadily growing market share and is 5:30 pm 6:30 pm Meet and Greet Reception
poised to become the market leader in mass-produced zero-emis- in Exhibit Hall
sions, all-electric vehicles with the production of the Nissan LEAF
9:30 am 6:30 pm Exhibition Hours
beginning later this year. In his keynote address, Mark will describe
how Nissans forward-looking vision to promote sustainability, ef-
ficiency and quality has become part of the culture. WEDNESDAY, SEPTEMBER 1
7:00 am 6:00 pm Registration at the Nashville
Convention Center
Get a $1,195 7:30 am 8:00 am Continental Breakfast
Noria Training Coupon FREE 8:00 am 9:50 am Conference Sessions
Full conference registration includes an $1,195 training coupon 10:00 am 10:50 am Refreshments in Exhibit Hall
you can use toward Norias training courses for up to one year. 11:00 am 11:50 am Conference Sessions
Use it yourself or give it to a co-worker to use for training. Its like
12:00 pm 1:20 pm Lunch in Exhibit Hall
attending the conference and getting Noria training for free! Terms
and conditions below. 1:30 pm 5:20 pm Conference Sessions
Imagine the possibilities 3:30 pm 4:40 pm Refreshments in Exhibit Hall
5:30 pm 6:30 pm Networking Reception in Exhibit Hall
Attend Reliable Plant 2010 in Nashville. Then redeem your
coupon for three days of Noria classroom or online lubrication 6:00 pm 9:00 pm Certification Testing (ICML)
best practices training. 9:30 am 6:30 pm Exhibition Hours
Bring a group of 10 to Reliable Plant 2010 in Nashville for
only $350 each. Get 10 coupons for Noria training worth THURSDAY, SEPTEMBER 2
$1,195 each.
7:30 am 11:00 am Registration at the Nashville
Attend Reliable Plant 2010 in Nashville. Give your coupon to a co- Convention Center
worker for three days of Noria lubrication or oil analysis training.
7:30 am 8:00 am Continental Breakfast
Bring a group of 3 to Reliable Plant 2010 in Nashville for only 8:00 am 8:50 am Conference Sessions
$550 each. Get 3 coupons for Noria training worth $1,195 each.
Terms and Conditions. Only one coupon will be issued per person. The coupon is trans-
8:50 am 9:20 am Refreshments in Exhibit Hall
ferrable within your organization and must be presented when registering for the training.
The coupon is valid for Noria public training courses in the United States taking place
9:20 am 11:10 am Conference Sessions
between September 4, 2010, and September 3, 2011, or online training courses purchased
prior to September 4, 2011. Coupons are given to full conference (Tuesday Thursday)
11:15 am Giveaways in Exhibit Hall
attendees who pay their conference registration fee and attend the conference. Speakers 8:50 am 12:00 pm Exhibition Hours
and exhibitors are not eligible unless paying full conference registration fees. Coupons
may not be used for onsite training.

3
 Need a Reason to Attend
TEAM D
Bring yo
ur te
ISCOUN
TS
Who Should Attend
session am and cover a Whether youre entry-level or a seasoned
s at Re ll of th
Reliable Plant 2010? See pag liable Plant 201 e
e 16 for
details. .
0
member of your plants management team,
youll benefit from the comprehensive schedule
of sessions, case studies and peer interactions.
Heres a preview of what youll be able to do after Attendees include:
attending the educational sessions: Asset Care Planners
CBM Coordinators & Specialists
Chief Engineers
Design Engineers
Make lubrication PMs more effective Provide efficient maintenance systems while Engineering Managers
satisfying customer demands Engineers
Choose the best personnel for lubrication jobs
Improve a condition monitoring program Facility Managers
Employ precision greasing for rolling element
bearings through continuous improvement and General Managers
measurement
Modify reservoirs and gearboxes for Hydraulic Specialists
contamination control and serviceability Systematically engineer costs out of your
maintenance budget Industrial Maintenance Supervisors
Use a rational and systematic approach to Industrial Mechanics
selecting a new lubricant supplier Use TPM to move from reactive to proactive
maintenance Infrared/Vibration Technicians
Design an effective contamination control Lab Managers
program Use more effective problem-solving methods
in maintenance Lean Leaders
Use best practices to consistently pull
data-rich, representative oil samples Engage and invest in your people to improve Lean Managers
your reliability program Lube Analysts
Spec a new filter cart to meet your exact needs
Develop a FRACAS system to drive equipment Lubrication Specialists
Reduce energy consumption and operating asset reliability
expenses with a lubrication program Lubrication Technologists & Technicians
Determine whether an electric motor is truly Machinery Engineers
Control sludge and varnish in lubricants green
Convert to lubricant storage best practices Maintenance Engineers
Build reliability and maintainability into new or
Maintenance Managers
Set oil target cleanliness levels modified assets
Maintenance Planners
Conduct an audit to identify gaps in your Integrate energy management into your
lubrication program reliability and maintenance strategies Maintenance Supervisors & Foremen
Managers of Maintenance & Reliability
Apply lean manufacturing concepts within Mechanical Engineers
a non-manufacturing environment
Operations Managers
Make effective use of kaizen teams and
PdM Analysts & Specialists
kaizen projects
Maximize the talent of a team so it works at Planners & Schedulers
the highest potential Dramatically reduce your cycle times, as
well as scrap and rework costs Plant Engineers
Reduce your changeovers from hours to Plant Managers
minutes with SMED Increase your inventory turns and on-time
delivery Preventive Maintenance Coordinators
Accelerate operational improvement results
Attain the lean goals of better, faster and Preventive Maintenance Specialists
by applying lean principles to maintenance
and reliability cheaper Production Managers
Project Leaders
Quality Managers
Reliability Coordinators
Certification Reliability Engineers
Set Yourself Apart as a Leader Among Peers Reliability Team Leaders
The International Council for Machinery Lubrication (ICML) will offer certification exam Reliability Technicians
opportunities during Reliable Plant 2010. Advance registration is required. All exams will be
Safety Managers & Directors
conducted at the Nashville Convention Center on Monday, August 30, from 5:30 to 8:30 p.m. and
on Wednesday, September 1, from 6:00 to 9:00 p.m. Senior Reliability Engineers
To learn more about the certification types, registration fees and exam preparation, visit the TPM Coordinators & Facilitators
ICML Web site at www.LubeCouncil.org or call 918-259-2950 and more
For complete conference and expo information
4 and updates, visit conference.reliableplant.com

