ML Sept Oct 2017

September - October 2017
This issue sponsored by:
TM
Royalmfg.com
Machinery>>
Best Ways to Eliminate
-
Hydraulic Oil Leakage
Overcoming the Risks of
Cold Machine Starts
'
,-
How to Evaluate
a New Lubricant
DDDDD By Dave Wooton, Wooton-Consulting
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Contents
6COVER STORY
How to Evaluate a New Lubricant
Take an in-depth look into industry-accepted tests for predicting lubricant life, including results from actual
commercial lubricants.
September-October 2017
2AS I SEE IT
Make the Lube Room Your Lubrication
Command Center
40 LESSONS IN LUBRICATION
Overcoming the Risks of Cold Machine Starts
By becoming aware of the potential effects that temperature can
have on your lubricants, you can better understand how a machine
For any plant seeking lubrication excellence, there needs to be a
could fail and hopefully prevent future failures.
46
visual starting point that sets the stage for whats to come elsewhere
in the facility. There is no better place for that than the lube room.
14
PERSPECTIVE
INDUSTRY FOCUS Understanding the Changing Requirements
2017 Salary Survey: Salaries for Lubrication for Food-grade Lubricants
Professionals Holding Steady With the full implementation of the Food Safety Modernization Act
The latest results from Machinery Lubrications annual salary survey (FSMA), there will be many changes in the requirements for compa-
50
reveal some interesting insights into the lubrication industry, as nies that make food and beverage products.
compensation rates appear to have remained steady over the past 12
TRAINING AND CERTIFICATION
24
months with less than a 1 percent change in earnings.
Newcrest Minings Cadia Valley Operations
HYDRAULICS Wins Gill Award
Best Ways to Eliminate Hydraulic Oil Leakage Newcrest Minings Cadia Valley Operations in Australia has been
By properly setting the pressures, installing accumulators and shock selected as the recipient of the 2016 Augustus H. Gill Award by the
suppressors, verifying that the system is piped and hosed correctly, International Council for Machinery Lubrication for excellence in
54
and adjusting pilot chokes, you should be able to reduce or even oil analysis.
eliminate shock and leakage in your hydraulic systems.
34
BACK PAGE BASICS
LUBE-TIPS Volatility vs. Flash Point: What You Should Know
Our readers offer advice on a host of lubrication-related issues, Learn the differences between an oils volatility and flash point,
including tips for testing lubricant compatibility, changing pillow- including how these properties correlate to each other, as well as
block bearings and sampling oil from hard-to-reach locations. the best methods for determining them.
MoreEditorial Features
32 GET TO KNOW
Departments
28 ASK THE EXPERTS
35 BOOKSTORE
36 PRODUCT NEWS
38 NOW ON MACHINERYLUBRICATION.COM 30 PRODUCT SUPERMARKET 39 TEST YOUR KNOWLEDGE
L ubricant S torage and Handling
AS I SEE IT
J im F itch | N oria C orporation
Make the
LUBE ROOM Your Lubrication
COMMAND CENTER
F or any plant seeking lubrica-
tion excellence, there needs to
be a visual starting point that
sets the stage for whats to come elsewhere
in the facility. There is no better place for
that than the lube room. In fact, Ive never
heard of a plant exhibiting excellence in
machinery lubrication that doesnt also
exude excellence in the lube room. The
lube room serves as the centerpiece and
reference state for lubrication excellence.
You have to get it right.
This is important because transfor-
mation can take a while for large plants.
Rome wasnt built in a day. To succeed,
you must have a solid foundation and a
constant reminder of what quality and
success should look like. It effectively The False Economies
punctuates that this standard of excel-
lence should be replicated at each machine
of Cheap
Experts agree that the best way to over-
where lubricants are in use. Theres a
come a catastrophic machine failure is not to
huge and very important psychological
have one. However, those in the maintenance
element here.
field understand that machine reliability
If you cut corners in the design and
comes at a price. On the one hand, focusing
quality of your lube room, more critical
on machine reliability alone may fail to control
corners will be cut elsewhere in the plant wasteful and excessive expenditures. To the
as well. Mediocracy becomes the norm and other extreme, initiatives that slash current
will be imbedded in the culture. When this maintenance expenditures without consid-
occurs, the lube room transforms into a ering long-term reliability consequences are
pigpen of tools, pumps, hoses, grease frequently penny wise and pound foolish.
guns, bottles, totes and drums. Dont let Poor reliability and premature machine
that happen. Be fussy and demanding, failures have a compounding financial
and set a high standard that encourages impact. Half-heartedly measuring one
reliability excellence throughout the rest element will spread like a cancer when
of the plant. measuring something else. Dont get me
2 | September - October 2017 | www.machinerylubrication.com

Machinery
Lubrication ML
PUBLISHER
Mike Ramsey - mramsey@noria.com
GROUP PUBLISHER
wrong, excellence comes from optimum choices is not the result of money spent, but rather a Brett OKelley - bokelley@noria.com
and certainly not wasteful or unnecessary high state of tidiness, attention to detail, quality EDITOR-IN-CHIEF
choices. Precision lubrication means a state and organization. The lube room should be a Jason Sowards - jsowards@noria.com
of not too much and not too little. You want showcase of what enables machines to run reli- SENIOR EDITOR
a lean, optimum state of excellence. The oper- Jim Fitch - jfitch@noria.com
ably and at the lowest possible cost. It should TECHNICAL WRITERS
ating conditions and need for reliability define
be a place of pride and a glaring statement of Wes Cash - wcash@noria.com
the optimum state. Alejandro Meza - ameza@noria.com
The lube room is the perfect place to display strong and effective lubrication and reliability Bennett Fitch - bfitch@noria.com
values. It should represent and instill the rights Loren Green - lgreen@noria.com
and emphasize the best example of optimized Michael Brown - mbrown@noria.com
lubrication excellence. A big part of excellence of lubrication. Garrett Bapp - gbapp@noria.com
CREATIVE DIRECTOR
Ryan Kiker - rkiker@noria.com
GRAPHIC ARTISTS
Patrick Clark - pclark@noria.com
Josh Couch - jcouch@noria.com
Greg Rex - grex@noria.com
ADVERTISING SALES
Tim Davidson - tdavidson@noria.com
800-597-5460, ext. 224
MEDIA PRODUCTION COORDINATOR

Libby Bahlinger - lbahlinger@noria.com
CORRESPONDENCE
You may address articles, case studies,
special requests and other correspondence to:
Editor-in-Chief
MACHINERY LUBRICATION
Noria Corporation
1328 E. 43rd Court Tulsa, Oklahoma 74105
Phone: 918-749-1400 Fax: 918-746-0925
Email address: editor@noria.com
MACHINERY LUBRICATION Volume 17 - Issue 5 September-October

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Copyright 2017 Noria Corporation. Noria, Machinery Lubrication and

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Reproduction in whole or in part in any form or medium without express
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Noria Corporation reserves the right, with respect to submissions, to
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CONTENT NOTICE: The recommendations and information provided in

Machinery Lubrication and its related information properties do not purport
to address all of the safety concerns that may exist. It is the responsibility of
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does not make any representations, warranties, express or implied, regarding
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to the use of information or recommendations provided.
AS I SEE IT
Conspicuously Display managers, often on bulletin boards outside

their offices. A quick glance can tell you what
Excellence in Practice defines the performance goals of the team
Read More on How to
Use the walls of your lube room as that he or she manages. Improve Your Lube Room
bulletin boards to display and emphasize Oil and grease analysis are metrics on the For more information on how to achieve
a world-class lube room, visit Machinery-
critical messages, especially the need for state of lubrication and machine reliability.
Lubrication.com. You will find numerous
change. Dont assume lube technicians Condition monitoring metrics such as these articles that have been published through
and other maintenance staff members should not be lost on a computer hard drive the years on this important topic. To help
remember and understand the tenets of or in files inside a desk drawer. Instead, narrow your search, the titles and web
addresses of some of the most popular
lubrication excellence. They may have been key data must be on display in real time to
articles are listed below:
told during training, but that doesnt mean communicate all non-conforming conditions
they remember or will readily change the way as well as successes from well-behaved Is Your Lube Room Up to Par? (www.machinery
work is done in the plant. and strongly earned data. Such aware- lubrication.com/Read/1133/lube-room)
Lube room walls and bulletin boards ness enables control and sustainability of Constructing a World-Class Lube Room
should paint a clear picture of what is needed program goals. (w w w.machiner ylubrication.com /Read /536/
and expected. They are your front page and Machine categories can be grouped constructing-lube-room)
masterplan for change. Examples of what together to show broader plant perfor-
mance. Use control charts to display oil Lube Room Essentials and Best Practices
can be displayed as frequent reminders of
analysis trends such as particle and mois- (www.machinerylubrication.com/Read/29008/
your critical messages include housekeeping
ture trends, viscosity analysis, elemental lube-room-essentials)
policies, safety policies, new standardized
work procedures and tasks, training posters analysis, ferrous density, and varnish Oi l Stora ge, Ha nd ling a nd Decon-
and wallcharts, and machine and lube room potential. Big-picture metrics should also tamination Can Decide Program Fate
inspection tips. be added, including PM route compliance, (www.machinerylubrication.com/Read/28376/
Consider showing annotated photos of contamination control compliance, overall storage-handling-decontamination)
best practice and perhaps what is no longer lubrication effectiveness (OLE) and percent
Designing the Optimum Lubricant Storeroom
allowed. Some companies use TV monitors planned maintenance.
(w w w.machiner ylubrication.com /Read /212/
to loop training videos on such things as oil lubricant-storeroom)
sampling, contamination control, grease Dont Overlook
gun procedures, inspection tips, storage and Intangible Benefits The lube room provides that necessary
handling methods, etc. When people do bad work, they feel starting point square one. When you have
bad about themselves and their job. Like- a high-quality lube room, you finally begin
Dont Forget Metrics wise, when people do good work, they the process of getting high-quality, sustain-
Use the lube room as a command post feel good about themselves and their job. able lubrication at the machine. This
to display key performance indicators Training, empowerment, housekeeping translates to far greater attention to detail
(KPIs), including leading (whats going to (tidiness), tools, culture, documenta- when performing lubrication tasks, more
happen) and lagging (what just happened tion, measurement, communication intense inspections, better oil samples,
or is happening) indicators. In all work and machine readiness all enable good cleaner machines inside and out, etc. Your
environments, people need to know whats work. Reliability doesnt happen by itself. lube room becomes the command center or
important and whats being measured. There is a human-behavior element that mission control for lubrication excellence.
Metrics shape and define an organization. is critical. About the Author
Weve all been subject to various What happens when you have a world-
Jim Fitch has a wealth of in the
measurements since childhood. Those class lube room that is clean, organized
trenches experience in lubrication, oil
early experiences ranged from the winning and complete with everything needed? It
analysis, tribology and machinery failure
score of a little-league baseball game to the telegraphs a subtle message to lube techs, investigations. Over the past two decades,
painfully serious day we brought home a low operators and others performing mainte- he has presented hundreds of courses on
grade on a school report card. We learned nance tasks that quality work in the plant these subjects. Jim has also published more
that what counts is what is measured. We is recognized as important. Furthermore, it than 200 technical articles, papers and publi-
are what we measure. broadcasts a statement that management cations. He serves as a U.S. delegate to the
Use the lube room to focus and cele- will invest in excellence and expects work ISO tribology and oil analysis working group.
brate the work that enables lubrication to be done to the same standard. The Since 2002, he has been the director and a
excellence. Construct a group of metrics culture of excellence becomes a conta- board member of the International Council
and KPIs designed to stress the importance gion that spreads and is soon engrained for Machinery Lubrication. He is the CEO and
of doing just that. Im always curious to see in everyone. At last, the people part of a co-founder of Noria Corporation. Contact
the charts and graphs that are posted by lubrication excellence gets under control. Jim at jfitch@noria.com.