Case Studies at Reliable Plant 2010
Learn from These Practical, Real Life Examples
Pre-Conference Workshops Monday, August 30
How to Optimize
Preventive Maintenance Plans
Eliminate useless tasks and get more ROI
from PM activities
Drew D. Troyer, Sigma Reliability Solutions
8:00 4:30, August 30
Are you getting the return on investment youd like from preventive
maintenance activities? Do wasteful PM activities continue to drain your
resources? In this workshop, learn the logic and process for creating
effective, optimized PM plans.
Youll first learn how to critically evaluate current PM plans to assess
their value proposition. Then, youll learn effective decision-making
approaches and when to choose each approach. Next, youll learn the
process of building an enterprise-level PM plan for various equipment
classes, and determine how to apply those plans at the site-specific and
equipment-specific levels. The objectives for this workshop are to teach
you how to:
Assess the value proposition of current preventive maintenance plans
Eliminate tasks that fail to add value or actually create problems
Reduce the ambiguity of maintenance tasks
Avoid PM stacking, where condition monitoring tasks are incorpo-
rated in the plan but you fail to eliminate the time-directed tasks theyre
intended to replace
Standardize PM plans for enterprise-level deployment
Pre-Conference Workshops
One-day with Full Conference Registration ..................................................$375
One-day without Full Conference Registration ..............................................$450
Real Strategies.
Measurable Results.
How to Rate and Select Oil Filtration
Make informed filtration decisions and eliminate
costly trial and error
Jim Fitch, Noria Corporation
8:00 4:30, August 30
Every day, contamination is robbing industrial lubricants and machin-
ery of precious life. Most plants realize significant losses from lubricant
contamination. But smart companies are taking action. By systematically
reducing in-service lubricant contaminant levels, they are boosting ma-
chine and lubricant life. Small improvements in oil cleanliness are
handsomely rewarded with dramatic declines in bearing replacements,
pump failures, turbine and gearbox repairs, and more.
The opportunity is significant, but selecting the right filtration for the
job can be confusing. Filter performance ratings dont align with oil clean-
liness codes and there are hundreds of filter sizes and types to choose
from, making it easy to specify too much or too little filtration.
After this workshop, youll have a clear understanding of oil filter rat-
ings and how to achieve oil cleanliness goals quickly and efficiently. Youll
make informed filtration decisions and eliminate costly trial and error.
Contamination is the No. 1 cause of bearing
damage that leads to premature removal.
TRW Bearings Division
You will learn:
How to achieve target cleanliness levels at the lowest possible cost
3 types of filters to replace or upgrade immediately
How to understand oil filter performance and test specifications
Filter strategies that remove more contamination for less money
When and where offline filtration makes sense
Effective strategies for filtering high-viscosity oils
7 simple methods for getting longer filter life and reducing filtration costs
New and practical ways to reach oil target cleanliness levels
5
 Learning Sessions
Essentials for Best-Practice Lubrication
PMs and Inspections
Jim Fitch, Noria Corporation
Daily one-minute inspections can often be more effective
than even the most sophisticated oil analysis program per-
formed monthly. The key is high frequency (daily) and the
revealing quality and thoroughness of the inspection. Simi-
lar to fishing, you cant catch a fish unless your hook is in the
water (inspection frequency), and youve got to know how
to fish (quality of the inspection). Leading organizations have
learned these skills. In this session, youll learn the tech-
niques of these essential inspection practices.
What It Takes to Build an
Award-Winning Lubrication Program
Rick Staley, predictive maintenance analyst,
Energizer Battery Company
In this session, Rick Staley will discuss the lean journey
Energizers lubrication program went through from dirty oil
entering the plant to its current status as an international
award-winner (2009 Augustus H. Gill Award recipient). He
will stress pitfalls, challenges and how to gain support from
management to get buy-in. He will cover oil analysis trending,
how early detection paid huge benefits and proper sampling
techniques. The presentation will consist of the fundamen-
tals, which is the foundation to a strong program. Also
covered will be setting standards that must be maintained to
prevent setbacks (its much easier to hold a standard than to
slip and have to rebuild), performing audits for these set stan-
dards, and choosing the correct personnel for positions.
What Makes a Good Lubrication PM?
Mark Barnes, Noria Corporation
Lubrication preventive maintenance (PM) tasks tradition-
ally have been vague at best. It is still not uncommon to
come across a lubrication PM for a critical machine that sim-
ply states: Lubricate the machine. This special double
session will explore what really makes a good lube PM and
what format it should be presented in. Youll learn why and
how to use a variety of formal PMs, which include full refer-
ence procedures for the new lube technician, task sheets for
the experienced tech and visual documents for operators.
Selecting a New Lubricant
Supplier Beyond Price
Mark Barnes, Noria Corporation
Theres more to selecting a new lubricants supplier than
the price of lubricants. Price does play a role, but today,
most suppliers offer a range of products and services to
support your lubrication excellence initiatives. This session
will help you navigate the window dressing and help you
formulate a rational and systematic approach to selecting
a new lubricant supplier.
6 and updates, visit conference.reliableplant.com
A Comprehensive Look at
How a Temple-Inland Plant
Changed its Lubrication Program
Randy Hall, predictive maintenance technician, Temple-Inland
In this case study session, Randy Hall will share his in-
sights on the progress of the Temple-Inland Gypsum
Wallboard plants lubrication program. Included in this pres-
entation are the improvements made to the lubrication
storage shed, servicing equipment and bulk oil filtration. He
will highlight the modifications that were made to reservoirs
and gearboxes to help prevent contamination and make
servicing easier. He will share some ideas that didnt work
very well and what was done to correct them. He also will
provide a list of items used and where they were purchased.
Oil Sampling Fundamentals:
A Step-by-Step Guide to Doing it Right
Jeremy Wright, Noria Corporation
Proper oil sampling is critical to an effective oil analysis
program. Without a representative sample, further oil analy-
sis endeavors are futile. There are two primary goals in
obtaining a representative oil sample. The first goal is to
maximize data density. The sample should be taken in a way
that ensures there is as much information per milliliter of oil
as possible. This information relates to such criteria as
cleanliness and dryness of the oil, depletion of additives,
and the presence of wear particles being generated by the
machine. The second goal is to minimize data disturbance.
The sample should be extracted so that the concentration
of information is uniform, consistent and representative. It
is also important not to contaminate the sample during the
sampling process. In this session, youll learn the sampling
procedures, sampling hardware and sampling locations for
getting the best possible, consistent oil samples.
Best Practices for Analyzing Used
Lubricating Grease
David Turner, lubricants technical advisor, Shell Global
Solutions
The analysis of in-service lubricating grease is often a
challenging task, since the amount of grease in many ap-
plications is quite small, the grease is often totally replaced
each time new grease is added, and access to the lubri-
cated contact zone may be difficult. Many commercial
in-service lubricant analysis laboratories lack the special-
ized test equipment required for grease analysis, so that
type of analysis is performed by a limited number of labo-
ratories, primarily those of the grease manufacturers.
Various techniques are employed to determine both the
macro and micro condition of used lubricating grease.
Those techniques, their strengths and weaknesses, and
how the results are combined to provide a complete picture
of the state of grease lubricated equipment are discussed
in this session. A few case studies are included to illus-
trate the value of analysis of used lubricating grease.
For complete conference and expo information
Designing Your Contamination
Control Strategy
Jarrod Potteiger, product and educational services manager,
Des-Case Corporation
This session will help you design an effective contamina-
tion control program and the topics covered include: defining
optimum fluid cleanliness levels, identifying the most cost-
effective measures to achieve those targets, and finally how
to effectively measure contaminant levels. Youll learn the
most common lubricant contaminants, how they affect ma-
chinery and how to stop them. Plus, youll leave with some
simple-yet-effective methods for analyzing the cost and ben-
efits of contamination control to ensure that available
resources are deployed in the most effective way possible.
Causes, Effects and Mitigation of Varnish
Jim Fitch, Noria Corporation
Varnish, sludge and surface deposits are a persistent
problem among lubricant users. Often, the problem has
been extremely chronic, leading to expensive repairs and
lost production. While we know much more today about
the causes and some solutions, no silver bullet is currently
available to eradicate the problem entirely. This session fo-
cuses on the current state of these problems and the future
needs for a permanent solution.
The Future Significance of FTIR for
Condition Monitoring Analysis
David Pinchuk, co-founder and president, Thermal-Lube Inc.
This presentation will review the new ASTM accepted
practice and methods for FTIR analysis of in-service lubri-
cants. It will also detail the direction FTIR research is
heading using indirect engineered chemical markers to
generate quantitative (in lieu of qualitative), repeatable and
reproducible data such as acid content, base number,
moisture and fuel dilution.
Lubrications Role in Equipment
Energy Consumption
John Sander, vice president of technology,
Lubrication Engineers Inc.
Today more than ever before, plant managers are driven
to reduce operating costs. Yet due to government regula-
tions, they are now being asked to do things that are in
direct contradiction to reducing costs, such as increased
safety measures and reducing plant emissions. Surpris-
ingly, one of the major ways to achieve these goals is
through their lubrication program. It may seem far-fetched
that something as seemingly minimal as lubricants can pro-
vide hidden returns. This session will describe exactly how
a plants energy consumption and emissions can be de-
creased while reducing and operating expenses through a
plants lubrication program.
Your full-conference badge gets you into
sessions from all three co-located conferences.
Oil Analysis Gets to the Root of a
Power Plants Gearbox Problem
James D. Pete Peterson, senior CBM specialist,
Alabama Power Company
This case study session explores the action plan of Ala-
bama Power Company when a problem was discovered on
a pulverizer gearbox. This was the very first find that the
speaker was involved in after being brought on to the
plants condition-based maintenance team. It provides a
good demonstration of the importance of having in-house
oil testing capabilities.
Achieving Hydraulic and Lubrication
System Reliability in a Tough Environment
Aaron Hoeg, operations manager, Hy-Pro Filtration
Saw mills operate multiple pieces of large equipment
with sensitive hydraulic and lubrication systems. When
this equipment faces unplanned downtime due to impor-
tant components becoming fouled from contaminated
lubricants, profits decrease while production costs in-
crease. Applying a total systems cleanliness approach is
necessary to maximize uptime, extend component life, ex-
tend fluid life, reduce maintenance resource demands and
reduce fluid disposal costs.
This approach was implemented recently at a saw mill achieve, how it attempts to address weaknesses and lever-
by upgrading existing filter elements, breathers and adding age strengths, and where the company is in the
additional dedicated off-line filtration where suitable.
Cyber Caf - FREE E-Mail
Stay connected with the office and home while youre in
Nashville. Take advantage of free e-mail access in the ex-
hibit hall. Available during show hours.
Sponsored by:
Strategic Greasing for Rolling
Element Bearings
Stephen Sumerlin, Noria Corporation
When compared to other lubrication tasks, greasing is
one of the more simple tasks in execution, but it can prove
to be a difficult task to execute without flaw. This session
will explore the strategies for proper greasing techniques
for element bearings, and will expand your perception of the
dedication and precision that is required to get the most
from each stoke of the grease gun.
Lubrication Program at Goodyear:
Goals, Gains and Challenges of
Multi-Plant Deployment
Mike Shekhtman, manager of maintenance and reliability,
Goodyear Tire & Rubber Company
Practicing Lubrication Excellence in a large-scale manu-
facturing facility with intricate equipment of great variety
presents significant challenges. Doing so in a multi-loca-
tion organization with every plant having both their
individual advantages and their own issues of manufactur-
ing objectives, technical expertise, historic cultures,
resources allocation and local collective bargaining agree-
ment precedents is a much more demanding task. In this
session, the speaker will show what Goodyear is trying to
implementation process.
Bookstore
Conference was great! I will be
applying many of the products and
processes in my plant immediately.
Real Strategies.
Measurable Results.
Managing Risk with Food-Grade
Lubricants and the HACCP Program
Stephen Sumerlin, Noria Corporation
Determining where food-grade lubricants should and
should not be used is sometimes a tricky and tedious task
simply due to misguided regulations and improper in-house
techniques. The Hazard Analysis and Critical Control Points
(HACCP) program was developed to aid in determining crit-
ical points and their safety hazards related to contamination
and key health and safety risks. The primary area of use for
the HACCP program is the food and beverage industry, but
industries such as pharmaceuticals and cosmetics are
adopting the program now as well. This session will discuss
the HACCP program and show how food contamination can
be limited with the use of food-grade lubricants.
Preventing Ingress Contamination
through Bearing Cavity Pressurization
Henry Dombroski, president, Air-Tight LLC
In this session, youll learn about prevention of ingress
contamination by means of: 1) hermetically sealing the bear-
ing cavity; 2) pressurizing the bearing cavity with low air or
nitrogen pressure; 3) controlling the pressure in the bearing
cavity 24/7; 4) giving a visual indication of the amount of
pressure; and, 5) indicating bearing cavity integrity 24/7. If
you have current bearing contamination issues, and have
tried everything, attend and learn about these alternative
methods for preventing ingress contamination.
Looking for more information on a
session topic? Excited about learn-
ing more from an expert speaker?
Review and purchase a wide range
of helpful titles in the bookstore.
Sponsored by:
7
 Learning Sessions
Best Practices for the Use of
Off-line Filtration Units
Christopher Eger, product manager for oil services,
Schroeder Industries
To have the best off-line filtration requires that you un-
derstand three basic areas: What are particulate, water
and gas contamination? What does contamination cost
you? Where are you in regards to contamination and where
do you need to be? After understanding the basics of con-
tamination, what products are available in the market to
provide you with a solution? Off-line filtration systems in-
clude filtration carts and skids, contamination monitors,
dehydration systems and diagnostic equipment.
MillerCoors Approach to Lubrication
Excellence and Asset Reliability
Leonard Bouwman, manager for asset management,
MillerCoors
Increasing pressure to drive out operational cost
throughout the manufacturing organization in a highly com-
petitive beer market necessitated a radical shift from
reactive maintenance to one of being proactive. This ses-
sion will share some of the steps covered to show a 26
percent improvement in machine efficiencies. It features
the integration of maintenance into operations as part of
fully integrated team structures, where operations owns
production, maintenance, quality, service and safety. At-
tend this session and learn how an increase in performance
can defer the need for capital expenditures by getting cur-
rent installed capacity to perform optimally.
One Hydraulic Filter for Your Entire
Factory Is it Possible?
Garret Hendrix, owner, Hendrix Engineering
Purchasing, tracking and stocking dozens of different hy-
draulic filter elements burdens many companies and has a
negative impact on hydraulic reliability when replacement
elements arent available. This session will introduce you to
hydraulic filter standardization based on SAE Standard
J6022, with the ultimate goal of using only one filter element
type for the entire factory. A case study of a standardization
project implemented for a Tier 1 automotive supplier having
more than 160 hydraulic power units, and approximately 80
different filter types and sizes will be presented.
How to Set Oil Target Cleanliness Levels
Jim Fitch, Noria Corporation
Controlling particle-induced machinery failures must
begin with defining a customized standard of oil cleanli-
ness for each machine that it affects. This session reviews
the range of methods used to define the correct target
cleanliness level and the most critical influencing fac-
tors. Youll learn the most reliable and effective tools used
in the lubrication field relating to setting cleanliness goals
and establishing contaminant tolerance.
8 and updates, visit conference.reliableplant.com
How to Use a Lubrication Program Audit
to Increase Equipment Reliability
Tom Hiatt, reliability engineer, Covance Inc., and
Wayne Ferguson, associate consulting engineer reliability,
Eli Lilly and Company
This session provides an overview of the development
and performance of a lubrication program audit. These au-
dits lead to the creation of an action plan that addresses
the gaps in your lubrication program, and if implemented,
will lead to an improvement in equipment reliability. Lubri-
cation audits measure your current program practices
against industry best practices.
Specifying Filter Carts
Correctly for Maximum ROI
Jeremy Wright, Noria Corporation
Filter carts are an ideal way to periodically decontami-
nate lubricated systems. Every filter cart should be
compatible with the lubricant and the intended application.
When considering the addition of a filter cart to your con-
tamination control program, there are many things to
consider. This presentation will cover all of the variables
that need to be accounted for to help determine exactly
what details you need to provide your supplier. The leading
suppliers will be able to design the filter cart to meet your
exact needs, giving you the most for your investment.
The 100 Failure Modes of Lubrication
from RCM Analysis
Terry Harris, president, Reliable Process Solutions
Understanding failures modes of your equipment,
processes and individual components is an important func-
tion. Every manufacturing or processing plant has rotating
equipment that is performing plant functions. When this
equipment stops working, your processes cease to perform
their designed expectations. The negative impacts are oper-
ations downtime, reduced capacity, lower quality and EH&S
incidents. Reliability-Centered Maintenance can be used to
define these failure modes. Lubricants and lubrication pro-
grams have more than 100 failure modes that can be defined
and controlled. Understanding each failure mode can help
your plant decide how to prevent and eliminate each of them.
How Cargill Transformed its Lubrication
Practices at its Sioux City Facility
Troy Rooney, lubrication technician, Cargill
This session will explain the evolution of a machinery lu-
brication program, focusing on the oil portion. The speaker
will detail the past, present and future of lubrication at the
plant. He will cover everything from pulling oil samples, set-
ting up gearboxes, handling and storing oil, filtering and
setting up permanent filtration on bigger assets as well as
assets that are almost impossible to safely access.
For complete conference and expo information
Expert Advice on Creating a
World-Class Lube Room
Rick Staley, predictive maintenance analyst,
Energizer Battery Company
Rick Staley was instrumental in transforming the lubri-
cation storage room at Energizers factory in Maryville,
Mo., into a world-class example of organization, cleanli-
ness and functionality. In this session, he will share the
lessons learned from the transformation at Energizer and
will outline whats required for creating a world-class lu-
brication storage room at your facility. Topics and tips will
range from storage and filtration to breathers and spill con-
tainment systems to identification and safety measures.
Attend this session and gain the knowledge to make over
your lube room.
Setting Up a Cost-Effective Preventive
Maintenance Program
Tor Idhammar, president, IDCON
This presentation discusses how operations and main-
tenance should closely integrate equipment and process
inspections and preventive measures in a cost-effective
manner. Several simple steps, tools and thought processes
that you can apply in your plant immediately will be dis-
cussed. You will see examples of inspection standards for
common components using colorful documents and easy-
to-understand Excel data sheets that you can use in your
organization to analyze cost-effective PMs. Financial tools
for analyzing which maintenance method is most cost ef-
fective will also be presented.
The Benefits of Synthetic Greases
Kim Smallwood, product line manager greases, CITGO
Synthetics offer persuasive options that can go a long
ways in helping to solve maintenance and performance is-
sues. It is to this effort that a fundamental review of these
advantages is being presented along with evaluation of
case studies relating the use of synthetic greases.
Methods for Comprehensive
Contamination Control in
Industrial Fluid Applications
Christian Bauer, staff scientist, Pall Corporation
In this session, youll learn the common types of con-
tamination in industrial hydraulic and lube systems, the
devastating effects of these types of contaminants and ef-
fective methods for controlling and reducing them. The
benefits of implementing a comprehensive approach to
cleanliness control, coupling high-efficiency filtration sys-
tems for the removal of particulate contamination with
vacuum dehydration purifiers for the removal of free and
dissolved water, and diagnostic instrumentation for meas-
urement of levels of particulate and water contamination
will be discussed.
Your full-conference badge gets you into
sessions from all three co-located conferences.
Dynamic Equilibrium Revisited
The Behavior of Large Particles
in Lubricating Oil
Thomas G. Barraclough and Daniel P. Walsh, Spectro Inc.
The term dynamic equilibrium describes the process by
which particles of a given size range reach their own unique
equilibrium level. It is these levels which can be used to
trend and set alarms. This result is often not intuitively ob-
vious when setting up an oil sampling strategy. This session
revisits some previously documented mathematical mod-
els on this subject that show from first principles how
particles of a given size reach a ceiling value.
Reduce Water Content, and Save Oil
and Cash with Vacuum Dehydration
Jon P. Michel, engineering and maintenance manager,
ArcelorMittal, and Richard Trent, technical field services
manager, Hy-Pro Filtration
In this case study session, learn how in a recent steel mill
rolling mill application, vacuum dehydration reduced the
water content of an 8,000-gallon reservoir from 29,000 ppm
(2.8%) to 17,735 ppm (1.7735%) in one day. Over two weeks,
the water content fell to 383 ppm (.0383%). Applying vac-
uum dehydration also allowed the mill to end the decanting
routine, saving 25,200 gallons of oil (valued at approximately
$201,600) annually and decreasing lubricant disposal costs.
Ensuring Pump Reliability with Oil Mist
Lubrication
Don Ehlert, manager of EPC sales and business development,
Lubrication Systems Company
New technology always brings a learning curve, and oil
mist has had its share of misapplications and misunder-
standings. Systems installed in the 1960s over-lubricated,
plugged up and were not reliable. During the late 1970s
and into the 1980s, the systems were studied and exam-
ined to better understand the shortcomings and what was
needed to make them more reliable. With renewed interest
and determination, the modern-day oil mist systems are
extremely reliable. Come learn about oil mist and how it
can work for you.
HYDAC / Schroeder Industries
Networking Reception
Nashville Convention Center
Wednesday, September 1
5:30 - 6:30pm Sponsored by:
How to Develop a World-Class Lube
Program Through a Team Concept
Tom Hiatt, reliability engineer, Covance Inc., and Wayne
Ferguson, associate consulting engineer reliability, Eli Lilly
Developing a world-class lubrication program takes a
concerted effort to implement and sustain. From the lubri-
cation technician to the lubricant supplier, teamwork is the
key to success. In this session, you will get an in-depth
view of the path we took to build an award-winning pro-
gram. You will learn the benefits of a lubrication program
and how to get started on your own path toward success.
How to Interpret an Oil Analysis Report
Stacy Heston, field services manager, POLARIS Laboratories
Reading an oil analysis report can be an overwhelming
and sometimes seemingly impossible task without an
understanding of the basic fundamentals for interpreting
laboratory results and recommendations. This session will
explain the cause and effect relationships between certain
test results and how the changes or trends in these results
affect the maintenance recommendations made. It will also
stress the impact of accurate and complete equipment and
lubricant information on the severity assigned to the report.
Knowing the components of an oil analysis report and how
they relate to the condition of the component and the lu-
bricant will take the mystery out of reading an oil analysis
report and allow users to make the most of the mainte-
nance actions recommended.
New Methods for Analyzing In-Service
Greases
Rich Wurzbach, president, MRG Labs
This session will discuss the challenges and options to
obtain representative and consistent grease samples from
motors, gears and other critical equipment. It also will intro-
duce a new method for reliably and repeatably determining
changes in consistency for samples of grease as small as 1
gram, and efficiently preparing those samples for subsequent
analysis by oil analysis lab equipment to determine wear,
oxidation, contamination and consistency conditions.
Real Strategies.
Measurable Results.
Establishing an Effective Condition-
Based Oil Analysis Program for Wind
Turbines
Dave Wooton, principal, Wooton-Consulting, and Greg
Livingstone, executive VP of marketing and technology, Fluitec
This presentation will outline how to establish an effec-
tive CBOA program for wind turbines. Interested attendees
of this session are those that are involved with establish-
ing oil analysis programs, operators of wind turbines and
service providers (including labs, filter manufacturers, gear-
box manufacturers, service companies, etc.) to the wind
energy market. They will learn the basics of establishing a
condition-based oil analysis program and how that is ap-
plied to wind energy applications.
An Explanation on the ISO-Based
Changes to ICML Certification Programs
Suzy Jamieson, executive director,
International Council for Machinery Lubrication
ISO 18436-4 is the first international standard on quali-
fication and assessment of field lubricant analysis
personnel. This session will explain in easy-to-
understand terms the career path outlined in this ISO
standard for lubrication and analysis professionals. The
presentation will cover the purposes, categories, require-
ments and syllabus as per this standard, as well as the
alignment ICMLs certification program has undergone to
reflect its equivalence to ISO 18436-4 categories and the
role it has played in the development of this and other up-
coming standards of interest for the lubrication and
analysis professional.
TEAM DISCOUNTS
Bring your team and cover all of the
sessions at Reliable Plant 2010 and save
up to $645 per person
9
 Learning Sessions
Building The Total Maintenance System
Samuel Bethea, director of North American maintenance and
reliability, Campbell Soup Company
This session will examine how the application of process
management, Six Sigma and other facets can enhance main-
tenance processes and the implementation of an optimized
maintenance strategy. Driven by the need for improved sup-
ply chain efficiencies such as lower inventories and by
producing to the demand schedule of customers, mainte-
nance teams have had to become nimble and flexible in their
approach to establishing maintenance efficiency. Youll learn
ways to navigate the needs to satisfy customer demands
while providing efficient maintenance systems. Methods of
integrating maintenance best practice tools into the day-to-
day manufacturing process to facilitate optimized
maintenance will also be discussed.
How to Maximize Your Condition
Monitoring Program and Really
Impact the Bottom Line
Alain Pellegrino, reliability technician and senior technical
consultant, Laurentide Controls
In recent years a lot of plants have invested in condition
monitoring technologies. Many realized early successes
and reduced downtime, improved availability and lowered
maintenance costs. But many investments havent realized
their full potential. We have new tools but still use them the
old way. Using a real case study of a large zinc smelter, this
session describes the strategies deployed to improve a con-
dition monitoring program through continuous improvement
and measurement. Youll see how these improvements im-
pact the plants bottom line, and how small, continuous
improvements can change the way you do business into a
new business as usual that is more efficient and cost ef-
fective, directly impacting the bottom line.
Failure Reporting, Analysis and
Corrective Action System (FRACAS)
Strategies for Manufacturing
Drew Troyer, Sigma Reliability Solutions
Data is the difference between deciding and guessing. In a
benchmark study by the Aberdeen Group, 59% of top-quartile
performers utilize real-time and historical asset performance
data to drive decisions and actions, compared to 21% for the
laggards. Top performers report 88% OEE and 2% unsched-
uled downtime, compared to 75% OEE and 18% unscheduled
downtime for the laggards. FRACAS is about leveraging data
to improve decisions and is the process for gathering infor-
mation about failures and other losses, analyzing them, and
creating and implementing corrective actions as required.
Unlike FMEA, which is predominantly utilized in the de-
sign phase of the assets life cycle to hypothesize potential
failure modes and effects, FRACAS is more real world
and empirical. In this session, youll learn how to develop
a FRACAS system and then use the collected information
to drive equipment asset and manufacturing process reli-
ability and profitability.
10
Improve Operator Confidence and All I Really Need to Know About
Reduce Errors with Decision Trees Maintenance I Learned in a
Nuclear Submarine
Julien Le Bleu Jr., SageGuides.com
Decision trees logical, visual tools that list relevant ques-
Ned Mitenius, senior consultant, Periscope Consulting
tions and likely outcomes can be highly beneficial in leading Share everything. Play fair. Dont hit people. Hold hands
trained operators to fact-based conclusions. To be useful, theand stick together. We learned these practices in kinder-
questions asked must be straightforward, such as those that garten and can apply the wisdom of them to life today. The
operators are likely to run into on a regular basis (Is the oil
speaker for this session learned maintenance and operational
too hot? Is the level too low? Is there too much vibration?)
practices 30 years ago aboard U.S. Navy nuclear sub-
The beauty of a decision tree methodology is that, if agreed marines, achieving greater than 99% system reliability. These
to by management and followed faithfully by operating per- practices are directly transferable to manufacturing industry
sonnel, it makes doing the correct thing clear-cut and easy.
today. Design. Train. Clean machines. Follow procedures.
Management will see better decisions and reduced Standardize. Lube. Listen. Inspect. Record/Analyze. Stock.
maintenance costs by incorporating decision trees into the Motivate. Be accountable. Drill. How can these practices be
operating culture. For example, by training operators to use applied today to your factory to improve your reliability?
a logic tree for pump decisions, a petrochemical facility re-
duced maintenance overtime by 30% by reducing the
number of pumps that were not repaired on an emergency
or expedited basis. Successful Reliability Program
Implementation Begins with Strategic
Planning and Key Partnerships
Effective Problem Solving in the
Clay Calk, Lubrication Engineers Inc.
Maintenance and Reliability Organization Most maintenance professionals understand the impor-
John Crossan, former manufacturing and maintenance leader tance of implementing or upgrading a reliability program,
(recently retired), Clorox Corporation, and Randall Quick, and they already have the knowledge and training about
engineering manager, Manufacturing Solutions International what to do and how to do it. Unfortunately, because of the
Most companies still use the traditional approach of hav- daily demands and responsibilities of their jobs, the need to
ing elite groups solve problems, and then pass their solutions increase production outputs and the constant firefighting
on to those who must now actually do the work. Using this required to keep critical systems running, they often fail to
approach, you can get to adequate performance. You might allocate enough time to the strategic planning that is cru-
even get to good, depending on your definition of good. But cial to program success.
you will never get to excellent. Excellence takes routine in- Strategic planning and key vendor partnerships can sim-
volvement at all levels, using problem situations as ways to plify the strategic planning process and provide the
involve and develop people, rather than just as issues to
answers to these questions, paving the way for a seam-
solve. John Crossan and Randy Quick have worked on oper-
ational and maintenance improvement at the shop-floor level less, turnkey program customized to fit the companys
reliability objectives. To be successful, the program should
in plants for many years. In this session, they will describe
ways to build this routine involvement and development. address the needs of the maintenance staff, source all ma-
terials required for installation, ensure onsite assistance
through all phases of implementation, provide education
and training to staff, and set up the metrics and tracking
Bearing Life: If 90% of Bearings that justifies the programs overall cost.
Outlast the Asset Theyre Put In,
Why Dont Mine?
Equipment Failure Modes: Your
Dave Staples, business development manager,
SKF Reliability Systems Components Can Last Forever!
In order to make predictions regarding bearing life, most Terry Harris, president, Reliable Process Solutions
do the L10 math. However, theory doesnt always repre-
In this session, youll learn the various failure modes that
sent reality. The bearing didnt reach end-of-life because of
lead different components down the path to early wear-out.
metal fatigue; it failed sooner. It failed, perhaps, due to fac-
tors not considered in the L10 calculation, like wear, By using methods from RCM analysis and FMEA, youll ex-
plore the failure modes of some basic equipment and
contamination, misalignment, corrosion, or as a result of
equipment components in most industrial plant operations.
cage, lubrication or seal failure. The L10 calculation is an
For every example, a proactive or precision technique will
older theory based on traditional ISO and ABMA standards.
This does not take into consideration operating conditions be presented and discussed. Can a motor last for 10 to 15
that are considered by newer calculations like the New years without failures? Can a bearing last 30 years without
Life Theory or the Adjusted Life Theory. Bearing life can failing? Can belts and chains last five to six years without
be calculated with different degrees of sophistication and failing? These and many other components of plant operat-
(as a result) accuracy, depending on the knowledge of the ing equipment will be studied. For every dollar you save in
real operating conditions and environmental variables. This maintenance due to improved equipment reliability, there is
session will take a look at these newer calculations. another $5 to $10 added to the bottom line.
For complete conference and expo information
and updates, visit conference.reliableplant.com
Your full-conference badge gets you into
sessions from all three co-located conferences.
Strategies for Energy Management
and Energy Reduction
Johnny Bofilios, director of global asset sustainability, INFOR
It is well known that there is a direct connection between
the reliability of assets and their consumption of energy. In
fact, energy use is a leading indicator of predictive perform-
ance of an asset. But what are the strategies to start
managing and reducing your plants energy? Did you know
that you can factor energy use with asset management to
maintain and extend the life of equipment and, therefore,
lower your costs? In this session, find out the best practices
to integrate energy into your reliability and maintenance
strategies so you can start identifying, optimizing and au-
tomating proactive maintenance, comparing both the asset
performance and its energy usage across your enterprise.
This presentation will be based on case studies of a high-
profile paper manufacturer, a well-known East Coast
university and a Tier 1 automotive manufacturer, who have
already reduced energy consumption by a minimum of 6%
and reduced their carbon emissions at the same time.
Predictive Maintenance/Condition
Monitoring Through Airborne
Ultrasound Technology
Mark Goodman, vice president of engineering,
UE Systems Inc.
Instruments based on airborne/structure-borne ultra-
sound technology offer many opportunities for plant-wide
predictive maintenance activities, ranging from determin-
ing a lack of lubrication to locating compressed air leaks.
Usually portable, these instruments are used to trend and
analyze bearing condition, detect leaks, identify electrical
problems such as corona, arcing and tracking, and identify
potential problems in operating mechanical equipment. This
presentation will provide a brief overview of the technology,
its applications and suggested inspection techniques.
How to Systematically Engineer Costs
Out of Your Maintenance Budget
Drew Mackley, product line manager,
Emerson Process Management
In an increasingly competitive market, organizations are
challenged to run their plants more profitably and with
greater efficiency. Yet mechanical equipment deteriorates,
causing a decrease in performance, a reduction in through-
put and a rise in operating costs or an unplanned shutdown
grinds production to a halt, resulting in a large loss in rev-
enue. Deterioration in machinery health and performance is
usually associated with misalignment or imbalance, corro-
sion and wear, fouling, sediment buildup or poorly lubricated
parts. Detecting these underlying problems early allows you
to correct issues before they affect your process, optimizing
the performance of your plant. In this session, we will focus
on best practices for planning for and implementing the pre-
dictive maintenance technologies and services necessary
for cutting expense out of your maintenance budget. Real-
world examples and case histories will be included.
Real Strategies.
Measurable Results.
Moving from Reactive to Proactive: The Secret Asset: Whats Missing
How to Get TPM Working for You in Your Reliability Program?
Ellis New, senior management consultant, Productivity Inc. Larry Hoing, reliability and engineering systems manager,
Moving from reactive maintenance to proactive mainte- Wells Dairy
nance requires a whole new look at the way the maintenance Asset performance is the name of the game in everyones
process is managed. To reach this goal, you must declare war book. The thought process is, if we can increase our asset
on unplanned equipment downtime due to failure and build a performance, which increases our return on net assets
maintenance organization unburdened by firefighting. Mov- (RONA), then this will help us lower the total cost of goods
ing from technical fixing to equipment management means sold and increase our profit margins. Simple, right? So, why
having reliable and available equipment providing the flexibil- is it that a large number of companies never fully achieve
ity necessary to substantially reduce costs and generate the net positive results of the investment to improve their
additional income by increasing overall capacity. assets, or if they do have some improvement, they cannot
sustain it for any period of time? Have you considered your
In this session, we will look at what it takes to transi- people assets in the same way that you do your physical
tion from reactive to proactive by using the principles of
assets? Most every company mission or vision statement
Total Productive Maintenance in an accelerated and cost- includes the following sentence. Our people are our great-
effective manner. Well look at the pillars of TPM and how
est assets. Is this really true? Do we really invest in and
and when you implement them to get the biggest return in continuously improve our people assets? How many im-
the shortest period of time. Plus, we will talk about the
provement or updating activities did we do for them in the
proper use of predictive technologies and learn what is nec- last fiscal year? Oh yeah, thats right, the training budget
essary to build strong, effective teams to support an overall was the first thing to go in the budget-cutting process. The
equipment reliability improvement effort. fact of the matter is we cannot perform at a higher level of
During this session we will explore: asset reliability and not invest in a skilled, well-informed,
The role of TPM in a lean implementation
well-educated and engaged workforce. The key for success
in any reliability or lubrication program is the people.
The benefits of a team-based approach to equipment care
Lubrication is the cornerstone for any reliability program.
Root cause tools like visual management, checklist The cornerstones for a successful lubrication program are
and CMMS to guide your transition the people. How do you invest in your people to make them
The use of predictive maintenance technologies as successful? How do you grow or revive a lubrication pro-
part of the overall effort gram? What are the keys to success? Attend this session;
we will explore some of the possibilities of how to engage
The importance of building peoples capabilities to
some of your greatest assets your people.
sustain the effort
The significance of having operators involved mainte-
nance activities
Transition metrics, standard work and proactive main- What Makes a Good PM, and How to
tenance policies Make Sure It Is Executed Properly
Jeff Shiver, managing principal, People and Processes
In a recent survey of more than 1,300 plant profession-
How to Really Use Metrics and KPIs to als in 40 countries, 62% said they either did not have a
Improve Your Maintenance Program preventive maintenance program or are in the process of
building one. Do you have a real program? A better ques-
Kevin Desrosiers, engineer, Anheuser-Busch InBev tion might be How would my engineering and operations
Maintenance practices and execution can't improve with- partners respond to a similar survey? Can you truly meas-
out continuously measuring where you are and taking steps ure and communicate the success your PM program
to improve. But what are the right metrics or key perform- generates to ensure a favorable survey response from
ance indicators? Unfortunately, there is no "one size fits all" those partners? What would happen if you were asked that
answer. A maintenance organization in the early stages will question in a court of law? Does your CMMS data support
measure differently than one with a well-established pro- perceptions or reality? Do you know if your data is the
gram. If you are maintaining airplanes where a failure could result of pencil-whipping? Are the PM task activities the
be catastrophic, you will look at maintenance differently right work and value-added? How can you tell?
than you would for a series of pumps where there is re- This presentation will address the components of a good
dundancy and failures do not have a major impact. PM and methods to ensure the PM activities are executed
In this session will discuss various maintenance KPIs properly. In addition to the PM components necessary, learn
how they can be used (or not used) when evaluating your tools and techniques for establishing an effective PM process,
maintenance program. You'll learn how to benchmark your adding a continuous improvement loop for optimization,
maintenance program for both content and costs and dis- measuring the value of the PM program and inspecting to en-
cuss what to do if people find ways to "cheat" the metrics. sure the right execution. Understand why pencil-whipping
Plus, you'll learn how to use the KPI data to improve rather occurs and how to break the habit. Gain insights on commu-
than as a hammer. Regardless of where you are in your nicating and managing the perceptions with your operations
maintenance evolution, you'll get several new ideas on how and engineering partners to eliminate disconnects so that
to improve their maintenance program. everyone is on board with the value your organization adds.
11
 Learning Sessions
How to Determine Whether a
Motor is Truly Green
Noah Bethel, VP of product development, PdMA Corporation
The ever-present emphasis on technological efficiency
is just one of several forces behind the pressure on com-
panies to go green despite a trying economy. The ultimate
criterion that determines whether a motor is truly green is
energy efficiency. Technology, long the key to efficiency,
can help resolve this issue through detailed computerized
analysis of the motor, the power environment in which it
operates, and even its reliability.
So Whats the Need for
Predictive Maintenance?
Terry Haycraft, national reliability manager, Frito-Lay
Each 0.1 percent of equipment downtime reduction gets
tougher to get each year. As seasoned mechanics retire
from Frito-Lays workforce, the companys cannot afford
the learning curve for new mechanics. In many cases, ac-
cording to this sessions speaker, there is no direct feedback
on corrective or preventive maintenance jobs in the CMMS.
Frito-Lay needed tools to start the transition from
time/usage PMs to condition-based predictive maintenance
and help it avoid the premature failure due to unnecessary
over-lubrication of equipment. This session will provide a Claudia Faye, reliability engineer, Alcoa
brief overview of the companys Alpha / Beta sites utilizing
the Ultraprobe 10000 and Utraprobe 201 Grease Caddy that
achieved enough positive results to quantify the implemen-
tation of the predictive technology on a national level.
Effective Inspection of Steam Traps
and Valves Through Ultrasound
Paul Klimuc, national service manager, SDT North America
This presentation will cover how ultrasound allows for
the effective inspection of steam traps and valves. It will
also explain the basic principles of how ultrasound detects
leakage and other basic faults.
Design for Maintainability and
Reliability: How to Get Everyone
on the Same Page
Ramesh Gulati, asset management and reliability planning
manager, Aerospace Testing Alliance at Arnold Engineering
Development Center
Most reliability programs focus on creating an effective
maintenance program for existing assets. Those who have
been involved with a Reliability-Centered Maintenance
analysis project on existing assets know that some designs
create additional challenges that may have been avoided if
operators and maintainers had an opportunity to provide
input based on resident knowledge and experience. This
session will discuss how Arnold AFB/ATA capital project
managers and designers work in conjunction with opera-
tors and maintainers to build reliability and maintainability
into new or modified assets. Attend this session and learn
how to truly optimize your life cycle costs.
12
Reliability: The Ultimate Green Initiative
Robert Apelgren, Reliability-Centered Maintenance analyst,
ITT Corporation
There is a new focus in society for going green in al-
most everything we do. Manufacturing is no exception and
has been negatively impacted by diverting funds to green
initiatives. This generates no revenue and can carry in-
creased cost, which affects a companys competitive
viability. Many times, these diverted funds come from other
areas that have a heavy impact on reliability. Reliability is
the ultimate green initiative. Though rarely referred to as
green, it is most beneficial to the company, consumer and
the environment. Reliability is achieved through the culmi-
nation of training and various tools from reliability analysis,
root cause, maintenance planning and scheduling, and pre-
dictive technologies. Proper employment of these tools
leads to many green benefits, which include energy effi-
ciency, waste reduction and increased productivity. In this
session youll learn how to employ Reliability-Centered
Maintenance effectively, how to set goals, and how to de-
termine when to start investing in other green initiatives.
How to Maximize the Life Cycle
Costs of Production Equipment
If 85 to 97 percent of base life cycle costs are commit-
ted by the time that equipment is handed over to
operations and maintenance, then life cycle costs (equal
to approximately 20 times the total installed cost) can be
most influenced during the capital process. However, 3 to
15 percent of life cycle costs can be influenced outside the
design, purchase, construction and installation of new
equipment. How can businesses really affect their cost of
production? Attend this session and find out!
Plant System Reliability with On-line
Condition Assessment
Wayne J. Chatterton, Ph.D, technical applications sales
manager, UtilX Corporation
On-line condition assessment analyzes the entire power
system when current activity is at operating voltage. No
switching operations or outage time occurs while this ca-
pacitance testing is performed. The entire system is
analyzed, including cable, switchgear and any attached
transformers or terminations. The responsive capacitance
sensor can detect partial discharge (PD) activity, as well
as numerous pre-discharge events, such as the growth of
water trees and defects in the cable or components. A lab-
oratory-controlled PD occurrence will demonstrate how
pre-discharge activity is visible numerous minutes prior to
PD activity. Systems are graded from Level 1, where the
component is in excellent condition, to Level 5, where the
component is at the end of its useful life. The condition as-
sessment technology is a useful tool to assist in prioritizing
maintenance tasks and facilitating a planned maintenance
program, as it provides critical performance data on the
condition of installed cables and components.
For complete conference and expo information
Overcoming the Challenges to
Implementing an ISO-Certified
Asset Management Process
Ramesh Gulati, asset management and reliability planning
manager, Aerospace Testing Alliance at Arnold Engineering
Development Center
This paper will discuss quality systems requirements for
physical asset management and what challenges are faced
to establish an effective system that is compliant with in-
ternational standards ISO 9000 and PAS 55. ISO 9000 is a
family of standards for quality management systems, in-
cluding the management of physical assets. PAS 55
Optimal management of physical assets is a Publicly Avail-
able Specification published by the British Standards
Institution. The latter gives guidance and a 28-point re-
quirements checklist of good practices in physical asset
management. Asset management at the Arnold Engineering
Development Center (AEDC), located at Arnold Air Force
Base, has been an ISO-certified organization since 2004.
The Critical Elements of Procedure-
Based Manufacturing
Drew Troyer, Sigma Reliability Solutions
Standard operating and maintenance procedures can pro-
foundly influence the reliability of your equipment assets and
manufacturing processes. A recent study found that 70% of
top-quartile performers employ documented operating and
maintenance procedures, compared to 20% of the lower-quar-
tile performers. Top-quartile performers enjoy an 88% OEE,
compared to 75% for the lower-quartile performers. Their
downtime is only 2 percent, compared to 18% for the lower-
quartile performers. In another study, it was discovered that
75% of what goes wrong in the factory is, in fact, human error.
The same study revealed that lack of procedures tops the list
of reasons why. In this session, well discuss: why procedure-
based maintenance is so critical to your success, how to
convert tacit knowledge into documented knowledge, and
how to deploy your preferred practices enterprise-wide.
Get Your Head in the Clouds -
Machine Condition Monitoring
and PdM over the Web
Robert D. Corak, Eric J. Olson and Daniel P. Walsh, Spectro
Inc./QinetiQ North America
CMMS and LIMS software in typical deployments leave
large gaps in a comprehensive condition-based PdM program.
Their inability to connect oil analysis data, vibration, ther-
mography and ultrasound measurements to asset history,
operational condition, maintenance activity and root cause
analysis leave predictive tools limited in their analytical capa-
bilities. The new capabilities of cloud connectivity (Internet)
are changing the paradigm and asset owners can make main-
tenance decisions based on holistic machine condition, by
giving them end-to-end data access. This session will focus
on the benefits of an asset-centric system vs. the traditional
LIMS system and detail some significant advantages that
Web-based systems can have over traditional systems.
and updates, visit conference.reliableplant.com
Your full-conference badge gets you into Real Strategies.
sessions from all three co-located conferences. Measurable Results.