WhenResults Are
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This article will describe industry- older formulation, a new formulation and a determine their condition. The second group
accepted tests for predicting new premium formulation. The PAG formula- of analytical tests included ASTM D5185,
lubricant life, including results tion was based on a Group V (synthetic) base D6304(C), D665(A), D974, D2272, D1401,
from real commercial lubricants. Many of stock. There are three types of synthetic PAG D6971, D7414, D7843 and D892.
these tests are used by formulators when oils: water soluble, water insoluble and oil
designing and evaluating new lubricants. soluble. This study focused on water-insol- Compatibility
Comparing and analyzing these actual test uble PAG turbine oil. To complete the study, The first consideration when changing
results will reveal how to examine informa- in-service lubricants were also obtained for lubricants is whether the new lubricant
tion from various resources and help you these formulations if available. and the in-service lubricant are compat-
make better decisions about your lubricants. ible. This issue can impact flushing and
The Tests change-out decisions as well as result
The Lubricants Since newer lubricant formulations may in significant costs. Group V synthetics
The lubricants in this study were turbine not have been in operation long enough for are often thought to be incompatible
oils, which fall in the category of rust and a comparable long-life measurement, bench with Group I-IV hydrocarbon fluids. This
oxidation (R&O) fluids. The samples tested aging tests are often used. The industrys should be the first issue addressed, but
included one polyalkylene glycol (PAG) oil accepted aging tests include ASTM D2272, it is also one of the easiest to answer.
and three different mineral oil formulations. D2619 and D665(A). The lubricants in this ASTM D7155 explains how to test fluids
The mineral oil formulations were chosen study were aged by these standard test methods for compatibility.
from a list of commercial products based on to assess their suitability for operation first In this study, lubricant ratios of
the American Petroleum Institutes Group II as new lubricants. After the aging tests were 90-to-10 and 95-to-5 were tested using
and II-Plus base stocks. They consisted of an performed, the lubricants were measured to two different Group II lubricants with
the Group V PAG lubricant. These are the measured by the formation of insoluble solids
typical contamination levels observed during (ASTM D7843); and liquid-liquid, measured
a lubricant exchange. by the lubricants demulsibility (ASTM D1401).
Visual Compatibility Foam

Visual compatibility was the first phase of The change in the liquid-air interaction is
the compatibility testing. The lubricants were measured using the ASTM D892 foam test. This
observed after they were blended and stored measurement looks for a negative change in 90% PAG/10% 90% PAG/10%
for three to five days. ASTM D7155 describes Mineral Oil 1 Mineral Oil 2
performance after the lubricants are blended.
how to study samples and provides an appear- Results of the visual compatibility tests
The test reports three values: the amount of
ance guide for rating compatibility. Are the foam at the end of the 5-minute blowing period the settling time. Most new lubricants have a
lubricants clear and bright or do they appear (foaming tendency), the amount of foam at the foaming tendency ranging from 10-60 millili-
cloudy? To meet the compatibility criteria, end of the settling time (foam stability), and ters and a foam stability of 0 milliliters.
the blended lubricants must be absolutely
bright. As seen in the photos on the right, BLENDED FOAMING
the studied lubricants all passed the visual LUBRICANTS TENDENCY FOAM STABILITY SETTLING TIME
compatibility tests. 90% PAG/10%
60 mL 0 mL 39 minutes
If the two lubricants do not have good Mineral Oil 1
compatibility, three interactions are affected: 90% PAG/10%
50 mL 0 mL 33 minutes
liquid-air, measured by the lubricants foaming Mineral Oil 2
properties (ASTM D892); liquid-solid, Foam test results
www.machinerylubrication.com | September - October 2017 | 7
COVER STORY
The test results for the blended fluids in ASTM D1401. This test blends 40 milliliters
TESTING MINERAL MINERAL
the study (shown on page 7) indicate that of water and oil, reporting the amount of oil,
SERIES PAG OIL 1 OIL 2
the lubricants passed the foam criteria for water and emulsion after a predetermined
Weight
compatibility at this concentration. amount of time. According to ASTM D4304, Change of
a lubricant should have less than 3 milliliters -0.367 -0.008 0.017
Copper Panel
Membrane Patch Test of stable emulsion. The results for the blended (mg/cm2)
The formation of solids is a serious fluids in the study are shown below and reveal Appearance
problem with lubricant compatibility. This that these lubricants failed the test. of Copper Shiny IB Shiny IB Shiny IB
Panel
is typically an additive issue in which one
additive has poor solubility in the other Rust Original
When water limits are exceeded, most Viscosity at 24.70 33.35 31.36
lubricants base stock, or the additives in one
40C (cSt)
lubricant react with the additives in the other condition monitoring programs alert
40C
lubricant. If severe, this can be observed in users about the lubricants condition due
Viscosity 26.17 33.31 31.36
visual testing. However, the concentrations to potential rust issues. Since the studied After (cSt)
are often too low for observation. lubricants were R&O fluids, passing a rust
% Change
ASTM D7843, commonly referred to as test was a primary concern. in Viscosity
ASTM D4378 defines water as critical 5.95% -0.12% 0.00%
the membrane patch colorimetry (MPC) (D445 at
test, can be used to observe solid formation. at 200 milligrams per gram (mg/g) of 40C)
Results are reported as a dE value based on lubricant. The synthetic PAG lubricant Original Acid
the CIE Lab scale. The MPC results for most failed this test. Even when blended, the Number
0.06 0.08 0.03
lubricants water levels still did not meet (D974) (mg
new lubricants are in the 2-5 dE range.
KOH/g)
The test results for the blended fluids in the recommended amount.
the study (shown below) indicate that the The initial study evaluated the new Acid Number
lubricants (PAG, mineral oil 1 and mineral After (D974) 2.44 0.05 0.13
lubricants passed the liquid-solid criteria for
(mg KOH/g)
compatibility at this concentration. oil 2) and determined that they passed the
rust criteria. The next step was to perform Change in
Demulsibility the tests with aged lubricants. For this, the Acid Number
(D974) (mg
2.38 -0.03 0.10
Demulsibility is the lubricants ability to lubricant was run to 75 percent to the end KOH/g)
separate from water. It is measured using of a rotating pressure vessel oxidation test
(RPVOT). This is based on ASTM D4378, Total Acidity
of Water
BLENDED LUBRICANTS dE VALUE which explains that a fluid is at its end of 6.93 2.85 0.95
Layer (mg
90% PAG/10% Mineral Oil 1 4.3 life when the RPVOT reaches 25 percent KOH)
of the new fluid (75 percent to the end of
90% PAG/10% Mineral Oil 2 4.5 Percent
the RPVOT). RPVOT adds excess water to 0.004% 0.000% 0.012%
MPC test results Insolubles
the lubricant as part of the test, so water
is already present to cause potential issues. End of Test
EMULSION Fluid ICP
BLENDED (TIME IN The rust test (ASTM D665A) for the new 5 Nil Nil
Copper
LUBRICANTS OIL WATER MINUTES) and oxidation-tested lubricants showed (ppm)
90% PAG/10% 1
passing results. The rust inhibitor in all
0 mL 79 mL (30) three fluids was found to be sufficient to
Mineral Oil 1 mL Hydrolytic stability results for the
90% PAG/10% 2 protect equipment even at high water levels. tested lubricants
1 mL 77 mL (30)
Mineral Oil 2 mL
5% Mineral Oil 1
0 mL 79 mL (30)
2/95% PAG mL
95% Mineral Oil 0
32 mL 48 mL (30)
2/5% PAG mL
Demulsibility test results
AMOUNT OF
BLENDED LUBRICANTS WATER
90% PAG/10% Mineral Oil 1 3,900 mg/g
New Oils PAG 75% to EOT Mineral Oil 1 75% to Mineral Oil 2 75% to
90% PAG/10% Mineral Oil 2 4,400 mg/g
2272 EOT 2272 EOT 2272
Rust test results
The results of the rust test include a visual rating of steel pins as shown above.
COVER STORY
However, the synthetic PAG lubricant indi- and sediment layers are separated for anal-
cated some discoloration that could be of ysis. This test reveals the maximum weight NEW LUBRICANTS ASTM D2272 - RPVOT
concern, but it was not defined visually as change of copper and the maximum total PAG 657
rust, so the sample passed. acidity of the water layer. Mineral Oil 1 1531
Both mineral oil lubricants passed this Mineral Oil 2 1285
Hydrolytic Stability test, but the PAG lubricant failed. The Mineral Oil 3 2383
The hydrolytic stability of a lubricant is change in lubricant viscosity was another IN-SERVICE LUBRICANTS
its ability to hold up to the ingress of water. important parameter the PAG did not pass.
Mineral Oil 1:
Water can be a very reactive component to These experiments also indicated water 1304
5 years in service
the lubricants additive system. Hydrolytically sensitivity in the PAG lubricant, which should
Mineral Oil 2:
unstable hydraulic fluids form acidic and make keeping it dry a maintenance objective. 1344
4 years in service
insoluble contaminants, which can cause
system malfunctions due to corrosion, valve Oxidative Aging Stability Mineral Oil 3:
8 years in service
1414
sticking or a change in lubricant viscosity. ASTM D2272 is one of the most popular
RPVOT results for the tested lubricants
ASTM D2619 is the standard method for tests for evaluating how lubricants behave
defining the hydrolytic stability of a lubricant. during aging. This test method utilizes an
In this test, a lubricant is mixed with oxygen-pressurized vessel to determine the oxidation stability of the test sample. With
water and a copper test specimen, sealed oxidation stability of turbine oils in the pres- just a 50-gram sample, you have enough fluid
in a pressure-type beverage bottle and ence of water and a copper catalyst coil at 150 to perform additional experiments.
rotated for 48 hours at 93 degrees C. At degrees C. The number of minutes required to Two types of experiments were
the end of the reaction time, the oil, water reach a specific drop in oxygen pressure is the performed using the D2272 test. The first
reacted the fluid until the defined end of test.
The second reacted the fluid until the time
reached 75 percent of the new fluid value (25
TESTING SERIES MPC - ASTM D7843 (dE) TESTING SERIES MPC - ASTM D7843 (dE)
percent of the RPVOT time remaining). Once
PAG: RPVOT EOT 86.0 PAG: 75% RPVOT 65.5
the fluids have oxidized, their condition can
Mineral Oil 1: Mineral Oil 1: be assessed with additional tests.
97.9 54.9
RPVOT EOT 75% RPVOT
Mineral Oil 2:
RPVOT EOT
76.8
Mineral Oil 2:
75% RPVOT
61 Varnish
ASTM D7843 is the industry standard
Mineral Oil 3: Mineral Oil 3:
75.4 74.6 for testing the varnish potential of in-service
RPVOT EOT 75% RPVOT
lubricants. All four tested lubricants exhibited
Varnish potential test results Test results with 25 percent of the RPVOT
time remaining similar failing varnish values at the end of the
RPVOT test. Even the MPC patches showed
the lubricants were in a failing condition.
According to ASTM D4378, you should
consider replacing an in-service lubricant when
the RPVOT results reach 25 percent of the new
lubricant values. Therefore, the new lubricants
were tested until they reached 75 percent of
the new lubricant value (or 25 percent of the
PAG: RPVOT EOT Mineral Oil 1: RPVOT Mineral Oil 2: RPVOT Mineral Oil 3: RPVOT RPVOT time remaining). MPC values for these
EOT EOT EOT
oxidation samples were then obtained. Again,
MPC patch test results the MPC patches showed the lubricants were
in a failing condition.
The results of this test indicated lower
than expected varnish levels. However, the
levels were still considered critical, so it was
recommended to change all four lubricants at
or before 25 percent of the new oils RPVOT
value. The varnish formation of both the
PAG: 75% RPVOT Mineral Oil 1: 75% Mineral Oil 2: 75% Mineral Oil 3: 75% mineral oils and the synthetic PAG lubricants
RPVOT RPVOT RPVOT showed similar varnish levels at the recom-
MPC patch test results with 25 percent of the RPVOT time remaining mended change value (25 percent of the new
lubricant value).
COVER STORY
1,000 minutes, the MPC for the fluid was

LUBRICANT ACID NUMBER
measured to be 72.3 dE, which was still Questions to Ask
PAG: New Oil 0.03 in the same range of the previous results.
PAG: 75% RPVOT 2.36 When determining whether a lubricant has
However, the viscosity was very high, making
reached the end of its service life, several
PAG: RPVOT EOT 21.73 the MPC measurement difficult. In this case, questions must be asked:
Mineral Oil 1: New Oil 0.01 the viscosity would be the most important
What should you do about lubricant replacement?
Mineral Oil 1: 75% RPVOT 0.25 value, as opposed to varnish.
Mineral Oil 1: RPVOT EOT 4.26 Do you put the same lubricant back in again?
Mineral Oil 2: New Oil 0.01 Acid Number What if the lubricant has been changed and no
Mineral Oil 2: 75% RPVOT 0.47 Acid number, as defined by ASTM D974, longer exists?
Mineral Oil 2: RPVOT EOT 5.31 has often been described as the criteria for
Do you rely on the new lubricants promotional materials?
a lubricants end of life. For years, this was
Acid number test results Do you rely on the experiences of your colleagues?
the condemnation standard for mineral oils.
ASTM D4378 recommends a warning level of Should you obtain your own performance testing data?
LUBRICANT COPPER (PPM) 0.3-0.4 milligrams of potassium hydroxide
Answers to these questions will be valuable
(KOH) per gram increase over the new oils in your decision-making process.
PAG: New Lubricant Nil
acid number. PAG lubricants have a suggested
PAG: 75% RPVOT 66 limit of 5 mg KOH/g.
PAG: 100-minute RPVOT 793 At 75 to 100 percent of the end of the The copper sensitivity found in the
Mineral Oil 1: RPVOT test, all three lubricants had an acid
Nil hydrolytic stability test for the PAG lubri-
New Lubricant number in the range suggested by ASTM cant was again detected in this test. It
Mineral Oil 1: 75% RPVOT 11 D4378 as the end of the fluids life. The high was observed at a higher level due to the
Mineral Oil 2: acid number in these results might also explain higher oxidation of the lubricants. This
Nil
New Lubricant the rust observed in the ASTM D665 test for offers some distinguishing parameters for
Mineral Oil 2: the PAG lubricant. comparing the lubricants.
5
75% RPVOT
Mineral Oil 3:
Nil Elemental Analysis RULER
New Lubricant
Elemental analysis is a test that isnt Oxidation is often studied in relation to
Mineral Oil 3: 75% RPVOT 24
generally studied in relation to RPVOT. the quantity of antioxidant remaining in the
Copper test results RPVOT uses a copper metal catalyst coil lubricant. This parameter is measured using
in the fluid. If the copper dissolves into the the Remaining Useful Life Evaluation Routine
It should be noted that the RPVOT life lubricant, it acts as an oxidation catalyst and (RULER) test (ASTM D6971). ASTM D4378
of the new mineral oil lubricants was more could accelerate the test. If copper corrosion suggests a warning limit of less than 25 percent
than 1,000 minutes, while the PAG lubricant poses a potential problem at the end of the of the new lubricants antioxidant level.
was measured at 657 minutes. When the ASTM D2272 test, it should be seen in the Based on the test results shown in the
test for the PAG lubricant was extended to elemental analysis as an increase in copper. table bellow, it was recommended to change
SAMPLE % CHANGE SAMPLE % CHANGE SAMPLE % CHANGE ANTIOXIDANT

PEAK AREA FROM NEW PEAK AREA FROM NEW PEAK AREA FROM NEW CHEMISTRY
PAG Mineral Oil 1 Mineral Oil 3
New 46218.5 16617.5 (RUL1) Phenolic

Lubricant
5889 1783 (RUL2) Amine
75% 22097.5 47.8% 9280 55.8% (RUL1) Phenolic

RPVOT 1633.5 27.7% 744 41.7% (RUL2) Amine
RPVOT 14767 32.0% 0 0.0% (RUL1) Phenolic
EOT 1550 26.3% 529 29.7% (RUL2) Amine
7325 15.8% (RUL2) Amine
1,000-minute RPVOT
RULER test results

ML
the lubricant at 75 percent of the end of tests? Field samples are difficult to obtain A Better Approach
the RPVOT time (25 percent of the new for many reasons, not the least of which is
When evaluating new lubricants, it can be
oils value) for both the PAG and mineral the time required to generate them. difficult to determine whether the information
oil examples. In examining the data below, you can see being advertised by manufacturers is valid. A
the same trends in the field as in the bench better approach is to utilize these standard
In-service Samples testing of the lubricants. This should provide performance tests that have been used success-
Now the question becomes what do you confidence in bench testing and allow for fully in the industry for years. They can enable
see in the field. Is the field behavior of the rational conclusions about the lubricants you to make better business decisions and help
lubricants the same as the bench oxidation being studied. optimize your lubrication program.
DEMULSIBILITY RPVOT MPC (RUL 1) (RUL 2)

TESTING SERIES AN (ASTM D974) (ASTM D1401) (ASTM D2272) (ASTM D7843) AMINE PHENOL
8-year-old 0.34 0-2-78 (30) 468 9 38077
PAG 82%
5-year-old 0.11 40-40-0 (25) 1304 20.3 5775
Mineral Oil 1 98%
12- to 14-year-old 0.11 30-38-12 (30) 1312 18.0 4169
Mineral Oil 1 71%
4-year-old 0.01 42-38-0 (20) 1344 22.3 1262.5 4919

Mineral Oil 2 19% 74%
In-service field samples
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2017 SALARY SURVEY
The results from Machinery Lubrications annual survey of lubrication professionals in the United States have been tabulated, and they reveal
that salaries held steady from 2016 to 2017, with less than a 1 percent change in earnings. Other interesting findings from the survey include
the number of raises received over the past year reaching its highest level since 2014, and men earning almost $10,000 more per year on average
than women. More younger workers also seem to be entering the industry, as not only did the average age drop two years from 2016, but the
number of respondents who have been with their current employer for less than five years increased by 10 percent. Certification continues
to rise in popularity, with the number of survey participants who have earned at least one certification increasing by nearly 15 percent from
a year ago and by almost 25 percent since 2015. We would like to thank everyone who took the time to complete the online survey.
WHAT IS YOUR CURRENT HAVE YOU RECEIVED A RAISE

ANNUAL SALARY? IN THE PAST YEAR?
32 %
21% 21%
23%
9 % 12% 77%
2% 3%
$150K+ $125-150K $100-124K $80-99K $60-79K $40-59K <$40K
The number of respondents receiving
The highest reported salary was $250,000, while the lowest was $25,000. a raise was the highest since 2014.
AVERAGE SALARY BY YEAR

2013 2014 2015 2016 2017
$82,000 $79,000 $78,112 $80,688 $80,424

ML
HOW DOES YOUR SALARY THIS YEAR WHAT IS YOUR AGE?

COMPARE TO LAST YEAR?
20-29 9%
30-39 16%
40-49 23%
50-59 37%
6-10% 1-5% SAME 10% 6-10% 1-5%
60+ 15%
2% 2% 20% 2% 5% 69%
The youngest survey participant was 20, and the oldest was 81. The average age
dropped two years from 2016 to 48.
AGE AND AVERAGE SALARY
20-29 $68,742 ARE YOU MALE OR FEMALE?
30-39 $66,453
40-49 $80,463
50-59 $87,041
60+ $87,842
96% 4%
DID YOU RECEIVE A BONUS
The average salary for men was $80,651, while the womens average salary was $71,063.
IN THE PAST YEAR?
YES NO TENURE AND AVERAGE SALARY

44%
56%
<5 YEARS 5-10 YEARS 11-20 YEARS 20+ YEARS
$74,511 $85,799 $78,428 $87,739
The number of workers who have been with their current employer for
less than 5 years increased by 10 percent over the past year.
HOW MANY YEARS HAVE YOU WORKED WHAT IS THE HIGHEST LEVEL OF SCHOOL
FOR YOUR CURRENT EMPLOYER? YOU HAVE COMPLETED OR THE HIGHEST
DEGREE YOU HAVE RECEIVED?
28% BACHELORS DEGREE
28% COLLEGE/NO DEGREE
HIGH-SCHOOL DIPLOMA 17%
<5 YEARS 5-10 YEARS 11-20 YEARS 20+ YEARS
36% 22% 21% 21% ASSOCIATE DEGREE 19%
The longest tenure reported was 42 years. GRADUATE DEGREE 8%

2017 SALARY SURVEY
EDUCATION LEVEL AND AVERAGE SALARY WHAT PROFESSIONAL CERTIFICATIONS

$120K DO YOU HOLD?
$100K ICML LEVEL I MACHINE LUBRICATION TECHNICIAN (MLT I): 27%
$80K ICML LEVEL I MACHINE LUBRICANT ANALYST (MLA I): 15%
$60K ICML LEVEL II MACHINE LUBRICANT ANALYST (MLA II): 11%
ICML LEVEL II MACHINE LUBRICATION TECHNICIAN (MLT II): 7%
$40K
ICML LEVEL III MACHINE LUBRICANT ANALYST (MLA III): 3%
$20K $68,288 $69,352 $78,238 $93,650 $116,621
0 The number of survey participants who have earned at least one certification
HIGH-SCHOOL COLLEGE BUT ASSOCIATE BACHELORS GRADUATE increased by nearly 15 percent from a year ago and almost 25 percent from 2015.
DIPLOMA NO DEGREE DEGREE DEGREE DEGREE
WHAT IS THE TOTAL NUMBER OF