sustained; 2) Standardized work to insure that the gains are sprint. Syngenta will share the experiences and learnings
The 3 Critical Steps to Integrate delivered everywhere; 3) Continuous improvement to iden- gained from using traditional lean tools in a non-traditional
Lean Six Sigma into a Corporate Culture tify the next improvement to become the standard; and 4) lean manufacturing environment. The companys continued
Leveraging insures everyone understands the standard and stumbling and victories prove that a lean journey is an on-
Aqua Porter, vice president, strategic projects and business new potential improvements are identified. Attend this ses- going marathon and not a 50-yard dash. The Syngenta case
results for Corporate Lean Six Sigma Operations, sion and learn the keys to workforce productivity, methods study is a story of application of lean manufacturing princi-
Xerox Corporation to attain management simplification and agility, and the man- ples in a continuous process agrichemical world.
At its core, Lean Six Sigma is a change management ini- ner in which to achieve standard performance through a lean
tiative. To successfully deploy Lean Six Sigma and sustain system across your companys divisions and plants.
results in the long term, organizations must create an en-
vironment with reinforcing loops to encourage smart How Does a Utility Implement Lean?
decision making and facilitate momentum. In her keynote Best Practices from the Countrys
address, Aqua Porter will discuss three areas critical to art- Applying Lean Practices to Largest Nuclear Plant
fully integrating Lean Six Sigma into a corporate culture: Maintenance and Reliability
The executive team creates a vision for using Lean Six Kirk Gould, process improvement consultant in the Center of
Sigma in an organization. Leading from the front involves Darrin Wikoff, education facilitator, Life Cycle Engineering Process Excellence, Arizona Public Service Company
getting hands dirty and empowering employees with re- Lean manufacturing, Lean Six Sigma or simply just lean Arizona Public Service is a power utility based in the
sources to be successful. How do executive leaders are all common terms used in todays manufacturing or- southwestern United States. With more than one million
become Lean Six Sigma champions? ganizations to describe a method of operational customers, Arizona Public Service must build and maintain
Organizations need to embrace the upside-down and in- improvement. But what about maintenance and reliability the electrical infrastructure and keep the air conditioners
side-out communication flow created by social media. improvement? Do lean principles and practices apply to the on for a large part of the Southwest. APS is a part-owner
Information doesnt always flow from the top anymore. Em- maintenance system? In 2007, IndustryWeek reported that of the Palo Verde Nuclear Generating Station, the largest
ployees use social networks to create a community and 74% of companies engaged in lean efforts were not satisfied power plant of any kind in the United States. APS operates
share best practices with each other and peers in the in- with progress being made and the subsequent results. We the plant for the other six corporate owners. This presen-
dustry. How can organizations use this collaboration already now understand that a significant risk to lean implementa- tation will be a case study on the journey Arizona Public
taking place to further Lean Six Sigma use in everyday work? tions is the lack of a stable foundation for improvement. This Service has taken to apply business process management
People are the most critical change agents, and culti- instability is a result of inadequate maintenance and relia- and lean manufacturing concepts within this non-manu-
vating strong project teams is the key to innovation and bility systems. In this session, participants will discover facturing environment.
implementation. For Lean Six Sigma to take hold in the cul- how lean principles can be applied to maintenance and re-
ture of the ranks, employees must be engaged and liability to accelerate operational improvement results.
consulted. What is the best way to maximize the talent of
a team so it works at the highest potential?
Master the SMED System in Your Plant
Employee Involvement and Mike Wroblewski, senior operations consultant,
Empowerment in Lean: Gemba Consulting
Learning to See: Finding Gold A Yamaha Case Study In this session, lean lessons spanning more than two
decades on mastering the SMED system will be shared
on the Plant Floor which can enable companies to achieve year-over-year
Eric Bigelow, lean industrial engineer and continuous
Mark Steward, senior manager for lean productivity, large- improvement expert, Yamaha Motor Corporation success in a lean transformation. The SMED system, or
scale food manufacturing company This session will explore the subject of employee in- single-minute exchange of dies, is one of the most power-
In many ways, we are often blinded by those things that volvement and empowerment within a lean environment ful methods in the lean approach, yet it is still not widely
are right in front of us. Our perception in day-to-day life is using a diagram that the speaker calls Lean Agri-Culture. used or successfully applied in many manufacturing com-
key to discovering pockets of gold as we make our way in The presentation will illustrate in a dynamic style the pos- panies. You will learn about the challenges and practices of
a life of continuous improvement. In this session, the sibilities and the successes that a company can experience incorporating and sustaining the SMED system. See why
speaker aims to help you gain a set of fresh eyes to use when the basic rule of kaizen is followed: People come first, 5-S is an important foundation to the SMED system. In-
in your daily life around the plant. The lessons explored in and everything else comes second. The speaker will pro- cluded in this presentation are several case studies with
this session were gained from years leading lean program vide examples of the concepts in action at Yamahas concrete examples of using the SMED system. Find out
improvements at large manufacturing companies in the 1,000-employee recreational vehicles plant in Newnan, Ga. how to achieve maximum productivity and flexibility using
power management and food products industries. this amazing system to reduce your changeovers from
hours to minutes.