IN WHICH REGION DO YOU LIVE? EMPLOYEES AT YOUR FACILITY?
50 OR LESS 51-100 101-250 251-500 501-1,000 1,000+
NORTHWEST: 8%RTHEAST: 24% 12% 24% 17% 11% 12%
16% The average was 503 employees.
NO
MIDWEST:
29%
SOUTHEAST:
AVERAGE SALARY BY REGION
SOUTHWEST:
21% 26%
NORTHWEST:
,43 T:
3
05 EAS
$76,031
$1 NORTH
MIDWEST:
$77,440
The states with the most responses were Texas, Wisconsin, Ohio and South Carolina.
SOUTHEAST:
WHAT IS YOUR JOB TITLE? SOUTHWEST: $87,280 $75,395
ENGINEER: 10%
RELIABILITY ENGINEER: 9%
MAINTENANCE/RELIABILITY MANAGER: 10%
PREDICTIVE MAINTENANCE TECHNICIAN: 8%
LUBRICATION TECHNICIAN: 14%
JOB TITLE AND AVERAGE SALARY
ENGINEER: $107,212
HOW MANY EMPLOYEES RELIABILITY ENGINEER: $95,217
DO YOU SUPERVISE? MAINTENANCE/RELIABILITY MANAGER: $85,030
PREDICTIVE MAINTENANCE TECHNICIAN: $68,414
LUBRICATION TECHNICIAN: $61,916
0: 57%
DESCRIBE THE PRIMARY BUSINESS
1-10: 31% ACTIVITY OF YOUR FACILITY:
PETROLEUM PRODUCTS: 11% POWER GENERATION: 6%
11-25: 8%
CHEMICALS: 10% FOOD PROCESSING: 6%
PAPER: 8% MINING: 5%
>25: 4%
RUBBER/PLASTIC: 6% MISC. MANUFACTURING: 4%
Among the companies participating in the survey included Bridgestone, the Hershey Co.,
Northrop Grumman, Chevron, Goodyear, Exelon, Kimberly-Clark and Ford Motor Co.
REDEFINING
HIGH-PERFORMANCE
SYNTHETIC
GEAR LUBRICANTS
Lubriplate
SYNTHETIC GEAR OILS
SYN LUBE SERIES Follow-Up Oil Analysis Monitoring Service
High-Performance, 100% Synthetic, Polyalphaolefin (PAO)-Based Fluids.
Compatible with Petroleum-Based Oils for Easy Conversion.
Available in ISO Grades 150 through 1000.
Is Included At No Additional Cost
On All Lubriplate Gear Oils. 3
SYN LUBE HD SERIES
Heavy-Duty, Polyalphaolefin (PAO)-Based Synthetic Gear Lubricants.
Meets AGMA EP (Extreme Pressure) Requirements.
For Heavy-Duty Applications.
SYNTHETIC WORM GEAR LUBRICANT

100% Synthetic, Polyalphaolefin (PAO)-Based Fluid, ISO 460 Grade.
Formulated Especially for Worm Gear Applications.
Provides Excellent Oxidation Resistance.
PGO & PGO-FGL SERIES

Ultra High-Performance, Polyalkylene Glycol (PAG)-Based, Gear Lubricants.
ECO-Friendly - Extended Service Life, Energy Conserving.
PGO-FGL Series is NSF H1 Registered, NSF/ISO 21469 Certified, Food Grade.
SFGO ULTRA SERIES

NSF H1 Registered, NSF/ISO 21469 Certified, Food Machinery Grade.
High-Performance, 100% Synthetic, H1 Fluids. PGO-FGL and SFGO ULTRA SERIES OILS Are Fortified With
Provides Excellent Oxidation Resistance. Lubriplates Proprietary Food Grade Anti-Wear Additive .
To Learn More About Lubriplates Products and Services Visit www.lubriplate.com

Backed By:
Lubriplate
ESP
Complimentary Extra Services Package
Plant Surveys / Tech Support / Training
Newark, NJ 07105 / Toledo, OH 43605 / 800-733-4755 Color Coded Lube Charts & Machine Tags
www.lubriplate.com / LubeXpert@lubriplate.com Lubrication Software / Follow-Up Oil Analysis
2017 SALARY SURVEY
ON AVERAGE, HOW MANY HOURS DO YOU HOURS WORKED AND AVERAGE SALARY
WORK EACH WEEK?
<40 HRS. 40 HRS. 41-49 HRS.

2 % 28 % 44 %
50-59 HRS. 60-69 HRS. >70 HRS.

19 % 6 % 1 % <40 HRS. 40 HRS. 41-49 HRS. 50-59 HRS.
$36,500 $67,294 $83,449 $89,918 $112,000 $75,000
60-69 HRS. >70 HRS.
DO YOU BELIEVE
HOW DO YOU EXPECT YOUR SALARY TO YOU ARE COMPENSATED FAIRLY?
CHANGE IN THE NEXT YEAR?
INCREASE: 69%
STAY THE SAME: 30%
DECREASE: 1%
HOW SATISFIED ARE YOU WHAT FACTOR MOST
WITH YOUR JOB? CONTRIBUTES TO SATISFACTION
WITH YOUR JOB?
CHALLENGE AND STIMULATION: 44%
WORK ENVIRONMENT/CULTURE: 22%
SALARY AND BENEFITS: 17%
COLLEAGUES: 7%
5% 21% 43% 31% CAREER/PROFESSIONAL DEVELOPMENT:
MAKING PRODUCTS THAT HELP PEOPLE:
6%
4%
DISSATISFIED SOMEWHAT SATISFIED VERY
SATISFIED SATISFIED
WHAT DO YOU DISLIKE ABOUT YOUR JOB? DO YOU CONSIDER YOUR JOB SECURE?
LACK OF MANAGEMENT SUPPORT: 38%
LACK OF RECOGNITION: 28%
SALARY AND BENEFITS: 20%
HOURS AND WORKLOAD:
WORK ENVIRONMENT:
17%
17% 84% 16%
UNABLE TO MAKE A DIFFERENCE: 13%
COMMUTE AND TRAVELING: 13% The number of respondents who consider their job secure rose by more than 10
percent over the previous year.
ML
WILL YOUR COMPANY BE ADDING ANY DOES YOUR COMPANY EXPECT TO LOSE
LUBRICATION-RELATED JOBS NEXT YEAR? LUBRICATION-RELATED JOBS NEXT YEAR?
DONT KNOW
NO
31%
64%
YES NO DONT KNOW YES
12% 48% 40% 5%

WHAT CHANGES WOULD YOU LIKE TO SEE WHAT IS YOUR GREATEST CONCERN
AT YOUR PLANT IN THE COMING YEAR? HEADING INTO 2018?
IT WOULD BE HELPFUL TO HAVE A DEDICATED LUBE CREW. NO LUBRICATION PROGRAM BEING DEVELOPED.
MOVING MORE TO CONSTANT DEMAND TO DO MORE WITH LESS (FUNDS AND STAFF).
PROACTIVE INSTEAD NEW PLANT MANAGER POSSIBLY NOT REALIZING THE IMPORTANCE OF
LUBRICATION AND RELIABILITY.
OF REACTIVE
MAINTENANCE. L ACK OF TR AINED
LONG OVERDUE MODERNIZATION AND UPGRADES.
PERSONNEL IN
MORE ENGAGEMENT OF OPERATIONS MANAGERS TO SUPPORT THE
THIS FIELD.
MAINTENANCE PROCESS. I PLAN TO RETIRE IN 2018, AND I DONT SEE ANYONE TAKING AN INTEREST
GREATER IMPLEMENTATION OF LUBRICATION BEST PRACTICES. IN WHAT I DO.
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WHAT IS RELIABLE PLANT? I am going

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for the 19th year of this must-attend event.
With an established and global reputation for technical excellence,

Reliable Plant brings together key plant and maintenance managers,
as well as reliability and lubrication professionals, from across the
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learning sessions and case studies designed to upgrade the skills and that are going
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In 2017, more than 1,500 attendees from 47 states, 27 countries and

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HYDRAULICS
Best Ways to
Eliminate Hydraulic Oil
Leakage
B y A l Smiley, GPM H ydraulic Consulting
Hydraulic oil in a pressure line can the suppressor near the pressure port of
travel at a speed of 15-30 feet per the valve. When the valve rapidly closes and
second, depending on the pres- the shock spike occurs, the nitrogen will
sure. When a valve is rapidly closed to block compress and absorb the pressure spike.
flow or a cylinder fully strokes, a pressure The suppressor is also useful in systems
spike will occur. that contain 90-degree bends in the piping
Unlike air, hydraulic oil is generally consid- or tubing. An additional benefit of the shock
ered to be non-compressible. Oil will only suppressor is that it also reduces noise. This
compress 0.5 percent when pressurized to can be useful in systems that utilize high-
1,000 psi. When a pressure spike occurs in the volume pumps and/or accumulators.
system, the pressure can increase four or five
times above the normal operating pressure. System Piping and Hoses
Since the average duration of a shock spike
When plumbing a system, eliminate the use
is 25 milliseconds, the pressure gauge cannot
of 90-degree fittings in the pipe and tubing.
respond fast enough to give an accurate
indication. Pressure transducers are normally When oil enters the fitting at a high velocity
The use of 90-degree fittings in piping
used to record pressure spikes. Shock spikes and rapidly takes a 90-degree turn, turbulence and tubing should be avoided when
will exist and shock will be generated. This plumbing a system.
that are not properly dampened or absorbed
can result in leakage and damage to the lines
and components in the system. One drop of
oil that drips once per second will result in a Nitrogen
loss of 405 gallons in a years time. At the cost Charging Valve
of $9 per gallon, that one leak costs $3,645
in one year.
Shock Suppressors
A shock suppressor acts very much like a
hydraulic accumulator except that it can be
mounted directly in the line. The suppressor
is pre-charged with dry nitrogen. The rubber
bladder separates the nitrogen from the oil.
The recommended pre-charge of nitrogen
is half the maximum system pressure. The
suppressor should be installed as close as Hydraulic 3-Baffle Nitrogen Bladder (Black Line)
Oil (Red) Chamber Charge (Blue)
possible to where the shock is occurring. Diffuser Tube
For example, if shock is generated by the
rapid closing of a directional valve, install A cross-section view of a shock suppressor

HYDRAULICS
will result in leakage at the fitting or elbow. be spaced every 5-8 feet, depending on the
A 45- or 90-degree sweep ell will reduce size of the line, and must be tightened on a
the turbulent flow as the oil flows through regular basis to eliminate movement of the
the line. pipe and subsequent leakage. A clamp should
Proper clamping is essential to reduce shock also be installed within 6 inches of the termi-
in the system. In the photo on the right, U-bolts nation point.
have been used to clamp the pipes. In this instal- When properly placed, hoses can absorb
lation, you can see that the pipe has moved due shock in the system. A hose should be
to hydraulic shock. This eventually will lead installed at the outlet of the pump prior to
to wearing of the pipe and leakage. U-bolts, entering the manifold or main header. This
conduit clamps and beam clamps are not built will reduce shock at the pump when the oil
flow is rapidly deadheaded.
to withstand the shock in a hydraulic system.
Hoses should also be installed prior to
A proper hydraulic clamp should be used
connecting to a valve, manifold or cylinder.
(as shown in the photo below). Clamps should
The only exception is if the cylinder is
mounted vertically. In these applications,
pilot-operated check valves or counterbalance U-bolts should not be employed to
valves are used to maintain oil in the cylinder clamp pipes.
when in the raised position. The hose should

therefore be installed before the check or
counterbalance valve.
Be sure to make the hose long enough,
as its length can change when the pressure
spike occurs. On the other hand, hoses
should not be made too long either, as they
will rub on another hose, catwalk, beam or
An example of a proper
hydraulic clamp other structure.
Hoses should be installed at the pump

outlet prior to entering the manifold
or main header.
Hoses that are too long may rub on

another hose or other structure.

Pressure Settings
Pressures are often randomly adjusted by the local plant knob-
turner in an attempt to increase the speed of the machine. When
a cylinder or hydraulic motor operates, the pressure will only build
up high enough to move the load. Therefore, the maximum pressure
limiter in the system should be set 200 psi higher than the pressure
required to move the load. If the pressure is set higher than that, exces-
sive shock will be generated when starting and stopping the actuator.
In a system with a pressure-compensating type pump, the
compensator setting determines the maximum system pressure.
When this pressure is reached, the compensator spool will shift open
and de-stroke the pump. The pump will then only deliver enough oil
to maintain the compensator setting.
In a fixed-displacement pump system, the relief valve determines
the maximum system pressure. Once the relief valves spring setting
is reached, the spool will shift open and port the pump volume back
to the tank.
I was recently asked to consult with a sawmill that was experi-
encing leakage and shock on its lumber stacker. The stacker used a
10-inch-diameter cylinder to raise and lower the stack. The hydraulic
schematic recommended that the relief valve be set to 1,200 psi.
However, someone had turned the valve up to 1,800 psi. When the
cylinder fully bottomed out, the pressure went up to 1,800 psi. A loud
bang was then heard, and all lines in the system vibrated.
You can calculate how much force was generated when the pres-
sure built up to 1,800 psi using the following formula:
Force = Pressure x the number of square inches on the full piston
side of the cylinder
Force = 1,800 psi x 78.54 square inches
Force = 141,372 pounds
Once the relief valve setting was lowered to the recommended 1,200
psi, the noise and shock severely decreased when the cylinder bottomed
out. With the pressure at 1,200 psi, you can calculate the amount of
force that was reduced on the cylinder using the same formula:
Force = 1,200 psi x 78.54 square inches
Force = 94,248 pounds
The difference in force between 1,800 psi and 1,200 psi is 47,124
pounds or almost 24 tons.
All plant personnel should be made aware of the negative effects
caused by pressures being out of adjustment. In addition to reducing
shock and leakage, turning down pressures decreases electrical energy
consumption of the electric motor and heat generation in the system.
If you have shock and leakage in your systems, there is something
you can do about it. By properly setting the pressures, installing
accumulators and shock suppressors where needed, verifying that the
system is piped and hosed correctly, and adding or adjusting pilot
chokes, you should be able to reduce or even eliminate shock and
leakage in your hydraulic systems.
About the Author

Al Smiley is the president of GPM Hydraulic Consulting Inc., located
in Monroe, Georgia. Since 1994, GPM has provided hydraulic training,
consulting and reliability assessments to companies in the United States,
Canada, the United Kingdom and South America. Contact Al at gpm@
gpmhydraulic.com.

ASK the EXPERTS
What are the benefits and pitfalls of an oil
reclamation service? Can it save you money?
Are there any negative results?
There are many benefits of using a reclamation service, allow you to compare the results and ensure you are getting what
such as its positive impact on the environment. you pay for. Additive packages can also be restored to their pre-used
Another advantage is you will not need to purchase state by the reclaiming service.
costly equipment, supply the labor or dedicate time to reclaim Many different types of oils can be reclaimed, including hydraulic
the oil yourself. There also will be no cleanup or mess to contend oils, turbine oils, circulating oils for bearing lubrication, paper
with after the reclaiming process. The oil will be cleaned to an
machine oils, gear oils, quench oils, some metalworking fluids,
ISO standard of your choice and returned to service likely cleaner
transformer oils, some synthetics and several specialty fluids. Unfor-
than when it was new.
Typically, you will receive a comprehensive report on the oil tunately, in most cases, only large amounts of oil (more than 550
before the reclamation and after it goes back into service. This will gallons) can be reclaimed.
The other pitfalls of using a reclamation service will largely
depend on the reclamation company that is used. Investigate the
quality of each company being considered and verify all references.
If not, you may end up with an oil that damages your machinery.
The risk of cross-contaminated oil is high if the reclamation
service does not flush its equipment after every use. In addition, if the
company does not have the appropriate permits to transport your
oils to its facility and there is a spill or incident, you could be liable.
Keep in mind that the reclaimed oil is no longer the oil you
purchased from the distributor but is now blended oil. Check the
warranty details of the reclamation service for what to do if you
have any issues with the oil. Also, ensure that the warranty on your
machinery is not voided by using reclaimed oil.
Oil reclamation can save you money. If you have large amounts
of oil you would like to keep in service without the cost of a full
change-out, reclamation can be a cost-effective option. In fact,
many reclamation companies claim they can save up to 85 percent
of the oils original cost. Just be sure to check the credentials of the
company beforehand to avoid a lot of heartache.
What is the best cleaning procedure for

contaminated oil drums?
There are several ways to
address this situation, from the
best practice of using a cleaned
and properly sized container for housing
and transporting the oil to the worst
practice of rinsing and refilling the drum.
All methods have pros and cons and will
impact the reconditioned oils lifespan.
The worst thing to do is to recondition the
28 September - October 2017 | www.machinerylubrication.com

turbine oil and then put it back into a drum porting and cleaning. Larger containers allow and safety risks. While this may not be the
that hasnt been properly cleaned. The same you to filter the oil in the container while most cost-effective option at the front end of
goes for putting new turbine oil into an minimizing handling. This will eliminate the the project, it will yield considerable benefits
already contaminated system. By doing so, time involved transferring the oil from a in the long term.
the antioxidants will be attracted to these
55-gallon drum to a larger container for If you have a question for one of Norias experts,
byproducts and be rendered useless before
filtering and reduce the environmental, health email it to editor@noria.com.
even being put into service.
Replacing each drum will save you time
and energy. The process of cleaning an oil
that has already led to a varnish problem can
be labor-intensive and very time-consuming.
Reconditioning used drums will not be easy,
but it can be done. A number of systems on
the market target varnish. The problem is
that every drum will need to go through this
cleaning process, which will take a significant
amount of time.
Other factors that should play into your
decision of which cleaning process to use
include the type of failure that occurred
within the lube oil, the type of varnish that
is present and the equipment that is at your
disposal. The process may be as simple as a
wand flush using a filter cart or filtering the
oil within the drum through an electrostatic
process. Either way, it will be a slow process.
The best and most economical solution
would be to use a larger container for trans-

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Machinery Lubrication I (MLI) provides

the foundational skill set for applying
If you missed the educational Summit Varnasolv will alleviate prob- best lubrication practices and product
lems from varnish and carbon in your knowledge. Through MLI, students
sessions at Reliable Plant 2017,
rotary screw or rotary vane compressor. can move away from the old-school
you can still get the conference
Clean your compressor while it is run- methods of vague, non-specific lubri-
proceedings. It includes the papers cation procedures and implement an
and presentations in PDF format ning, no need to disassemble. Use Var-
nasolv to clean heat transfer systems, excellent lubrication program in any
from nearly every learning session. industrial workplace.
high-temperature chains and gearboxes.
Noria Corporation
Summit Brand Kluber Noria Corporation
store.noria.com Lubrication NA LP store.noria.com
800-597-5460 www.klsummit.com 800-597-5460
800-749-5823
GET to KNOW
Sutcliffe Takes Proper Name
Lubrication Practices
Frank Sutcliffe
Age
50
Around the Globe

Frank Sutcliffes talents have taken him all across the world, from the United Kingdom and the
Job Title
Maintenance
Reliability and Turn
Around (MRTA)
Middle East to Russia, Nigeria and most recently Kazakhstan. He has also served in a number of Specialist
different positions, including as a reliability manager, certified reliability-centered maintenance
facilitator, principal technical expert of reliability and operability, compressor performance improve- Company
ment team lead, and category manager of rotating equipment. Before joining Shell, Sutcliffe even Shell
worked in the nuclear industry on risk assessment and decommissioning. While in the UK, he Location
once heard an experienced colleague say that proper lubrication is the most important maintenance Atyrau, Kazakhstan
activity and the most cost-effective way to avoid premature machinery failures. That advice has
Length of Service
stuck with him for more than 20 years.
20 years
Q: Whats a normal work Q: What is the amount and

day like for you? range of equipment you
A: I work both in the office and help service through lubri-
at the site, so there is no standard cation/oil analysis tasks?
work day. My recent focus has A: In terms of our equipment, we
been on reliability strategy and have a variety of pumps. Like many
building plans with stakeholders others in the process industry, we
for delivery of that strategy. A have more pumps than any other
key part of that is deepening and machines. We also have steam
broadening reliability skills across turbines, industrial and aero-deriva-
the business. Reliability is not tive gas turbines, and electric motors.
achieved solely by people with the
Q: What have been some
word in their job title, so I spend
of the biggest project
time coaching, mentoring and successes in which youve
building technical career skills played a part?
with the team here. A: In terms of impact, I think Id
Im also helping implement have to say the introduction of onsite
a move away from reactive lube oil analysis by condition moni-
root cause analysis to proac- toring in Oman. Before that, samples
tive threats and opportunity
management. In addition, I
took weeks to turn around, and the Be Featured in the Next
effectiveness of the program was
facilitate failure analysis using not what it should have been. That Get to Know Section
a causal learning approach and was coupled with huge improve- WOULD YOU LIKE TO BE FEATURED IN THE
will shortly be developing appli- ments in contamination control and NEXT GET TO KNOW section or know someone
cable and effective maintenance reducing high-temperature trips. In who should be profiled in an upcoming issue of
routines for existing and new the summer, temperatures routinely Machinery Lubrication magazine? Nominate yourself
systems using reliability-centered reach more than 50 degrees C (120 or fellow lubrication professionals by emailing a photo
maintenance. degrees F). and contact information to editor@noria.com.

Q: How does your company view machinery
lubrication in terms of importance and
overall business strategy?
A: Lubrication is viewed as being important and a
key in avoiding premature failures.
Q: What do you see as some of the more

important trends taking place in the lubri-
cation and oil analysis field?
A: Thinking ahead, Im sure there will be some useful
developments around nano-lubrication technology.
I also expect to see some smart people doing some
smart stuff with graphene technologies.
Q: What has made your company decide to put

more emphasis on machinery lubrication?
A: The expectations placed on industrial activity by
management, government and society overall
continue to increase, e.g., higher environmental
standards and stretch performance targets (do
more with less). This will not stop. Against this back-
drop, lubricating the way your father or grandfather
did, or what the industry did before, will no longer
be good enough.
THE LUBE-TIPS SECTION OF MACHINERY LUBRICATION
MAGAZINE FEATURES INNOVATIVE ideas submitted by our readers.
Additional tips can be found in our Lube-Tips email newsletter. If you have a
tip to share, email it to editor@noria.com. To receive the Lube-Tips newsletter,
subscribe now at www.MachineryLubrication.com/page/subscriptions.
Quick Test for Lubricant Compatibility Your sample bottle hand pump can be easily converted so the
suction unit will draw the sample directly into the bottle as the hand
Suppose you run out of a lubricant and are in critical need to top
pump did. Just install a new bottle and turn on the suction unit.
off the reservoir. If the equipment is force-lubricated from a sump,
You now can use both hands and all your concentration to get the
it usually is better to leave it a little low until you can obtain the
tubing into the oil in the sump. These units can be obtained from
proper fluid. If you simply cannot resist the temptation to conduct
any medical-supply store.
a science experiment, take a few minutes to perform the following
test: In a clean, clear plastic bottle, add equal amounts of both
lubricants, leaving some headspace. Shake the bottle vigorously
and allow to settle. Do you see more than one layer, a hazy or milky
appearance, any color change or sediment? Any of these results is
a red flag and a warning not to mix these fluids. In two separate
bottles, vigorously shake the samples of the two fluids separately.
Do the bubbles rise to the top and pop as quickly in the mixture as
they do in the individual fluids? If you skip the test and go ahead
and mix the lubricants, a foaming problem and subsequent major
disaster could be heading your way.
Prevent Damage When Changing Bearings

When changing pillow-block bearings with a cylindrical
outside diameter on the outer race, be sure to clean the grease
channel located in the housing prior to installation of the new
bearing. The grease in the channel tends to attract dust and dirt
over time. When the bearing is changed, this dirt can become
displaced into the grease channel as the new bearing is tipped
into the housing. The dirt can either pass through the applica-
tion hole in the outer bearing race or plug the hole, resulting in
damage to the new bearing.
Oil Sampling Made Easy

If you collect a lot of oil samples from tight areas or hard-to-
reach locations, obtain a battery-operated medical suction unit.