Using Traditional Lean Tools in a Non-

Sustaining the Gains through
Standardization and Leveraging
Jeff Slater, Operating Excellence leader, Sonoco
A consultant study of Operating Excellence productivity
projects at Sonoco showed that over a three-year span, ap-
proximately 50% of the benefits were no longer being
achieved. Back-sliding and project erosion has made it
harder for Sonoco to attain its net productivity goals. A good
rule of thumb is that without a system to sustain the gains,
an additional 15 to 20% per year of productivity projects will
be required to overcome erosion. A system locks in the gains
through: 1) Standard metrics to insure that gains are
Traditional Manufacturing Environment
Kelly Moore, lean manufacturing leader,
Syngenta Crop Protection
St. Gabriel, La., is home to Syngentas largest agrichem-
ical manufacturing and formulation site in North America,
and is comprised of eight continuous and batch chemical
production areas. In late 2006, a declining agrichemical mar-
ket and generic competition drove Syngenta to a strategic
decision that the St. Gabriel plant would become a lean
manufacturing site. In early 2007, the facility took its first
tentative steps on its lean journey. Six months later, in mid-
2007, an unexpected market uplift turned the journey into a
Machine and Line Reliability Can Help
You Become Better, Faster, Cheaper
Thom Longcore, senior productivity manager, Woodbridge
Foam Corporation
This session will explore how high levels of reliability
must be achieved to attain the lean program goals of bet-
ter, faster, cheaper. Furthermore, it will explain not only
how reliability has helped lean, but how lean has helped
reliability, and how these two concepts work together to
make your manufacturing facility a more secure work en-
vironment and a better money-making machine.

13
 Learning Sessions
Lean Safety A Safe Path to
Achieve Lean Results
Robert B. Hafey, RBH Consulting LLC
Without trust, lean is a bust! A common requirement to at-
tain either world-class lean or world-class safety is the
ongoing engagement of the workforce. Lean thinkers all
agree that it is this culture-changing employee engagement
activity that leads to long-term lean success. Too often, lean
has been employed as a cost-savings methodology by man-
agement and, as a result, gaining employee interest and
buy-in can be at best difficult. This keynote session suggests
a different path to lean success a safe path that focuses
the power of lean improvement on the universal topic of
workplace safety. By utilizing lean thinking, along with some
of the common tools in a lean thinkers toolbox, and focus-
ing on safety instead of cycle time, you can easily start to
build an understanding and the acceptance of lean while you
improve safety in your facility. Lean has to be taught, and
when you use safety as your textbook or road map, you will
gain everyones attention. Everyone will rally around safety
for it is and should be everyones first priority.
Examples and case studies of lean tool usage that si-
multaneously drove safety and lean improvement will be
covered in this session.
Raytheon Gets Back to Basics
(and Back on Track) with Lean
Julie Goswick, senior manager and Operations Excellence
leader, Raytheon Missile Systems
Tucson-based Raytheon Missile Systems (formerly
Hughes Aircraft) had everything going for it in the world of
lean. From 1996 to 2004, the defense industry buzzed about
Raytheons successes leaning out 14 factories using their
homegrown version of the Toyota Production System. In a
Hy-Pro Filtration Meet and
Greet Reception
Nashville Convention Center
Tuesday, August 31
5:30 - 6:30pm Sponsored by:
An extremely valuable conference. If youre looking to
get the most bang for the buck, this is the one event of
the year I would recommend to anyone involved in reliabilty
14
matter of just a few years, the company won the Arizona every resource needed to transform raw materials into your
Governors Award for Quality; the U.S. Navy designated the end products and every waste generated be understood and
Agile Improvement Process as an Industry Best Practice; quantified. This calls for a deep dive into each production
Hughes was recognized by IndustryWeek with Americas process and into your supply chain for the materials you use.
Best Plant award; and in 2004 (now Raytheon) won the Lean thinking focuses deeply on processes and engages
coveted Shingo Prize. The Missile Systems Lean Team had everyone in continuous improvement, and green thinking
developed and implemented a proven, repeatable deploy- does the same. Hence, the opportunity is clear to apply lean
ment process, the employees were trained on lean and in a green initiative. Attend this session and learn: the
focused on the elimination of waste, and the results real- green implication to every lean type of waste, the green
ized were amazing. Cycle times were dramatically reduced, data you need to capture in your value streams, and how
inventory turns were increasing, scrap and rework costs kaizens can be focused on environmental impact to provide
were decreasing, and on-time delivery, cost and quality transparency, planning and concrete bottom-line returns.
were at new levels. So, what happened ...?
Fast forward to 2010. Today, pockets of lean excellence
can be found throughout many of the original factories in Lean in High-Mix/Low-Volume
Tucson. Employees on occasion can be heard discussing Production
lean terms such as error-proofing, takt, kanbans, and 7-S
with a new and aggressive commitment for safety. Walk- Sam MacPherson, president, MacPherson Business Advisors
ing through the factories, though, one can clearly tell that (MBA), and dojocho, Lean Leadership Academy
something is missing. Do you struggle with applying popular lean tools based
on manual assembly cell or assembly lines to your large-
Follow the Raytheon Lean Team as we embark on Back
scale product? Do you have trouble visualizing how to apply
to Basics, a case study of what we missed along the lean
standardized work to a job shop? Have you struggled
journey the first time, and what we know now that we
with fitting lean concepts such as takt time, pull production
must do to get back on track.
and high-mix/low-volume mixed model production to
your operation because you have large-scale product, long-
duration machining cycle times and assembly times? Are
Linking Lean with Environmental you a producer of large-scale parts or OEM production
Sustainability equipment? Does your operation include batch operations
or does the thought of moving large-scale product or pro-
Phil Coy, partner and chief technology officer, EWT duction equipment into a U-shaped cell not appear to be
Green, or environmental responsibility, has crossed the an option or cost effective? In this session, attendees will
tipping point to become a mandatory element of corporate learn The Toyota Production System For Large-Scale Pro-
strategy. In challenging economic times, an open-ended duction. The speaker will present the secrets to
mandate to go green cannot be sustained without consid- standardizing production for the custom or job shop envi-
eration for bottom-line profit. While global warming, ronment in order to apply the concepts pull production, takt
greenhouse gases and oil spills in the Gulf of Mexico get at- time, standardized work, lean material handling and mix-
tention, creating a truly sustainable business requires that model production.
- Doug McBride, Temple-Inland
For complete conference and expo information
and updates, visit conference.reliableplant.com
 Real Strategies.
Measurable Results.

Exhibitor List (as of July 19, 2010)

The exhibits at Reliable Plant 2010 work in tandem with sessions and work- Interested in exhibiting at Reliable Plant 2010?
shops to enhance your experience. Youll have the opportunity to compare Contact Brett OKelley at 800-597-5460 extension 112 or e-mail
products, solutions and services from leading vendors. Take what you learn bretto@noria.com. Sponsorship opportunities also available.
in the classroom to find and evaluate solutions you need on the exhibit floor.

Academy of Infrared Training (AIRT) Hy-Pro Filtration POLARIS Laboratories

Air Sentry International Council for Machinery Lubrication Productivity, Inc.
Air-Tight, LLC IDESCO Corporation Quality Filtration
ALS Laboratory Group IFH Group R&G Laboratories, Inc.
Anton Paar USA
Indiana Bottle Company Rhino Tuff Tanks
Infor Royal Purple Ltd.
Argo-Hytos, Inc. Inpro/Seal Company SDT Ultrasound Solutions
A.T.S. Electro-Lube Insight Services SenGenuity (Division of Vectron Intl.)
Brady Corporation Internormen Technology Shell Lubricants
Cannon Instrument Company JAX INC. SKF USA, Inc.
CheckFluid, Inc. JLM Systems Limited Snap-on Industrial / J.H. Williams Tool Group
Kaman Industrial Technologies Specialty Manufacturing, Inc.
Chevron Product Company
Kimbro Oil Company Spectro, Inc.
CITGO Petroleum Corporation Koehler Instrument Company, Inc. Tannas Company
Des-Case Corporation Life Cycle Engineering Thermal Lube
Dexsil Corporation Lincoln Industrial UE Systems, Inc.
Donaldson Company, Inc. Liquidynamics University of Tennessee
Dupont Performance Lubricants Lubrication Engineers, Inc. Utilx Corporation
EasyVac, Inc. Ludeca, Inc. WD-40 Company
Midland Manufacturing Y2K Fluid Power
Emerson Process Management
MP Filtri USA *Sponsors shown in orange
Esco Products, Inc. Noria Corporation
Fluid Technologies, Inc. Novinium
Fluidall, LLC Oil Filtration Systems
Hach Company One Eye Industries, Inc.
Harvard Corporation Pamas USA
Parker Hannifin
Hendrix Engineering, Inc.
PdMA Corporation
Herguth Laboratories, Inc. Penn Hills Scientific
HYDAC Technology Corporation/ PerkinElmer, Inc.
Schroeder Industries Petro-Canada

Take Home the Tools Game

How to Win: Check out the latest products and services from the sponsoring
exhibiting companies, get your entry form stamped and then register to win. Visit our
Web site at conference.reliableplant.com for complete contest rules.
Come compare the tools for building a reliable plant and you might go home with one of three
Snap-on/J.H. Williams/Bahco tool sets for the garage or workshop. Three sensational prize pack-
ages one each day. Snap-on tools have inspired the trust and confidence of professional craftsmen
since 1920. Designed to deliver superior performance, durability and comfort, Snap-on tools not only
last for years, they last for generations.
Giveaways sponsored by:
CITGO Petroleum Corporation, Des-Case Corporation, Emerson Process Management, Fluidall, Herguth, HYDAC / Schroeder Industries, Hy-Pro Filtration, Infor,
Life Cycle Engineering, Lubrication Engineers, Midland Manufacturing Company, MP Filtri USA, POLARIS Laboratories, Rhino Tuff Tanks, Shell Lubricants, SKF USA,
Spectro, Y2K

15
Hotel and Venue
Reliable Plant 2010 is held at the Nashville Convention Center in Nashville,
Tennessee. Reliable Plant 2010 attendees receive discounted room rates at
the Renaissance Nashville Hotel, which is connected to the Nashville Con-
vention Center. You can take advantage of these rates by booking your
room(s) directly with the Renaissance using the group name Reliable Plant
Conference at the time of reservation. Availability is limited and you are
encouraged to make reservations early.
Renaissance Nashville Hotel
611 Commerce Street
Nashville, TN 37203-3725
Telephone: 800-266-9432 / 506-474-2009
Room Rates Book Early and Save
Before August 14 - Single Occupancy: $135.00
Rates Expire: August 14, 2010
* All room rates exclusive of state and local taxes or applicable service,
or hotel specific fees in effect at the time of the meeting. Hotel tax
rates are subject to change without notice.
Reserve Your Room Today!
Call the hotel directly at 800-266-9432 or 506-474-2009.
Be sure to provide the group name: Reliable Plant Conference.
Make all hotel reservation changes or cancellations directly with
the Renaissance.
Airlines and Car Rental
Air Travel
American Airlines is offering discounted fares for attendees of Reliable Plant
2010. Some restrictions may apply for airline tickets and discounts may not
be available on all fares. For reservations and ticketing information, call Amer-
icans Meeting Services Desk at 800-433-1790 from anywhere in the U.S. or
Canada and reference Authorization Number: 2780AP
Discount fares are valid for round-trip travel on American Airlines, Ameri-
can Eagle, American Connection Service and all oneworld Alliance Partners.
The percentage discount may be applied to American and American Eagle
flights booked online by visiting www.aa.com and entering the authorization
number as the aa.com discount code. Valid group travel dates are August 28
- September 5, 2010.
Car Rental
Discounted group car rental rates are available from August 23 -
September 9, 2010. Reservations can be made by calling 800-331-1600
or visiting www.avis.com. Reference Discount Code J907635 for
group discount rates.
Discounted group car rental rates are available from August 24 -
September 9, 2010. Reservations can be made by calling 800-654-2240 or
visiting www.hertz.com. Reference Discount Code CV#04B10002.
16
Conference Fees (USD)
Full Conference Registration ..........................................$995
Group Discounts
3 to 9 Attendees: Send three or more full conference registrations for only
$550 each, plus a 20% discount on all pre-conference workshop fees.
10 or More Attendees: Send 10 or more full conference registrations for
only $350 each, plus a 20% discount on all pre-conference workshop fees.
Multiple registrations must be purchased at the same time.
Call 800-597-5460 to take advantage of this offer.
Full Conference Registration Includes:
All sessions in the 3 co-located conferences
Conference Proceedings in CD-ROM format
Opening General Session
Exhibition Hall Access (Tuesday-Thursday)
Lunches in the Exhibit Hall (Tuesday-Wednesday)
Daily Refreshment Breaks (Tuesday-Thursday)
Daily Continental Breakfasts (Tuesday-Thursday)
Networking Receptions (Tuesday-Wednesday)
Plus, a FREE $1,195 Noria training coupon. See page 3 for details.
1-Day Conference Registration ....................................$395
1-Day Registration Includes:
Days sessions in the 3 co-located conferences
Opening General Session (Tuesday Only)
Exhibition Hall Access for One Day
Lunch in Exhibit Hall for One Day (Tuesday-Wednesday)
Days Refreshment Breaks
Days Continental Breakfast
Days Reception (Tuesday and Wednesday Only)
Exhibition Only Registration
With Exhibitor Guest Pass......................................................................FREE
Without Guest Pass..................................................................................$50
Pre-Conference Workshops
One-Day (with Full Conference Registration) ............................................................$375
One-Day (Workshop Only) ..............................................................................$450
Workshop Registration Includes:
Course Materials Opening General Session (Tuesday Only)
Refreshment Break(s) Exhibit Hall Access (Tuesday Only)
Spouse/Family Registration..............................................$135
Spouse/Family Includes:
Opening General Session (Tuesday Only)
Exhibition Hall Access
Daily Lunches in the Exhibit Hall (Tuesday-Wednesday)
Daily Continental Breakfasts (Tuesday-Thursday)
Receptions in the Exhibit Hall (Tuesday-Wednesday)
For complete conference and expo information
and updates, visit conference.reliableplant.com
 Real Strategies.
Registration Measurable Results.
Nashville, TN - August 31 September 2

August 31 - September 2 Nashville Convention Center Nashville, Tennessee

1. Registrant Information 4. Conference Proceedings on CD-ROM

Please print your name clearly. Your name and company will appear on your badge. With full conference registration . . . . . . . . . . . . . . . . . . . . . . . . . . .Included
PLEASE photocopy this form for an additional registrant.
Purchase without registration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$99
First Name __________________________________________________

Last Name __________________________________________________

Total Payment Due: $ ______________
First Name for Badge __________________________________________ Payment due upon receipt of invoice and prior to conference. No registration materials will
be distributed without full payment. Customers outside the U.S.: We accept checks drawn
Title ______________________________________________________ on U.S. banks in U.S. dollars.

Company ____________________________________________________

Address 1 __________________________________________________ 5. Method of Payment

Address 2 __________________________________________________
Payment must be received prior to the conference.
City ____________________________State/Province ________________ Check # _____________ is enclosed or will be mailed
Please make check payable to: Noria Corporation
Zip/Postal Code __________________ Country ____________________
Charge my: Visa MasterCard AmEx Discover
E-mail (required) ______________________________________________ Noria Corporation is authorized to charge the credit card below for my conference
registration fees in the amount indicated on this form.
Phone Number (required) ( ______ ) ______________________________

Fax Number ( ______ ) ________________________________________ Card Number ____________________________________________

Expiration Date ______ - ______

2. Conference Fees
Name on Card ____________________________________________
Individual Full Conference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$995
Cardholders Signature ______________________________________
Endorsing Organization Member . . . . . . . . . . . . . . . . . . . . . . . . .$945
Write-in
Organization Bill Me/My Company - Purchase Order No. ______________________
Guest-Spouse/Family . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$135
(Must accompany paid attendee)

Individual 1-Day . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$395 Register using any of the following:

Exhibition Hall Only . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .$50

BEST ! @ Online: By Phone:

Group Discounts VALUE conference.reliableplant.com 800-597-5460 or
Three to Nine full conference registrations only $550 each or Ten or More for $350 918-749-1400
each. Group discounts include a 20% discount on pre-conference workshop fees. Group M - F, 8 - 5 (CST)
registrations must be purchased at the same time. Call 800-597-5460 to take advantage
of this offer.
By Fax: By Mail:
Fax your completed Send this form and payment:
registration form to: c/o Noria Corporation
918-746-0925 1328 E. 43rd Ct.
3. Pre-conference Workshops Tulsa, OK 74105 U.S.A.

Save With Full

Registration
Cancellations/Substitutions
Monday, August 30 You may cancel a registration before July 31, 2010. Cancellations must be in writing. A $75 cancellation fee will be applied to all
cancellations received after July 31, 2010, but you will also receive a $75 coupon good for use against the cost of a Noria training
How to Rate and Select Oil Filtration . . . . . . . . . . . . . . . . .$450 . . . . . . .$375 course or conference. This coupon is fully transferable. If you dont cancel and you dont attend, you will be charged the full regis-
tration fee. Substitute attendees are welcome at no extra charge with written notice prior to the event.
How to Optimize Preventive Maintenance Programs . . . . .$450 . . . . . . .$375

17
 Get a Printable Version
CROSSWORD PUZZLER of This Puzzle Online at:
MachineryLubrication.com/puzzle

1 2

3 4

5 6

7 8

9 10 11

12

13

14 15

16

17

18 19

20

ACROSS
1 Instrument generally used to determine the specific gravity of oil.
4 Name of Noria Corporations annual conference and exhibition,
which will be held this year on August 31-September 2 in Nashville
(two words).
7 Kinematic viscosity is measured using this type of viscometer
(three words).
10 These products come in single-point and mutiple-point versions.
12 Parts per million, in short form.
16 Norias e-mail newsletter focused on filters and filtration systems
(two words).
18 Fourier transform infrared (FTIR) is used to quantify the presence
of this within an oil.
19 The term for contaminants entering a fluid from an external source
and the resultant generation of contaminants because of wear.
20 Whose Machinery Lubrication column normally ends with the
tag line As always, this is my opinion; Im interested in yours
(two words).
Get the solution on Page 29.
50 July - August 2010 www.machinerylubrication.com
DOWN
1 A common cause of lubricant oxidation (two words).
2 Product manufactured by company featured in this issues
cover story.
3 Vice president of manufacturing at Janes Dough Foods (see cover story).
5 This Nissan vice president will provide the opening keynote address
at Norias big event in Nashville (two words).
6 A method to measure chlorine contamination.
8 The role of this is to produce a barrier film on oil-wet ferrous
surfaces to repel water (two words).
9 A fluid that is used as a fire-resistant hydraulic fluid (two words).
11 The Oklahoma city where Noria Corporation is based.
13 Product line featured in the WD-40 advertisement in this issue
(two words).
14 The type of lubricants featured in the cover story on the Janes
Dough Foods plant in Columbus, Ohio.
15 A metal often seen on oil analysis reports that comes from the
additive ZDDP.
17 The last name of Back Page Basics author Jeremy.
Machinery Lubrication
OIL ANALYSIS

A New Technique for

Filter Debris Analysis
BY SURAPOL RAADNUI

cleaning of the used oil filter is accomplished by immersing the

D ue to the increasing fineness of filter elements in high-preci-
sion machinery lubricating oil systems, monitoring of filter
debris analysis (FDA) is gaining increased significance for the early
filter in a suitable solvent and removing entrapped debris by ultra-
sonic agitation and/or air pulsation.
failure detection of moving parts. These considerations led to the Major drawbacks of conventional FDA are: particle stacking
development of a new method to recover filtered debris particles gives an erroneous result, and the method is a fairly cumbersome,
efficiently, productively and economically. time-consuming process. A new FDA approach is proposed in this
article. A special particle separating tube (PST) is introduced.
A Brief Introduction Figure 1 shows a typical PST; the component also can be used for
Methods for detecting damage to rotating components in high- separation of solid particles from used lubricants1,2.
precision machinery lubricating systems operate on the
determination of types, size, shape and concentration of wear
particles in the lubricating oil. Detecting still relies on an oil sample.
Apart from the oil sampling technique, however, FDA is increasingly
growing in acceptance. Filter inspection is a method of long
standing, where the chance of detecting damage varies with the
method used to recover the particles from a filter element spec-
imen. FDA, in general, can therefore be thought of as consisting of
three discrete steps: removal and cleaning of the oil filter, recovery
of the removed debris, and examination of the debris. Typically,

Figure 3. Particle Separating Tube (PST) for FDA

Filtersonicgram
Maker Procedures
Here is a step-by-step walk-
through of the process.
1) Collect a used oil filter (i.e.
Figure 1. Typical PST for Solid Debris Separation hydraulic, turbine, engine).
2) Remove the filter housing with
a suitable tool. (Do not use a
hacksaw to open up the
housing as the metal saw dust
will have a significant effect in
the solid debris analysis stage.) Figure 4. Put the Sample
Figure 2. A Filter Element Specimen into the PST