BOOKSTORE
WELCOME TO MACHINERY LUBRICATIONS
BOOKSTORE, designed to spotlight lubrication- For descriptions, complete table of contents and excerpts from
these and other lubrication-related books, or to order online, visit
related books. For a complete listing of books of
store.noria.com or call 1-800-597-5460, ext. 204.
interest to lubrication professionals, check out the
Bookstore at store.noria.com.
Machinery Condition Monitoring: In-Service Lubricant and Machine

Principles and Practices Analysis, Diagnostics, and Prognostics
Author: Amiya Ranjan Mohanty Author: ASTM International
Providing the working principles This compilation of the Journal of
behind the important elements of ASTM International (JAI) contains
machines as well as the techniques papers presented at a sympo-
to understand their conditions, sium on in-service lubricant and
this book presents every available machine analysis, diagnostics and
method of machine fault detection. prognostics held Dec. 8, 2010, in
It draws on the authors more than Jacksonville, Florida. It includes
two decades of experience with recent developments in online oil
machinery condition monitoring condition monitoring sensors and
and consulting while introducing alignment with ASTM methods and
the practicing engineer to the techniques used to effectively practices, an overview of progress and new developments in
detect and diagnose faults in machines. FTIR lubricant condition monitoring methodology, guidelines
for alarm limits and trend analysis, and more.
Integrated Reliability:
Condition Monitoring Reliable Plant
and Maintenance of 2017 Conference
Equipment Proceedings
Author: John Osarenren Format: CD-ROM
This book incorporates reliable Publisher: Noria
engineering and mathematical Corporation
modeling to help you move toward If you missed the learning
sustainable development in reliability sessions at Reliable Plant 2017,
condition monitoring and mainte- you can still get the conference
nance. It introduces a cost-effective integrated reliability growth proceedings on CD-ROM.
monitor, integrated reliability degradation monitor, technological It includes the papers and
inheritance coefficient sensors, and a maintenance tool that presentations in PDF format
supplies real-time information for predicting and preventing from nearly every educational session. The real-world case studies
potential failures of manufacturing processes and equipment. at Reliable Plant 2017 were full of practical, experience-based
information and tools for lubrication and reliability programs.
Best Practices for
Lubricant Storage Home Sweet Home Poster
and Handling Publisher: Noria Corporation
Training Video This poster shows the best practices
Format: DVD for proper reservoir management.
Publisher: Noria Corporation Hang it to send a clear message
Squeezing maximum life out of that proper care for lubricants
lubricants and extending machine and hydraulic fluids is critical. The
life start with putting a healthy, 17-by-11-inch laminated poster
clean lubricant into the machine. offers 10 bulleted tips, such as
In this training video, youll learn the very best practices for tightly seal clean-out covers and
new oil storage and handling, as well as procedures you can hatches, and wipe down level
implement right away for managing lubricants from delivery to gauges, sight glasses and BS&W
dispensing and filling the machine. bowls for easy inspection.

PRODUCT NEWS FUEL FILTER
Baldwin Filters new BF46002 dual-stage fuel filter is a high-
performance alternative for protecting modern high-pressure
fuel systems. It incorporates a highly engineered media with
multiple layers to trap and hold the smallest contaminants,
including those less than 5 microns in size. Along with a high
dirt-holding capacity, the BF46002 is designed to last longer
by continuing to provide ISO 4406 12/9/6 cleanliness levels for
large amounts of fuel.
Baldwin Filters
www.baldwinfilter.com
800-822-5394
HEAVY-DUTY ENGINE OILS

The new SynShield CK-4 and FA-4 heavy-duty diesel engine
oils from Schaeffers Specialized Lubricants are formulated to
provide severe-duty protection for greater engine efficiency and
longer service life. Blended with advanced anti-wear additives,
antioxidants and friction modifiers, the series of oils includes
an OTR blend for prolonged productivity, a severe-duty dura-
bility formula for harsh conditions, an ultra-performance oil
for better soot control and a max MPG formula for increased
fuel economy benefits.
Schaeffers Specialized Lubricants
www.schaefferoil.com
800-325-9962
CENTRIFUGAL SEPARATOR
US Filtermaxxs 10,000G Centrifuge is an enclosed-base, programmable
centrifugal separator for fluid contamination problems. It is engineered
to quickly and easily remove heavy contamination that plugs standard oil
filters as well as submicron-sized particles that pass through some filters.
Suitable for batch cleaning or continuous cleaning of oils, coolants and
fuel, the high-speed centrifuge can separate water, antifreeze and partic-
ulate, allowing users to recover heavily contaminated oil and fuel while
reducing their waste oil stream and lowering waste oil collection costs.
US Filtermaxx
www.usfiltermaxx.com
904-334-2838
SOOT TEST KIT

The new field test kit from Geserco enables monitoring of the soot content in
used engine oils. Built around a handheld infrared spectrometer, the kit can
provide soot measurements up to 15 percent with a sensitivity as low as 0.01
percent. The high sensitivity allows the kit to measure soot in both diesel and
gasoline oil. The optical oil tester offers digital measurement of carbon matter
(soot) in oil content in less than 5 seconds.
Geserco
www.geserco.fr
+33(0)5-56-34-9229

HIGH-PERFORMANCE GREASES
Klbers new Klberbio LG 39-700/701 N high-performance greases are designed
for open gear drives, jack-up lifting systems and other onboard equipment that
may be in contact with sea water. The lubricants feature a base oil and additive
package that combines eco-friendliness with high load-carrying capacity, good
adhesion to surfaces, and anti-wear and anti-corrosive effects. Due to their
low-temperature behavior, the greases can be pumped in centralized lubricating
systems down to minus 22 degrees F and sprayed, even at 32 degrees F, allowing
the lubricants to be used over a wide temperature range.
Klber
www.klubersolutions.com
800-447-2238
METALS ANALYZER
The new Spectroport from Spectro Analytical Instruments is a portable arc/spark optical
emission spectrometry (OES) metals analyzer for analyzing elements at low and critical
levels. It features point-and-shoot performance, flexible portability, ease of use and mini-
mal standardization. The device is designed to be as fast as a handheld X-ray fluorescence
(XRF) analyzer, with many analyses taking only a few seconds. Unlike handheld XRF ana-
lyzers, the Spectroport can analyze elements such as carbon, sulfur, phosphorus, boron,
lithium, beryllium, calcium, silicon, magnesium and aluminum at low and critical levels.
Spectro Analytical Instruments
www.spectro.com
800-548-5809
FILTER ELEMENTS
Swift Filters new series of metal-felt filter ele-
ments are engineered for high-pressure, highly
corrosive, highly viscous and radioactive appli-
cations. The elements incorporate filter media
made of thin filaments of nonwoven stainless
steel. The metal felt employed is highly porous,
which allows for high flow rates of up to 20 times
those of other media types as well as long life.
Random fiber filtration (metal felt) can also pro-
vide absolute particle retention, longer on-stream
time and high dirt-holding capacity for less than
60-micron filter elements.
Swift Filters WIRE ROPE LUBRICANT
www.swiftfilters.com The new Biogen marine rope dressing from Rocol
877-887-9438 is an environmentally acceptable lubricant (EAL)
that is intended to help extend the operational life
of critical wire ropes. It is formulated specifically to
perform in the most challenging industry conditions,
including anywhere the environment is wet, humid
and salt-saturated. The formulation uses a unique
additive package that provides a high-performance
hydrophobic barrier and water wash-off resistance in
wet and submerged conditions.
Rocol
www.rocol.com
+44 (0)113-232-2600

NOW ON MACHINERYLUBRICATION.COM
FIND MORE GREAT ARTICLES AND CONTENT FROM Machinery Lubrication magazine
online. From web exclusives and industry news to videos, white papers, buyers guides and more,
everything that relates to machinery lubrication is available now on www.MachineryLubrication.com.
How to Choose the Right this common misconception and why the or making it appear cloudy. Air entrain-
problem is often not a lack of resources but ment can also lead to other issues such
Engine Oil rather how they are allocated. as foaming, cavitation and an increased
To choose the right lubricant for your oxidation rate. Access this 1-minute,
vehicles, use the viscosity grade(s) The Truth About 34-second video to find out how you can
recommended by the original equipment Fuel-economy Oils reduce air entrainment and control other
manufacturer serious air-related problems.
Fuel-economy oils have become popular
(OEM) for the
over the last several years, especially the
life of the engine Selecting the Right
and especially Lubricant Supplier
during the engines
Many of todays lubricant suppliers offer
warranty period.
an a la carte program of goods and
Viscosity grades
services. Some provide full service, while
are primarily
others serve niche-specific markets, each
recommended with varying value propositions. Check
according to the out this article on the ML site to learn the
expected ambient temperatures, particu- main criteria that must be assessed as
larly the starting temperatures. Read this well as a 10-step process for selecting a
0W20 and 5W20 oils. Most of these
article on the ML site to discover other lubricant supplier.
oils will provide at least a 1 to 2 percent
important considerations when choosing
increase in fuel economy over using the
an engine oil as well as when you should
next viscosity grade. Understand the many FEATURED WHITE PAPERS
use a synthetic lubricant.
variables to consider when switching to MachineryLubrication.com is the
place to turn for white papers on a
3 Simple Ways to Justify a a fuel-economy oil, including how the
host of lubrication-related topics.
vehicle will be used, by reading this article
Lubrication Program on the ML site.
Heres a sampling of the latest
white papers that are currently
Many organizations mistakenly believe they available for download:
do not have enough money or resources How to Control Oil Aeration A Case for Capturing and
When oil aeration occurs, air bubbles can Analyzing Trends in Your
Alignment Data
Keeping Out Contaminants:
Understanding Ingress
Protection Ratings
How to Work with Your OEM
to Find the Best Lubricant
Check out the full list of white
to implement a lubrication excellence papers by visiting www.Machinery-
program. Access this 1-minute, 55-second Lubrication.com and clicking on the
video to hear three ways to overcome become suspended throughout a hydraulic White Papers link.
or circulating system, darkening the oil
57%
of lubrication professionals use
hydrostatic drives or transmissions at
their plant, based on a recent survey at
MachineryLubrication.com

TEST YOUR KNOWLEDGE
THIS MONTH, MACHINERY LUBRICATION CONTINUES
ITS TEST YOUR KNOWLEDGE SECTION in which we Stay Connected With Noria
focus on a group of questions from Norias Practice Exam for
Level I Machine Lubrication Technician and Machine Lubricant
Analyst. The answers are located at the bottom of this page. The
complete 126-question practice test with expanded answers is
available at store.noria.com.
1. When should the reservoir be cleaned/flushed?