52 July - August 2010 www.machinerylubrication.com Machinery Lubrication

 OIL ANALYSIS
Figure 5. Typical Ultrasonic Washing Machine
Figure 6. Insertion of the PSTs into the Fixture
Figure 7. Inside of Washing Machine
After the PSTs are Put in Place
Figure 8. Utilization of Ultrasonic Washing Machine
54 July - August 2010 www.machinerylubrication.com
Figure 9. Filtersonicgram Slides Have Been Prepared
3) Cut part of the whole filter element as a specimen (Figure 2).
4) Put the filter element specimen into the top chamber of the
PST unit (Figure 3).
5) Pour proprietary solvent into the PST until the filter element
specimen is submerged under the solvent (Figure 4).
6) Put the PST(s) into the fixture inside the ultrasonic washing
machine (Figure 5).
A set of PSTs can be used to extract solid particles in multiple
samples simultaneously (Figure 6).
7) The samples are now ready to be washed inside the ultra-
sonic washing machine (Figure 7).
8) Operate the washing machine, which has an intensity of the
ultrasonic wave approximately at 42 kilohertz for an appro-
priate duration, which depends on the type of filters i.e.
engine oil filter, hydraulic oil filter, turbine oil filter, etc.
(Figure 8).
9) Switch off the washing machine and take the PSTs out of
the unit.
10) Up to this stage, the solid particles have been extracted from
the used filter element and also have been classified as per
their sizes.
11) Remove the drain plug to get rid of the unwanted solvent
(Figure 9).
12) Disconnect each section of the PST and remove the patches
which are now ready to be analyzed under an optical micro-
scope or similar device for debris classification and
identification by: size; color; shape; edge detail; thickness
ratio; surface texture; response to light (reflected or trans-
mitted light); and response to heat ( the wire mesh can be
used as a filter patch which can be heated up to certain
temperatures, depending on the wire mesh materials). This
Machinery Lubrication
 process can be used to identify fiber, elas-
tomer and alloy composition (i.e. copper,
aluminum, tin, lead). Sample slides are
shown in Figure 10.
13) The patch also can be weighed, which can be
used to quantify the extracted debris due to
their size ranges.
14) Debris morphology can be done in a more
comfortable manner as the particle-stacking
problem in the conventional filtergram
technique (by the conventional vacuum
filtration technique) is partly solved.
15) The wire mesh patch may be reused, if needed.
A Unique Assessment
and Examination Tool
Filtersonicgram is a novel method to recover
solid particles trapped in filter elements with the
simultaneous utilization of ultrasonic wave and a
conventional filtration approach. The recovered
particles on the multi-patch filters can be assessed
with the aid of a microscope or other device. Careful
examination of the debris morphology can give
specific information about the condition of the
moving parts of precision machine elements from
which they were generated, and the wear mode
and/or wear mechanism in operation in the system
from which they were filtered. This technique is at
present being tested in the field and it is the field
Figure 10. Typical Filtergram Slides
Machinery Lubrication
operators who will judge the efficacy of solid debris
separation and examination by this technique.
Acknowledgement
The work reported here has been funded by the
Thailand Research Fund (www.trf.or.th).
References
1) System and Method for Filter Debris Analysis,
International Patent Application (PCT) Number
PCT/SG2009/000465, date of filing December 3,
2009.
2) An Apparatus and Method for Particle Analysis,
International Patent Application (PCT) Number
PCT/SG2009/000264, date of filing July 27, 2009.
About the Author
Surapol Raadnui is an engineering faculty member
at King Mongkuts University of Technology North
Bangkok in Thailand and works in the schools
Machinery Health Monitoring and Tribology
Laboratory. Send your questions or comments via
e-mail to Surapol at s_raadnui@yahoo.co.uk or
srr@kmutnb.ac.th.
Hungry For More Information?
The Machinery Lubrication Web site is the
home for hundreds of technical articles, columns
and reports related to lubrication research,
solutions and best practices. Check out
www.machinerylubrication.com and learn more.
www.machinerylubrication.com July - August 2010 55
LUBRICANT STORAGE

Pennsylvania Power Plant

Gives Oil Storage Room a
Much-needed Makeover
BY MICHAEL MALPEZZI, CMRP

Results
T he oil storage room at the Elrama Generating Station in Elrama,
Pa., was located in a separate building specifically made to
house the oil at the plant (Figure 1). Oil drums were stocked on
Oil analysis indicates that new oil from the supplier is received
on site with an average ISO cleanliness code of 18/17/13. This is
racks, and an overhead crane lifted full drums to pour into steel consistent with the manufacturers claims and advertising. This is
containers that stored the oil for plant distribution (Figure 2). These not something a person can see with the naked eye, so the pictures
storage tanks were open to atmospheric conditions and were typi- in Figure 7 have been magnified 100 times to give you a better look.
cally left open as the manually operated oil pump dripped for Transferring into the old storage tanks made the oil dirtier
several hours after use. These tanks were an entry point for contam- than new. Oil samples from these tanks showed an increase in
ination into the system. No filtering took place. The lubricant was
placed into containers, bottles and buckets another entry point for
contamination. But, that was then. This is now.

Current Practice
The reconfigured storage room today consists of oil in stacked
plastic totes in a quantity representative to the SAP stocking level
(Figure 3). Drums are not stored in the room unless an oil analysis
is in process. The drums are pumped through 25- and 3-micron
filters on a filtering cart into the plastic totes. The totes are sealed
from the atmosphere and use a desiccant breather to dry the air
that enters the tote when draining the oil into filling bottles.
Totes are labeled with the oil manufacturers information to prevent
pumping into the wrong tote (Figure 4). Color- and shape-coordinated
labels also identify the oil type and help prevent cross-contamination
(Figure 5). The overall process is shown in Figure 6. Figure 2. This is a visual diagram of the previous practice
used to store and distribute oil.

Figure 1. Heres a snapshot of the old lubricant storage area.

It was not set up to achieve lubrication excellence. Figure 3. Today, oil is stored in stacked plastic totes.

56 July - August 2010 www.machinerylubrication.com Machinery Lubrication

Machinery Lubrication www.machinerylubrication.com July - August 2010 57
 LUBRICANT STORAGE
Figure 4. Totes are labeled to show oil type
and the manufacturer.
Figure 6. This is a visual diagram of the current practice
used to store and distribute oil.
the ISO cleanliness code to 19/18/14, or 50 percent dirtier than
when we first purchased the oil (Figure 8). Using this oil
following an oil change, we would never meet recommended
cleanliness targets. Meeting these targets would maximize equip-
ment and component life.
Installation of the new storage totes and filtering the oil before
placing it into the tote dropped the cleanliness code by 2/2/2 from
the drum and 3/3/3 from the old storage system. The amount of
particles in this oil is 87 percent lower than before. This allows for
extended equipment life and maximized oil life.
Figure 7. Pictures of oil samples taken from a fresh oil drum (left),
after transferral into the old storage tanks (center) and after the changes.
58 July - August 2010 www.machinerylubrication.com
Figure 5. Labels have a color and shape system
to prevent misuse.
Benefits
Using a life extension table created by Noria Corporation to
compare machine oil cleanliness, we saw that a three-level reduction
in cleanliness code extends the life of gearboxes by a factor of 1.5 and
journal bearing machines by a factor of 1.8 times. The Noria chart
makes a couple of assumptions in that you must maintain the oil
cleanliness level at that level for the life of the machine, which is very
difficult and almost never practical. It does show, however, that if the
oil is cleaner (and all other variables are equal), longer equipment life
will be the result. The question you should ask yourself is, How
much of your budget do you use to repair oil-lubricated machines?
If that amount is greater than $100,000 per year, then cleaner oil
would be a huge benefit to your bottom line.
An additional benefit of starting with cleaner oil is that oil change
intervals can be extended if the reason for changing the oil is high
particle counts. If you extend oil change intervals, your plant will
consume less oil during any measured period. This will result in an
overall savings and increased profit margin. If you extend the oil
change intervals on average by 20 percent and the annual plant oil
expenditure was $100,000, the savings would be $20,000 in reduced
oil purchases, plus the cost of labor for those oil changes, which
could easily double that amount, for a total savings of $40,000 per
year. I wont account for any benefit that a machine sees with
extended life because of the number of variables that exist.
Further Improvements
Best practices indicate that setting individual machine cleanli-
ness targets should be followed to maximize the life of lubricated
Machinery Lubrication
 filter larger oil reservoirs, such as boiler feed pumps and pulverizer
Particle Count Oil in drum Oil ltered in Oil in old Elrama gearboxes. Storage totes come in many different sizes, from 65 to 240
(particles per ml) ISO 4406:99 from supplier new storage totes storage tanks gallons. Some oil storage areas have their own spill containment units.
ISO Code 18/17/13 16/15/11 19/18/14 The cost to filter and store four different lubricants for a gas
>4 Micron 2446 461 3349 turbine plant may be in the $5,000 to $15,000 range, and the cost
>6 Micron 951 179 1302 to filter and store 10 different lubricants at a coal-fired plant may
>14 Micron 72 13 99 be in the $30,000 to 45,000 range.
>50 Micron 3 0 4
>100 Micron 0 0 0 Investment Return
Single Component Tests We conservatively calculate $40,000 as the annual benefit from
Acid # mg KOH/g 0.013 0.03 0.17 extended oil changes. This doesnt take into account lost margin
Water % Neg Neg Neg from any unit derate or outages, nor does it take into account bene-
fits from reduced maintenance due to extended machinery life. We
Figure 8. What oil do you want protecting your machines? also conservatively calculate $45,000 for costs on an oil storage
area, with 12 percent as a discount rate and a 20-year life
expectancy. The net present value (NPV) is calculated at $208,778.
Typical base cleanliness targets
Machine/element ISO Target
Roller bearing 16/14/12
An Air-Tight Case for Change
New oil arrives on site in varying degrees of cleanliness. It easily
Journal bearing 17/15/12
can be improved with the use of sealed storage tanks and by
Industrial gearbox 17/15/12
filtering the oil before storage. A minimum removal of 75 percent of
Mobile gearbox 17/16/13 all particulate contaminates can be expected with filtering.
Diesel engine 17/16/13 New oil is not clean enough to use if cleanliness targets are
Steam turbine 18/15/12 implemented and maintained. The NPV shows a positive figure of
$208,788 for a 20-year life cycle; the benefit-to-cost ratio is 4.6
Figure 9. Here is a sampling of base cleanliness targets for when a discount rate of 12 percent is used.
common machines and machine elements. These storage tanks should be used at every power plant facility.
This is a case of proactive maintenance contributing to machine
surfaces. Figure 9 represents targets for common machines and reliability and the companys bottom line.
machine elements.
If any of these targets are followed, then filtering the oil from the About the Author
drums is mandatory since the new drum oil will not meet any of Michael Malpezzi, CMRP, is a reliability engineer at Reliant Energys
these targets. Clean oil storage hardware and techniques are the Elrama Generating Station in Elrama, Pa. Elrama is a fully scrubbed, four-
key components to keep these targets low. unit, pulverized coal-fired generating station located on a 44-acre site
along the Monongahela River, 25 miles southwest of Pittsburgh. Elrama
operates as a baseload facility and has a net demonstrated capacity of 465
Costs megawatts. Units 1,2 and 3 were commissioned in the early 1950s, while
The cost of the Elrama oil storage tanks was $45,000. The cost Unit 4, the largest unit at the facility at 175 net megawatts, began commer-
of your lube room is dependent on a number of factors. How many cial operation in 1960. The flue gas desulfurization (scrubber) system, one
lubricants do you use on site? Do you need spill protection? Are you of the first full system retrofits of its kind, was installed in the mid-1970s
going to use filter carts or individual rack-mounted pumps with filters? and removes more than 80 percent of the sulfur dioxide produced during
Filter carts give you the added flexibility to roll around the plant and the combustion process.

Machinery Lubrication www.machinerylubrication.com July - August 2010 59

WEB PREVIEW
Get Even More Information
at machinerylubrication.com
and reliableplant.com
E very day, thousands of industrial professionals from around
the world visit our Web sites. See what makes these sites so
popular and so informative. Visit us today and every day at
www.machinerylubrication.com and www.reliableplant.com.
Articles & White Papers
Lube Storage & Handling Tips for
World-Class Contamination Control
Developing and implementing a world-class contamination control
program is a sizable undertaking, and it usually requires significant
modifications to machinery as well as changes in procedures and
methodologies. However, one component of contamination control
can affect the entire plant: the storage, handling and application of
new lubricants. This is a good place to start improving your program.
Find this in the White Papers section on the ML site.
10 Pointers for Off-line Filtration
of High-viscosity Lubricants
Follow the expert maintenance advice found in this article from
Noria Corporation. Heres one of the tips: When selecting filtration
for high-viscosity gear oils, you should first determine the optimum
target cleanliness level for that specific gearbox and ensure
adequate breathers are fitted, as any attempts at cleaning the oil
will be lost quickly. Find this article in the Web Exclusives section on
the ML site or type in Filtration Pointers in the ML Search bar.
A Discussion on Desiccant Breather Use & Application
Preventing the ingress of dirt and water into the lubricant is the
most effective, yet least fully utilized method of controlling contam-
Were Your Source for Free White Paper Reports
MachineryLubrication.com is the place to turn for free white paper reports on
a host of maintenance and reliability topics. Heres just a sampling of some of
the white papers currently available for download.
Cost-Effectiveness of Automatic Lubricators
Industrial Food-Grade Lubricants Guide
Automatic Grease Lubricators: What You Need to Know
Engineering an Effective Oil Analysis Program
Elements of a Good Preventive Maintenance Program
Controlling Gearbox Lubricant Contamination
Choosing the Correct Oil or Fuel Purification System for Water
Contamination Removal
Hidden Benefits of Lubricant Consolidation
Check out the full list of white papers. Visit www.machinerylubrication.com
and click on the White Paper link on the home page.
60 July - August 2010 www.machinerylubrication.com
ination. High-performance desiccant breathers enable front-end
protection and reliability optimization. Find this article it by typing
Breathe in the Search bar on the ML Web site.
Also
Term Glossaries
Nearly 100 lubrication and oil analysis terms are defined in the
Glossary on the ML Web site. Maintenance, reliability and lean
terms are defined on the RP Web site. Just click on the Glossary
link on the top of each home page.
Watch Videos
More than 160 free videos, vodcasts and slideshows on lubrica-
tion and oil analysis topics are available for viewing on the ML Web
site. Simply click on the Videos box on the ML home page. More
than 1,500 videos on maintenance, reliability, lean and manufac-
turing topics can be found on the RP site.
Industry News
Stay informed by reading news stories posted most every day.
Check out the Industry News box on the home page.
Write a Blog
We are looking for industry pros to write for a new blog section
of our Web sites. If you wish to be a blog author on the subject of
machinery lubrication or oil analysis, e-mail parnold@noria.com.
E-mail Newsletter
Sign up for Lube-Tips and Filtration Tips, Norias free lubrication-
related e-mail newsletters, which contain helpful articles, tips, trivia
and more. Just click on the Newsletters link at the top of the ML
home page. Additional newsletters are available via the Newsletters
link on the RP home page.
Subscription Services
Ensure that you will continue to receive award-winning Machinery
Lubrication magazine by filling out the free subscription form. Simply
click on the Subscribe link at the top of the ML home page.
Education On The Road
Get all the details on Norias industry conferences, seminars and
other educational events, including new and expanded Machinery
Lubrication and Oil Analysis courses. Just click on the Events link
found at the top of the ML and RP home pages.
Machinery Lubrication
CERTIFICATION NEWS
The Importance of Experience
in Attaining ICML Certification
BY SUZY JAMIESON, ICML
I t is standard practice in the field of personnel certification to
outline qualification requirements as part of the certification
process. In addition to such qualification requirements, there also
is commonly an element of assessment of such qualification to
confirm the knowledge base in question has been adequately
acquired. In common terms, this is where the certification exami-
nation comes in.
Regarding qualification in preparation for the assessment or in
other words, fulfilling the requirements in preparation for
successful examination people in industry have ease in under-
standing the need to have received training in the body of
knowledge of a specific certification program prior to attempting
the exam. It tends to be against human nature to attempt exami-
nation in something on which you have not been previously trained.
However, training is but one facet of the qualification process in
most certification programs, with experience normally being a
major component. Field experience is where the knowledge base
youve been exposed to in training takes shape, is tested and fine-
tuned, thus completing the learning curve. This, too, is logical, as
most education systems, courses, even life skills, need to be put
into practice before anyone truly masters the skills in question.
Yet with the case of many certification programs working along-
side theory-based training programs, at times an expectation on
the part of candidates exists that attendance to this or that training
course would lead to successful certification.
In the particular case of the International Council for Machinery
Lubrication, most programs require one or two years of experience
in the field for which certification is sought. Even in the case of the
Machine Lubricant Analyst Level I program, following ISO 18436-
4, where the minimum requirement of years of experience is based
on 16 hours per month, ICML still strongly suggests full-time expe-
rience in analysis, during the same period length as outlined, before
attempting examination.
Training Doesnt
Guarantee Certification
ICML certification programs were created with a very important
mission, that of dignifying the profession of lubrication technicians
and oil analysts, ensuring practitioners are respected as the skilled
62 July - August 2010 www.machinerylubrication.com
professionals they are, after proving their skills and attaining world-
renowned credentials. It is natural in the process of sorting
through the grapes that the exam be challenging and target
passing rates be maintained. In ICMLs case, an overall passing rate
of approximately 60 percent of the candidates is right on target.
With a prestigious credential that carries a fair, yet challenging
examination component, the role played by field experience
becomes even greater. It is evident that people with greater experi-
ence in the subject areas being tested will tend to do better in the
exams, especially considering the practical nature of the certifica-
tion programs exam questions the core of the program is the
where, when and how of proper machinery lubrication and
oil analysis. Thus, it is logical that if one hasnt had much chance
to witness first hand, by the machine, where, when and how
processes and procedures are properly carried out, such person will
be at a disadvantage when it comes to approval ratings in the exam,
independent of any training course undertaken.
While training is a key component of the qualification and as
such a requirement not only for certification, but even for quali-
fication as an exam candidate experience plays a very important
part. Training is but one aspect of the qualification process and a
very useful tool when viewed properly. It is important that candi-
dates taking training as part of a certification programs
qualification process understand that training is just one of the
requirements for sitting the exam and that no person should expect
to simply attend a course as a means of guaranteed approval.
Training, if appropriate and in the relevant body of knowledge of
the exam, is a great starting point to expose candidates to the
subject areas they will need to master in order to pass the exam; its
also a great refresher tool for the experienced professional.
Knowledge and Experience
Increase Chances
It is very important that training is chosen to match the subject
areas covered in the body of knowledge of the equivalent chosen
certification program. It is crucial that the experience require-
ments outlined be viewed as minimum requirements; also, that
experience be based on best practices after proper training, not
on one year of doing things the wrong way repeated many times
Machinery Lubrication
over. Lastly, it is very important that candidates understand the correlation
between the greater the proper, knowledgeable experience, the better
chances at approval on examination, vs. the myth that training programs
increase approval ratings.
A good, solid course of instruction in the exams body of knowledge is
very important, but it is not a sole requirement or sure shot at certification.
Seek a high-quality training program, apply the knowledge acquired during
training in field experience at your workplace, and then and only then,
pursue testing.

About ICML
The International Council for Machinery Lubrication (ICML) is a vendor-neutral, not-
for-profit organization founded to facilitate growth and development of machine
lubrication as a technical field of endeavor. Among its various activities, ICML offers skill
certification testing for individuals in the fields of machine condition monitoring, lubri-
cation and oil analysis. ICML is an independently chartered organization consisting of
both paid professional staff members and volunteer advisors. It provides lubrication and
oil analysis standard development support, scholarship, skill-based testing and certifica-
tion, and recognition of excellence. For more information about ICML, visit
www.lubecouncil.org.

Need to take an exam?

ICML regularly holds exam sessions throughout the United States and the
world. Upcoming dates and locations for ICML exams can be found at
www.lubecouncil.org

Machinery Lubrication www.machinerylubrication.com July - August 2010 63

CONTAMINATION CONTROL
Five of the Most Common
Filter Cart Mistakes
BY JARROD POTTEIGER
T he popularity of portable filtration units, often referred to as
filter carts, has increased dramatically over the past few years.
Just a decade ago, filter carts were primarily used by service providers
to decontaminate large systems or flush new equipment. Now, it is
uncommon for a plant not to have at least one filtration unit. The
biggest reasons for this change are most likely education and avail-
ability. Through education and training, maintenance professionals
have become aware of the tremendous value presented by portable
offline filtration. This awareness created a rapidly expanding market
for such equipment, and the makers of lubrication and contamina-
tion control products responded with a wide array of equipment to
meet the demands of most applications.
But while most plants use filter carts, they dont always use them
in the most effective way. There are unfortunately several common
mistakes that diminish the value or effectiveness of filter carts. The
good news is that they are easy to fix.
Mistake No. 1: Not Properly Fitting
the Filtration Unit to the Reservoir
If a reservoir is not fitted with suitable couplers to connect with
the filter cart, it will be difficult to efficiently or effectively decon-
taminate the oil. One of the first steps in a good contamination
control strategy is to identify the equipment modifications neces-
sary to facilitate sound lubrication practices. Opening a hatch on a
64 July - August 2010 www.machinerylubrication.com
reservoir and inserting hoses into the oil is not a good way to attach
a filter cart. Even if the hoses are inserted through an open port,
there still will be ample opportunity for further contamination. In
addition to further contaminating the oil, the effort required to
connect a filter cart to a sump which has not been modified can
make the task quite cumbersome.
Any lube oil reservoir or sump with which a filter cart may be
used should be properly accessorized. This process is often as easy
as attaching inexpensive hydraulic fittings to the drain port for
suction and an available port at or above the oil level as a return.
For those occasions where there is no available fill port or there are
fewer ports than accessories, a number or combination fittings are
commercially available that will allow a sample port, breather and
quick-connect to easily attach to one port.
Mistake No. 2: Using the Same
Filter Cart for Different Lubricants
While it is certainly permissible to use the same filtration unit for
different types of oil, it usually is not the best practice. If done prop-
erly, switching lubricants requires a significant amount of flushing,
which generates an unnecessary waste of oil and, more impor-
tantly, time. You dont have to save that many man-hours to pay for
a new filter cart. As maintenance staffs continue to suffer cutbacks,
any opportunity to improve efficiency should be investigated.
At the very least, filtration units should be dedicated to partic-
ular types of oil (such as one for gear oils, hydraulic oils, etc.).
Switching viscosity grades is not as problematic as switching formu-
lation types. Develop the best strategy for your budget and include
filter carts in your lubricant identification scheme. The use of an
effective color-coding system to identify lubricant-handling equip-
ment for different products is widely accepted as a best practice.
Mistake No. 3: Buying the Wrong
Filter Cart for Your Applications
All too often, maintenance professionals procure a filter cart for a
particular application only to find out that it doesnt work. It is imper-
ative to consider the following criteria when selecting a filter cart:
Viscosity What is the viscosity of the fluid to be filtered under
normal conditions? Remember to consider the fluids viscosity for
the temperature at which the fluid will be filtered.
Machinery Lubrication
 Flow rate What flow rate is desired for the
systems to be filtered? The minimum flow rate
should at least be able to accommodate the
entire sump volume once per hour. The ideal flow
rate would be at least several times this amount.
Filter performance How clean are you trying
to get the oil? If you want to clean the oil to
15/13/10, you wont get there with a 10-micron
filter. The filter pore size should be chosen based
on the cleanliness requirements for the machine,
and the beta rating should be at least 75,
although 200 would be better.
Power source How will you power the filter
cart? Most filter carts are available with electric
or air motors. In some facilities, power outlets are
not as common as air supply.
Equipment accessibility Where is the unit to
be filtered? Is it at the top of a ladder? How
reasonable is it to transport the filtration unit to
the equipment? Filter carts do come in many sizes.
This list doesnt cover every issue. The best
way to ensure that a product will work in a
certain situation is to work closely with your
supplier to make sure all of the primary specifi-
cations are correct.
Mistake No. 4: Not Realizing
All of the Uses of Filter Carts
Portable offline filtration units were originally
designed to decontaminate large systems, and
they do work well for that application. However,
there are many other uses for filter carts.
Probably the best use for a filter cart is as an
effective means to transfer oil to lubricated equip-
ment or pre-filter new oil before it is dispensed.
Not only does this practice help to ensure that
new oil additions are clean, it also makes the job
more efficient.
Machinery Lubrication
The two most common sources for particle
contamination in the average system are ingested
air and new oil. This method of oil transfer elimi-
nates contamination from new oil and reduces
airborne ingression by maintaining a sealed
system.
Mistake No. 5: Not Using
the Filter Cart at All
Believe it or not, this one is quite common.
Plenty of program managers know they should
use filter carts, so they buy them; however, they
dont have proper procedures in place to imple-
ment their use. A strategy should be developed
that identifies when, where and how filter carts
should be utilized. Some systems should be
filtered on a periodic basis. Some should be
filtered when their condition requires it. Others
may need permanent offline filtration to achieve
cleanliness goals. Whatever the case may be, it is
essential that the use of this type of equipment be
a documented part of the lubrication program.
Keep These in Mind
There are probably dozens of less common
mistakes made with the application of portable
filtration technology, but these are the big ones. To
make it simple, just remember to decide when and
where to use the equipment, ensure the unit will
work for your applications, and properly accessorize
the machine sumps to facilitate the task.
About the Author
Jarrod Potteiger is the product and educational
services manager for Des-Case Corporation, which
specializes in contamination control products for indus-
trial lubricants. For more information on the companys
products and services, visit www.descase.com or call
615-672-8800.
www.machinerylubrication.com July - August 2010 65
BACK PAGE BASICS
Telltale Signs and Tips
to Tame Machinery Vibration
JEREMY WRIGHT
NORIA CORPORATION
V ibration analysis, when properly done, allows you to evaluate
the health of equipment. By finding inherent failures before
they become catastrophic, maintenance personnel can minimize
unplanned downtime.
In simplest terms, vibration in motorized equipment is the back-
and-forth movement, or oscillation, of machines and components,
such as drive motors, driven devices (pumps, compressors and so
on), and the bearings, shafts, gears, belts and other elements that
make up mechanical systems.
Vibration in industrial equipment can be both a sign and a
source of trouble. Other times, vibration just goes with the terri-
tory as a normal part of machine operation, and should not cause
undue concern. This article focuses on those machines that are
designed to operate with minimal vibration.
When Vibration is a Problem
Most industrial devices are engineered to operate smoothly and
avoid vibration, not produce it. In these machines, vibration can
indicate problems or deterioration in the equipment. If the under-
lying causes are not corrected, the unwanted vibration itself can
cause additional damage.
Most Common Causes
of Machine Vibration
Vibration can result from a number of conditions, acting alone
or in combination. Keep in mind that vibration problems may be
caused by auxiliary equipment, not just the primary equipment. The
following are some of the major causes of vibration.
Imbalance: A heavy spot in a rotating component will cause
vibration when the unbalanced weight rotates around the
machines axis, creating a centrifugal force. Imbalance could be
caused by manufacturing defects (machining errors, casting flaws)
or maintenance issues (deformed or dirty fan blades, missing
balance weights). As machine speed increases, the effects of imbal-
ance become greater. Imbalance can severely reduce bearing life as
well as cause undue machine vibration.
Misalignment: Vibration can result when machine shafts are out
of line. Angular misalignment occurs when, for example, the axes of
a motor and pump are not parallel. When the axes are parallel but
not exactly aligned, the condition is known as parallel misalignment.
66 July - August 2010 www.machinerylubrication.com
Misalignment may be caused during assembly or develop over time,
due to thermal expansion, components shifting or improper
reassembly after maintenance. The resulting vibration may be radial
or axial (in line with the axis of the machine) or both.
Wear: As components such as ball or roller bearings, drive belts
or gears become worn, they may cause vibration. When a roller
bearing race becomes pitted, for instance, the bearing rollers will
cause a vibration each time they travel over the damaged area. A
gear tooth that is heavily chipped or worn, or a drive belt that is
breaking down, also can produce vibration.
Looseness: Vibration that might otherwise go unnoticed may
become obvious and destructive if the component that is vibrating
has loose bearings or is loosely attached to its mounts. Such loose-
ness may or may not be caused by the underlying vibration.
Whatever its cause, looseness can allow any vibration present to
cause damage, such as further bearing wear, wear and fatigue in
equipment mounts and other components.
Effects of Vibration
The effects of vibration can be severe. Unchecked machine vibra-
tion can accelerate rates of wear (i.e. reduce bearing life) and
damage equipment. Vibrating machinery can create noise, cause
safety problems and lead to degradation in plant working condi-
tions. Vibration can cause machinery to consume excessive power
and may damage product quality. In the worst cases, vibration can
damage equipment so severely as to knock it out of service and halt
plant production.
Yet there is a positive aspect to machine vibration. Measured
and analyzed correctly, vibration can be used in a preventive main-
tenance program as an indicator of machine condition and help
guide the plant maintenance professional to take remedial action
before disaster strikes.
Characteristics of Vibration
To understand how vibration manifests itself, consider a simple
rotating machine like an electric motor. The motor and shaft rotate
around the axis of the shaft, which is supported by a bearing at
each end. One key consideration in analyzing vibration is the direc-
tion of the vibrating force. In our electric motor, vibration can occur
as a force applied in a radial direction (outward from the shaft) or
in an axial direction (parallel to the shaft). An imbalance in the
Machinery Lubrication
 BACK PAGE BASICS
motor, for instance, would most likely cause a radial vibration as
the heavy spot in the motor rotates, creating a centrifugal force
that tugs the motor outward as the shaft rotates through 360
degrees. A shaft misalignment could cause vibration in an axial
direction (back and forth along the shaft axis) due to misalignment
in a shaft coupling device.
Another key factor in vibration is amplitude, or how much
force or severity is encompassed in the vibration. The farther out
of balance our motor is, the greater its amplitude of vibration.
Other factors, such as speed of rotation, also can affect vibration
amplitude. As rotation rate goes up, the imbalance force
increases significantly. Frequency refers to the oscillation rate of
vibration, or how rapidly the machine tends to move back and
forth under the force of the condition or conditions causing the
vibration. Frequency is commonly expressed in cycles per minute
or hertz (CPM or Hz). One Hz equals one cycle per second, or 60
cycles per minute.
Though we called our example motor simple, even this
machine can exhibit a complex vibration signature. As it oper-
ates, it could be vibrating in multiple directions (radially and
axially), with several rates of amplitude and frequency.
Imbalance vibration, axial vibration, vibration from deteriorating
roller bearings and more all could combine to create a complex
vibration spectrum.
68 July - August 2010 www.machinerylubrication.com
Prevention through Understanding
Vibration is a characteristic of virtually all industrial machines.
When vibration increases beyond normal levels, it may indicate only
normal wear or it may signal the need for further assessment of
the underlying causes or for immediate maintenance action.
Understanding why vibration occurs and how it manifests itself is a
key first step toward preventing vibration from causing trouble in
the production environment.
About the Author
Jeremy Wright is a certified Machinery Lubricant Analyst (MLA) Level I
and Level II and Machinery Lubrication Technician (MLT) Level I by the
International Council for Machinery Lubrication (ICML). In addition, he is
a Certified Maintenance and Reliability Professional (CMRP) by the Society
for Maintenance and Reliability Professionals (SMRP). Contact Jeremy at
jwright@noria.com.
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Alfredo Romaro,
Maintenance Technician,
Kawneer Company