Follow us on Twitter
A) Every time the oil is changed.
https://twitter.com/NoriaCorp
B) When the plant is in a shutdown.
C) When the system fluid viscosity changes by 7 percent or more.
D) When sludge and deposits are detected at the oil drain.
E) When the breather is changed.
2. Which of the following represents the highest NLGI consistency?

A) Block grease
B) ISO 460
C) 000 Like us on Facebook
D) 18/16/13 http://www.facebook.com/noriacorp
E) 8
3. A crackle test can only detect water above:

A) The saturation point, which depends on oil type and temperature
B) 100 ppm
C) 1,000 ppm
D) 10,000 ppm
E) 1 percent
Connect with us on LinkedIn
https://www.linkedin.com/company
/noria-corporation
or other volatile substance concentration.
saturation point, bubbles and audible crackling will be noticed based on water and/
Below the saturation point, there will be no visible or audible change. Above the
3. A
grease is 6. It is as hard as cheddar cheese spread.
Block grease represents the highest NLGI consistency. The NLGI number for block
2. A
unprotected and become oxidized in a short period of time.

rapid depletion of these important additives. Consequently, the base oil will be
pro-oxidants that attack the antioxidant additives of the new oil, resulting in the
and other deposits are oxidation byproducts. Some of these deposits work as
A tank should be cleaned/flushed to avoid contaminating the new oil. Sludge
Continue learning with us on YouTube
1. D
Answers http://www.youtube.com/user/noriacorp
Viscosit y
LESSONS IN LUBRICATION
B ennett F itch | N oria C orporation
Overcoming the
RISKSof COLD
Machine Starts
T Startup Temperature
he lubricant is arguably one of the appropriate lubricant viscosity, since
the most essential components viscosity has a dependent relationship with
Startup temperature is the ambient
of a machine, but it also happens the surrounding temperature.
temperature upon initial startup of a
to be one of the most vulner- machine before the lubricant has a chance
able. Greatly influencing this to reach the operating temperature. During
Cold Machine Starts
vulnerability is the temperature, which has typical operation, the many contributors The term cold machine starts refers
an inverse correlation to the most important to heat generation such as friction will to low ambient temperatures that can be
lubricant property viscosity. By becoming cause the temperature to rise and reach detrimental to a machines operability.
aware of the potential effects that tempera- an equilibrium with its surroundings, The vehicle and mobile equipment indus-
ture can have on your lubricants, you can also known as the machines operating tries have long been developing solutions
better understand how a machine could fail temperature. Knowing a machines oper- for this challenge of dealing with extreme
and hopefully prevent future failures. ating temperature is crucial when selecting temperatures, including those in very cold
Lubricant viscosity has a dependent relationship with temperature.
COLD STARTUP NORMAL EXTREME

-20C (-4F) TO 40C 40C (104F) TO 80C ABOVE 80C (176F)
(104F) (176F)
Multigrade High VI
(smallest rate of change)
VISCOSITY
Multigrade High VI
(small rate of change)
Monograde
(large rate of change)
TEMPERATURE

environments. This has led to the creation

of advanced lubricant formulations, such Beware of Vaporous Cavitation
as pour point depressant additives and
Vaporous cavitation is particularly concerning, as it is symptomatic of high pressure
multi-viscosity oils, as well as advanced differentials in the pump, such as during high viscosity cold starts. As oil is drawn in on
engine designs with the integration of block the suction side of a hydraulic pump, dissolved air is desorbed from the oil coalescing
and pan heaters. with vaporous bubbles, which then continue to expand. These larger vaporous bubbles
respond destructively when compression occurs during the pumps transition from the
Lubricant Failure suction side to the high-pressure side. This sudden and drastic increase in pressure forces
these bubbles to collapse, leading to damage of the nearby oil and machine surfaces
To comprehend the potential machine from the adiabatic effect.
failure modes associated with a cold start,
it is essential to review the ways in which For instance, certain extreme-pressure (if equipped), the filter element rupturing
a lubricant can fail from these conditions, additives are only activated at elevated or both. Because the viscosity increases
both physically and chemically. Not only temperatures as a result of surface fric- during a cold start, the pressure drop
does the lubricant become more viscous at tion from high speeds or high loads. If also increases due to increased resistance
cold temperatures because of the tempera- the machine is operating at slower speeds through the filter element.
ture-viscosity relationship, but it can during startup and in a cold environment, Unfortunately, the potential for failure
eventually congeal when it passes below a the additive can become significantly less is not isolated to the filter in these condi-
certain temperature point called the pour effective. Other additives like rust inhibitors tions. Not only can the filter rupture, but
point. Under test methods defined by ASTM can have poor solubility and stratify to the it can also trigger a chain reaction with
D97, the pour point describes the cold bottom of sumps and storage containers other secondary failures on the machine.
temperature point in which the oil begins to during prolonged stagnant periods in cold When the oil starts to channel in between
become immobile and will no longer flow. temperatures. If the oil continues to operate cracks as the filter ruptures, the buildup of
For example, gear oil at a cold enough at cold temperatures, the foam tendency can contaminants on the filter has a chance to
temperature can be placed on the floor and
increase, especially with low viscosity oils. push through all at once. The mass ingres-
stood upon like a block of ice. However,
All these degradative effects on lubricant sion of particles will then directly promote
unlike water, which maintains a constant
additives will result in limited protection of wear on the machine.
viscosity until it solidifies at an exact
the machine components from corrosion, Generally, the leading cause of failure from
temperature, oil will gradually become
premature wear and foam. cold-start conditions is from increased flow
thicker and congeal at varying rates. This
resistance. Even if the filter doesnt rupture,
makes it challenging to set lubricant selec-
tion standards for the equipment operation.
Filter Resistance and Failure the viscous oil will result in damage. The
All machines behave differently to table on page 43 illustrates how viscosity can
Therefore, even though the oil has not yet
reached the pour point, the viscous nature high viscosity in cold-start conditions, change as a result of a temperature change.
of the cold oil can cause substantial flow depending on the design of the machine and A 220 ISO VG oil with a viscosity index of
restriction in machine components like the component sensitivities. For example, in approximately 100 will increase to more
hydraulic or circulating oil pumps. The any system where fluid is circulated, such than 5,000 centistokes when the temperature
consequences of a pump flow restriction can as a forced circulating lube oil system or a drops to 0 degrees C (32 degrees F).
be catastrophic, with effects such as surface wet sump circulating system, the oil should
wear from vaporous cavitation and bearing flow through a filter. The filter elements will Lubricant Starvation
wear from starvation. naturally cause flow restriction. Higher flow Most mechanical methods that help
Some additives are affected by the low restriction results in a higher pressure drop, supply oil to lubricated components will
temperature conditions of machine startup. leading to the filter bypass valve opening become hindered when temperatures drop.
Cold Engine Starts (Viscosity Too High)

CONDITIONS EFFECTS SOLUTIONS
Extreme cold Air binding or flow limited Quality oil
Gradual cooling Loss of oil pressure Correct wintertime viscosity
Wrong wintertime viscosity Dry start Engine/oil pre-heater
Cold temperature plus high soot load Engine wear

ML
SAE GEAR OIL 75W 80W 85W 90 140

SAE ENGINE OIL 5W 10W 20 30 40 50
ISO Grade 15 22 32 46 68 100 150 220 320 460 680
F C Diesel
248 120 4 4 6 7 9 12 13 18 23
230 110 4 6 7 9 12 15 19 24 30
212 100 1 5 5 7 9 11 15 19 25 32 41
194 90 3 5 7 9 11 15 20 26 34 44 58
176 80 5 7 9 11 15 20 27 36 48 63 85
158 70 6 9 11 15 20 28 39 52 71 95 130
140 60 8 12 15 21 29 40 57 80 110 151 211
122 50 11 15 22 30 43 62 99 128 181 254 365
104 40 1 15 22 32 46 68 100 150 220 320 460 680
86 30 2 21 32 51 76 116 175 271 409 613 907 1,380
68 20 3 33 51 87 135 214 334 536 838 1,290 1,980 3,130
50 10 4 52 87 162 264 438 711 1,190 1,920 3,070 4,870 8,020
32 0 5 85 180 340 585 1,020 1,720 2,990 5,060 8,400 13,900 23,900
14 -10 9 185 375 820 1,500 2,770 4,880 8,890 15,700 27,200 47,000 85,000
-4 -20 15 400 800 2,350 4,650 91,20 16,800 32,300 60,000
Ref. Donaldson Filtration Solutions
Oil kinematic viscosity combined with temperature in centistokes (cSt)
As mentioned previously, if the oil is designed determine how grease restricts motion in a freely turning over at startup, if the oil sump
to flow through piping, such as a lube oil bearing under cold temperatures. is still in a gelled state, the lubricant cannot
circulating system, the oil can become greatly perform its role properly. This can lead to
restricted and starve the machine. Other Gearbox Systems engine seizure. Air pockets can form in the
oil-lifting devices can also lose their effective- Most types of gearboxes are at risk of gelled oil, called air binding, and starve the
ness under such conditions. Ring oilers start starvation, including splash-lubricated, pump of oil. To prevent this, pan heaters
to drag, causing unwanted friction, while oil wet sump circulating systems or forced and higher quality lubricants are often used
slingers hold onto the viscous oil, resulting lube oil circulating systems. When the oil to help keep the viscosity down. When condi-
in an insufficient distribution of lubricant to is too viscous during startup, it cannot tions are uncertain, you can observe the oil
higher lubrication zones. reach the gear meshing zones due to a lack flow from the tip of the dipstick for assurance
of injector pressure or channeling of the oil of the oils viscous state.
Grease Applications in splash-lubricated systems. As a result,
Grease has similar risks in cold envi- the unlubricated high-pressure contact Journal Bearings
ronments since the oil within the grease pivot points on the gear teeth can become The oil wedge formed during rotation of
still abides by the temperature-viscosity damaged. In addition, any gear system that a journal in the bearing housing is a careful
relationship. The potential for lubricant must overcome the churning effects applied balance of speed, viscosity and load. In any
starvation from a lack of grease application by the viscous oil will experience limited circumstance when the viscosity is undesir-
is a common issue. With any application power transmission as well. ably high, such as when temperatures are
method designed to push grease through an very low, the oil can begin to whip around
orifice or grease line, such as a centralized Engines the journal, causing the shaft to wobble.
grease system, single-point lubricator or even Nowadays, it is common for machines Excessive wear can then occur from the
manual greasing, grease movement may be in cold environments to be equipped with reduced working clearances.
significantly restricted in cold temperatures. heating elements to allow the machine to
Consequently, the grease may not be prop- start. However, as temperatures continue Hydraulics
erly applied in the components friction to drop, simply using block heaters does For hydraulic systems, the biggest risks
zones. Certain greases intended for cold not eliminate the risk to engine components in cold temperatures are cavitation and
temperatures are formulated to handle these which have not yet mitigated localized oil filter element failures in hydraulic pumps,
conditions. Test methods such as ASTM that remains below the pour point. For as mentioned previously. Another problem
D4793 and D1478 have been developed to instance, even though the machine may be that can arise involves hydraulic seals. While