ENROLL TODAY! Call toll free 800-597-5460 Presented by:

or visit www.noria.com Copyright 2010

3
Introduction to Machinery Lubrication and Oil Analysis
Course Outline
How Lubrication Affects Machine Reliability
Financial benefits from achieving lubrication excellence
Dont attempt reliability-centered maintenance (RCM)
without the 5I lubrication method
Five equipment maintenance strategies, and when each applies
Important implementation steps to lubrication excellence
10 roadblocks to achieving lubrication excellence
Lubrication Fundamentals
Six important functions of lubricating oils
How oils and greases are formulated and why it is important
How friction is generated in lubricated machinery
The importance of oil film thickness and critical clearances
Understanding Additives, Base Oils
and Grease Thickeners
How lubricant properties irreparably change
Seven important physical properties of a base oil
The importance of APIs five base oil categories
When to select one of the six most commonly used synthetic
base oils
How to use temperature to determine the right base oil for
your machine
How to select grease thickeners for your application
Lubricant Performance Properties
14 key additives that enhance lubricant performance
Understanding viscosity grades, measurement, and reporting
Why Viscosity Index is important and how it improves
your work
Lubricant performance tests and reporting
what you need to know
How water contamination generates other
contaminants
How to control and eliminate aeration problems
Food-grade and Environmentally-friendly Lubricants
Important USDA requirements and government regulations for
food-grade lubricants
What you need to know about food-grade additives, base oils
and grease thickeners
Advantages and disadvantages of food-grade lubricants
Lubricating Grease Application Methods
Seven tips for avoiding incompatible grease mixtures
Advantages and disadvantages of centralized
lubrication systems
Best practices for greasing motor bearings
How to calculate greasing intervals and quantity
Best practices for ultrasonic/sonic-based greasing
Important tips for working with your motor rebuild shop
Lubricating Oil Application Methods
Overview of oil lubrication methods and devices
How to use oil mist and other automatic lubrication methods
Using pressure spray methods for gearboxes
Best practices for the maintenance of grease guns and fittings
Overview of single-point direct lubrication systems
Selecting Lubricants
Journal and rolling-element bearings
Open and closed gears
Gas engine and gas compressors
Air compressors
Hydraulic fluids
Steam and gas turbines
Process pumps
Multipurpose grease
Oil mist lubricants
Contamination Control
Building reliability through contamination control
Seven most destructive contaminants and how to
control them
Three steps to proactive maintenance
Understanding the ISO Solid Contaminant Code
10 ways to maximize filter cart usage
Oil Drains, Flushing, and Reservoir Management
How to optimize and extend oil change intervals
Interval vs. condition-based oil change
How to monitor lubricant consumption
Best practices for oil changes
How and when to perform a flush
Selecting appropriate cleaning and flushing procedures
Storage, Handling, and Managing Lubricants
How to set up a world-class lube room
How to optimize lubricant selection/procurement
How to implement a lubricant consolidation program and
select suppliers
Best practices for inspecting/testing new lubricants
Used lubricant storage, handling, and disposal best practices
Design and Inspect for Lube Excellence
World-class strategies for accessorizing equipment for
lubrication excellence
Seven critical accessories for inspection and sampling
Seven critical accessories for contamination control prevention
Eight essential lubrication accessories
What your breather is telling you about your machine
Used Oil Analysis Fundamentals
What oil analysis can tell you
Types and categories of oil analysis
Applications for oil analysis
Overview of oil analysis tests
Oil Sampling The Very Best Practices
11 elements of a successful oil analysis program
How clean should sample bottles be?
How to find the best sampling locations
Sampling valves and hardware recommendations
A quick method for optimizing sampling intervals
An oil sampling technique that ruins trending
The importance of primary and secondary sampling points
How to properly sample circulating systems
Safe, effective high-pressure sampling from hydraulic systems
Best practices for sampling splash-, collar-, and
ring-lubricated systems
Essential Field Inspections
12 questions your filter will answer about your machine
Which visual inspections can provide big results
Used filter inspections
Quick tips for using scent, sound, and touch to
inspect lubricants

Meet your trainer, Jim Fitch, Drew Troyer,

or Mark Barnes
Got a Group to Train?
Jim Fitch We can customize Introduction to Machinery
Lubrication and Oil Analysis or any of our other
courses to meet your unique needs. Well provide
expert instruction at a time and place most convenient
Drew Troyer for your group. Want to know more? Call Brett
OKelley at 800-597-5460 ext. 112. Whether you have 5
or 500 people to train, Noria is the answer.

Mark Barnes

4 ENROLL TODAY! Call toll free 800-597-5460 or visit www.noria.com

 Join this list of world-class companies who have benefited from Noria training
3M Borg Warner Eastman Kodak Harley-Davidson Michelin Sun Company
76 Lubricants Cargill Eli Lilly HB Zachry Northern States Power Temple-Inland
Air Products Castrol Entergy Holcim Nova Chemicals Texaco
Akzo Nobel Caterpillar ExxonMobil Intel Owens Corning Texas Instruments
Alabama Power Centralia Mining First Energy Houston Metro Transit Oxy Chem Texas Utilities
Alcoa Chevron Florida Power International Paper Pacific Gas & Electric U.S. Army
Allied Signal Citgo Ford Motor Co. John Deere Peabody Coal U.S. Navy
Alumax Clopay Formosa Plastics Kinder Morgan PPG Industries U.S. Postal Service
Ameren ConocoPhillips General Electric Koch Industries Procter & Gamble Via Rail Canada
Arco Destec Energy General Motors LaFarge Canada Reliant Energy Westinghouse
BHP Copper Detroit Edison Geneva Steel Lockheed Martin Rio Tinto Weyerhaeuser
BP Amoco Dow Chemical Georgia Pacific Lubrication Engineers Seattle Times Whirlpool
Bristol Myers Dow Corning Georgia Power Lukens Steel Seminole Electric Willamette Industries
Boeing Duke Power Goodyear M&M Mars Shell Oil Wyeth
Boise Cascade DuPont Great Lakes Chemical MillerCoors Southern Companies

Get Certified!
Why Certify? What is ICML?
Certification is an important part of the training process because it The International Council for Machinery Lubrication (ICML) is a
confirms you possess the skills to do the job. Combining training vendor-neutral, not-for-profit organization founded to facilitate growth
and development of machine lubrication as a technical field of endeavor.
with certification creates a knowledgeable and valuable employee.
Among its various activities, ICML offers skill certification
Which Certifications? testing for individuals in the fields of machine condition
This course is designed to help you prepare for the following ICML monitoring, lubrication, and oil analysis.
certification exams:
How to Certify
Level I Machine Lubricant Analyst (MLA)
Level I MLT and Level I MLA certification testing will be held the
Level I Machine Lubrication Technician (MLT) Friday following the training. To register for the ICML certification
Find out more about these ICML certification exams at the ICML web exam, go to www.LubeCouncil.org or call 918-259-2950 for more
site: www.LubeCouncil.org information.
Sa
more ve
*By policy, ICML does not endorse training events or study aids as preparation for the examination.
than
$7
From our Resource Center 5
The Level I MLT / Level I MLA Study Packet lubrication, lubricant storage and handling, and lubri-
This Study Packet is designed to be used for both cant conservation.
ICML Level I MLT and Level I MLA certification.
Oil Analysis Basics Book is the No. 1 book in the lubri-
Level I MLT/MLA Flash Cards More than 385 flash cation industry and makes oil analysis for machinery
cards designed as a study aid for preparing for both condition monitoring easy to understand.
ICML Level I MLT and Level I MLA certification.
The Practical Handbook of Machinery Lubrication Once
Lubricating Grease Guide is written for beginners you start reading this book, you probably wont stop until you
who are starting in the grease field or for practitioners whofinish it. It is that easy to read. Youll find understandable expla-
would like to broaden and deepen their knowledge of lubri- nations of how lubricants work, what theyre made of and how
cating grease. they break-down. Topics ranging from engine lubricants to indus-
Lubrication Fundamentals discusses lubricant basics, machine trial oils and hydraulic fluids are covered.
elements that require lubrication, methods of application, Retail Price: $410.95 Your Price: $335
$12 for shipping will be added to all study packet orders

5
 Introduction to Machinery Lubrication and Oil Analysis Registration Form
Training Schedule
1 Training Course The phone numbers and codes below are for booking hotel reservations
Course City: _____________________________________________ only. To register for the course call 800-597-5460 ext 143.

Course Date: ____________________________________________ Seattle, WA Mobile, AL

July 27-29, 2010 October 5-7, 2010
2 Who Will Be Attending Mayflower Park Hotel Renaissance Riverview Plaza Hotel
405 Olive Way 64 South Water Street
Mr./Ms.: ________________________________________________ Seattle, WA 98101 Mobile, AL 36602
Job Title:________________________________________________ 206-623-8700 800-922-3298
E-mail: _________________________________________________
(Please list additional registrations on a separate sheet and attach) Columbus, OH Louisville, KY
August 10-12, 2010 November 9-11, 2010
3 Company Information Hyatt on Capitol Square Hyatt Regency Louisville
75 E. State St. 320 West Jefferson Street
Organization: ____________________________________________ Columbus, OH 43215 Louisville, KY 40202
Address: ________________________________________________ 888-421-1442 800-421-1442
Mail Stop: ______________________________________________
City: ________________________ State/Province: ____________ Las Vegas, NV Check Noria.com for more dates
September 21-23, 2010 and locations
Country: ____________________ Zip/Postal Code:____________ Platinum Hotel
Phone: ______________________ Fax: _______________________ 211 E. Flamingo Road
E-mail: _________________________________________________ Las Vegas, NV 89169
877-211-9211
4 Industry Information
Agricultural General Manufacturing or Other Pulp & Paper, Lumber
Automotive Manufacturing Government/Military Textiles & Apparel
4 Ways to Register
Aviation, Rail, Maritime, Trucking Laboratory Tire/Rubber
Chemicals & Allied Products Mining/Metals Tobacco
Construction & Allied Products Petroleum Products & Refining
Utilities
Consulting/Services/Training Pharmaceutical (Electric, Water, Gas, Waste)
Food Process Manufacturing Plastics & Allied Products Other
Phone Fax Mail Online
800-597-5460 918-746-0925 Noria Corporation www.noria.com
5 Certification Study Packet Or 918-749-1400 ATTN: Training
1328 E. 43rd Court
Quantity
Tulsa, Oklahoma 74105
The Level I MLT/MLA Certification Study Packet - $335 ______
$12 for shipping will be added to all study packet orders. Registration Information
Course: Introduction to Machinery Lubrication and Oil Analysis
6 Method of Payment Course Fee: $1,195
(Certification exams are optional and not included in the training price. Contact ICML at 918-259-2950 Course Hours: 8:00 am to 4:00 pm daily. Check-in begins at 7:30 am.
or lubecouncil.org to make arrangements to sit for the exam.)
Check enclosed payable to: Charge to: For fast registration, call 800-597-5460 ext. 143 toll-free between 8:00
Noria Corporation a.m. and 4:00 p.m. central time Monday through Friday. Or, fax your regis-
tration form to 918-746-0925 at any time. The fax line is open 24 hours a
Mail to: day, 7 days a week. We will send a confirmation of your registration via
Card Number: __________________________
Noria Corporation email. If your confirmation does not arrive within 48 hours please contact
Expiration Date: ________________________ us to process your registration immediately. In lieu of cash, check and credit
ATTN: Training
Name on Card:__________________________ cards are preferred when paying at the training site.
1328 East 43rd Court
Signature: ______________________________ Your fee provides you the best training around, a comprehensive manual,
Tulsa, OK 74105
a free package of training materials, continental breakfast, lunch each day
Purchase Order attached: #
and refreshments.
____________________________________ You may cancel your registration prior to the course date or send a
substitute. If you cancel, we will refund your entire payment, cancel your
7 Emergency Contact invoice or, if you prefer, apply your payment to a future Noria course.
Name:__________________________ Phone: __________________
Certification Exams
8 Food Allergies (Please list any food allergies so that we can better serve you.) Certification testing is offered by the ICML the morning following this
__________________________________________________________________________ training course at the same hotel. Please contact the ICML to register for the
__________________________________________________________________________ certification exam or register online at their web site:
International Council for Machinery Lubrication
Phone: (918) 259-2950 Fax: (918) 259-0177
Email: info@lubecouncil.org Online: lubecouncil.org
6
 BOOKSTORE

Welcome to Machinery Lubrications Bookstore, designed to spotlight

How to Grease a
lubrication-related books. For a complete listing of books of interest to Motor Bearing Training DVD
lubrication professionals, check out the Bookstore at www.noria.com. Format: DVD
Publisher: Noria Corporation
How to Grease a Motor Bearing provides plant
Lubricating Grease Guide personnel an overview of the best practices for lubricating
electric motor bearings. Anyone responsible for the main-
Author: NLGI
tenance, operation and reliability of electric motors will
This guide serves as a source of basic information on
lubricating grease and is a handy quick-reference book. benefit. Use it to train operators, lubrication technicians,
Written for the beginner or for the practitioner who wants mechanics, electricians and maintenance personnel for
to broaden knowledge. It includes a grease application years to come.
guide for beginners. Youll know when to select the right The product has three main benefits:
grease for your machinery and easily determine which Lubrication technicians will have a clear understanding
greases are compatible. of why proper motor bearing lubrication is critical.
Youll reduce motor failures, downtime, rebuilds and
replacement costs.
Practical Lubrication for Youll replace old-time
Industrial Facilities lubrication procedures
Author: Heinz Bloch with vendor-neutral, best-
Helps reliability professionals, mechanics, machinists or practice procedures that
lubrication specialists understand what matters most in a lubri- work.
cant, and to distinguish mere sales talk from relevant facts. It is
intended to assist the
professional in ensuring
that machinery operates The Practical Handbook of
at optimum performance Machinery Lubrication
levels with a minimum of
Author: L. Leugner
costly downtime.
If you want to establish yourself as the lubrication expert in
your company, this book is a must-read. Once you pick it up, you
Oil Analysis wont put it down until youve finished it. Its that easy to read.
Basics
Publisher: Noria Corporation
Written by the editors
Introduction to Lubrication
of Machinery Lubrication
magazine, Jim Fitch and Drew
Fundamentals Training DVD
Format: DVD
Troyer, this book is a great Publisher: Noria Corporation
resource for anyone involved The Introduction to Lubrication Fundamentals
in oil analysis or lubrication. training DVD teaches lubrication basics through high-
Oil Analysis Basics makes oil analysis for machinery quality animation and video. DVD training makes learning
condition monitoring easy to understand. You will learn fun and convenient while helping employers provide stan-
everything from how to take a proper oil sample to how to dardized training for every employee, every time.
select a test slate for your applications.

For descriptions, complete table of contents and excerpts from these and
other lubrication-related books, and to order online, visit:
www.noria.com or call 1-800-597-5460, ext. 104

July - August 2010 www.machinerylubrication.com Machinery Lubrication