contamination and installation issues are the temperatures be the root cause of unfavorable Hochmann. M. (2013, March). Gear
most common reasons why seals leak and lubricant conditions, but their presence can also Lubrication Gear Protection Also at Low Oil
fail, cold starts and cold operating tempera- trigger a chain reaction, leading to highly viscous Temperature. Gear Solutions.
tures also pose a threat of seal embrittlement. lubricants, which introduce the opportunity for Khonsari, M. & Booser, E.R. (2007, March). Low
lubricant starvation, increased contamination, Temperature and Viscosity Limits. Machinery Lubrication.
Bearings premature wear generation, inactive additives Manney, D. Extend the life of your gearbox
and other impending effects. Once machine with predictive maintenance. Retrieved from www.
Bearings with rolling elements will have
lselectric.com/extend-the-life-of-your-gearbox-with-
reduced mobility when oil or grease becomes operators and reliability engineers are aware of
predictive-maintenance.
too viscous in cold temperatures. Viscous the risks that cold temperatures present, partic-
OWI-Lab invests in -40C cold start-up
oil leads to churning losses and skidding of ularly at startup, adjustments can be made to
test bench for wind turbine drivetrain compo-
the rollers. Skidding will damage the rolling prevent these chain reactions from occurring.
nents. Retrieved from www.owi-lab.be/content/
elements and cage structure. Friction increases
References owi-lab-invests-40%C2%B0c-cold-start-test-bench-
as these components are damaged and can wind-turbine-drivetrain-components.
Applied Hydraulics Magazine. (1956, February).
result in a failure. In grease applications, the oil Wikstrm, V. (2000, November). Lubrication of
67-70.
in the grease becomes considerably challenged Bearings at Low Temperatures. Retrieved from http://
Bbehrouz, A. (2014, September). Dead
at low temperatures. The base oil separation evolution.skf.com/us/low-temperatures.
Sensor. Mechanical Engineering Magazine.
rate will be insufficient at low temperatures
Cash. W. (2016, April). Best Ways to Combat
because the viscous oil will stay trapped in the
Oil Gelation. Machinery Lubrication. About the Author
thickener held outside the raceway. During Diemand. D. (1990, December). Lubricants Bennett Fitch is a senior technical consultant
these conditions, lubricant starvation can cause at Low Temperatures. Cold Regions Technical Digest. with Noria Corporation. He is a mechanical engi-
early bearing failure. Fitch, E.C. (2002, July). Temperature neer who holds a Machine Lubricant Analyst (MLA)
Stability of Lubricants and Hydraulic Fluids. Level III certification and a Machine Lubrication
Avoiding Machine Failure Machinery Lubrication. Technician (MLT) Level II certification through the
During Cold Starts Fitch, J.C. (2012, August). The Hidden Dangers International Council for Machinery Lubrication
of Lubricant Starvation. Machinery Lubrication. (ICML). Contact Bennett at bfitch@noria.com.
Thankfully, over the last few decades,
lubricant manufacturers have become aware
of the effects that cold temperatures can have
on machines. This has led them to develop
formulations that can handle these conditions,
including during machine starts. The base
oil plays a major role, as many highly refined
mineral oils and synthetics are less affected by
temperature swings. This is represented by the
viscosity index. Viscosity index improvers can
enhance this property. The higher the viscosity
index, the less change in viscosity per a change
in temperature. Pour point depressants can
also improve the characteristics of oil in cold
temperatures. These base oil and additive prop-
erties, along with a correctly selected viscosity
grade or multi-viscosity grade, offer viable solu-
tions in cold temperatures.
Nevertheless, at times lubricant formula-
tions may not be enough to avoid the pitfalls
of cold starts. In these cases, machines can
be equipped to overcome the frigid elements
through the installation of block and pan
heaters, as mentioned previously, as well as
pre-lube systems that prepare the machines
components for a cold start.
The consequential failure that can arise from
not properly preparing for cold-start conditions
will be gradual and indirect. Not only can cold

Food-grade Lubricants
PERSPECTIVE
L oren G reen | N oria C orporation
Understanding the
CHANGING Requirements for
FOOD-GRADE LUBRICANTS
I n January 2011, the Food

Safety Modernization Act
(FSMA) became law in the
United States. With roughly
15 percent of the U.S. food
supply imported, this law was intended
quences or death. The law also requires
any facility engaged in the manufacture,
processing, packing or holding of food for
consumption in the United States to be
registered with the secretary of Health and
Human Services, and allows the debarment
to strengthen the food safety system. of importers with a history of repeated or
Previously, the Public Health Security and serious food import violations. These two
pieces of legislation granted the FDA the
Bioterrorism Preparedness Response Act
power to confiscate adulterated food and
had been signed into law following the
potentially close a business.
events of Sept. 11, 2001. It gave the Food
The FDA also has resurrected usage of
and Drug Administration (FDA) the deten- the Park Doctrine, which is based on a 1975
tion authority over food items if there is Supreme Court decision affirming the right involving death, the fine is $250,000. Keep
a credible threat of serious health conse- to bring criminal charges against corporate in mind that these penalties are just for the
executives according to a strict liability executives. The organization can be fined
theory. This enables the FDA to charge $250,000 for a case not involving death and
executives with a criminal misdemeanor for $500,000 if a death is involved. If the viola-
violations of the Federal Food, Drug and tion is found to have been committed with
Cosmetic Act (FD&C) of 1938. Penalties the intent to defraud or mislead, or occurs
for these violations are a maximum of one after a prior conviction, the penalties are up
year in prison and/or a $100,000 fine if the to three years of imprisonment and/or a fine
violation does not result in a death. In a case of $250,000 and $500,000.
Please note that these violations can
Plant managers could be held result in hefty fines and possible prison
sentences for executives regardless of the
criminally liable for food being intent or knowledge of violations occurring

within an individuals area of responsi-
adulterated or contaminated with bility. It is also important to understand

that the definition of executives includes
oils and greases used in manu- plant managers.
FSMA Regulations
facturing and other related The FSMA has created six new types of
processes of food production.

criminal violations under the FD&C and
brought about the implementation of a
seventh. These violations are:

ML
Operating a facility not in compliance with the FSMA Preventive that may be intentionally introduced, including acts of sabotage
Controls Regulations (for both human and animal food) or terrorism, as well as develop a written analysis of the hazards.
Failure to comply with the FSMA Produce Safety Regulation A major piece of the required documentation is a food safety
plan. This plan addresses, among many other things, lubricants and
Failure to comply with the FSMA Food Defense Regulation
lubrication. It should also include written hazard analysis, preventive
Refusal or failure to comply with an FDA recall order controls, a supply chain program, procedures for monitoring preven-
Knowing and willful failure to comply with consumer recall tive controls, corrective action procedures, verification procedures
notification requirements and a recall plan.
The importing or offering for importation of a food if the
importer does not have a foreign supplier verification program
HACCP Principles
in compliance with the FSMA Foreign Supplier Verification The HACCP system provides a logical, scientific approach for
Program Regulation controlling safety issues in food production. The seven principles that
make up an HACCP plan are: to conduct a hazard analysis, identify
Failure to comply with the Sanitary Food Transportation critical control points, set critical limits for each critical control point,
Act Regulation
create monitoring procedures, determine corrective actions, develop
In September 2013, two melon farmers in Colorado were arrested record-keeping procedures, and establish verification procedures.
for violations of the FD&C Act following a deadly listeria outbreak
that was traced back to their produce. They pled guilty to the Hazard Analysis
charges and were sentenced to five years of probation, with the first According to the HACCP principle, conducting a hazard analysis
six months under house arrest, 100 hours of community service and involves preparing a list of steps in the process where significant
$150,000 to the victims of the outbreak. hazards occur and describing preventive measures. A food safety
In September of the following year, the former owner, president
hazard is defined as any biological, chemical or physical property
and CEO of the Peanut Corporation of America was found guilty
that may cause a food to be unsafe for human consumption. The
on 67 federal felony counts associated with a salmonella outbreak.
focus of this article is on the chemical properties.
His brother, who was the vice president of the company, was found
guilty on 30 charges.
While these are extreme examples, it is apparent the FDA is not
taking violations of the law lightly. It is also easy to see how plant
managers and others could be held criminally liable for food being
adulterated or contaminated with oils and greases used in manu-
facturing and other related processes of food production.
Other changes outlined in the FSMA include fees associated with
reassessments conducted by the FDA. The rate for these fees is $221
per hour for domestic travel and $285 per hour for international
travel, which can add up quickly. These fees are to be paid by the
responsible party within 90 days of receiving the invoice.
A Focus on Prevention
One of the cornerstones of the FSMA is the realization that the
FDA likely would not be staffed sufficiently to oversee all the changes
mandated by the law. Much of the burden falls on a companys CEO
and board of directors to ensure that the food they produce is safe.
The primary guiding principle is the application of the Hazard Anal-
ysis and Critical Control Points (HACCP) to the roughly 80 percent of
the food supply regulated by the FDA. This represents a major shift
in ideology. Previously, the focus had been on responding to contam-
ination in the U.S. food supply. Now the focus is on prevention.
Section 103 of the Food Safety Modernization Act deals specif-
ically with prevention. It requires the owner, operator or agent in
charge of a human or animal food facility which manufactures,
processes, packs or holds food to evaluate hazards that could affect
food safety, identify and implement preventive controls to prevent
those hazards, monitor those controls and maintain monitoring
records, and conduct verification and reverification activities. In
addition, the responsible parties are to identify and evaluate hazards

PERSPECTIVE
Based on the U.S. Department of Agri-

cultures Guidebook for the Preparation of
HACCP Plans, chemical hazards fall into
two categories: naturally occurring poisons,
chemicals or deleterious substances that
are natural constituents of foods and are
not the result of environmental, agricul-
tural, industrial or other contamination;
and added poisons, chemicals or delete-
rious substances that are intentionally or
unintentionally added to foods at some
point in growing, harvesting, storage,
processing, packing or distribution. This
second group of chemicals can include
lubricants, cleaners, paints and coatings.
The U.S. Department of Agriculture
stresses the importance of being aware of
chemical hazards at the following points:
prior to receiving chemicals at your facility,
upon receiving chemicals, at any point
where a chemical is used during processing,
during the storage of chemicals, during the
use of any cleaning agents or maintenance
chemicals, prior to shipment of the finished
product, and in trucks used to ship the
finished product.
Once the types of hazards and how they
occur have been identified, it is possible to
conduct an analysis for each process and/or
product to be covered under your HACCP
plan. This plan should be as specific to each
individual facility as possible. Separate the
analysis into two activities: brainstorming
and risk assessment. Also, if one does
not already exist, develop a process flow
diagram to identify each step in the process.
This may include a walkdown of the facility,
starting at the raw material delivery stage ation for hazards. Next, observe the actual Critical Control Points
and continuing through to loading of the operating practices. Finally, assess the likeli-
A critical control point is defined as
finished product. hood and severity of the hazards occurrence. a point, step or procedure in a food
The hazard analysis can be divided into The analysis should allow for the identifi- process at which a control can be applied
three steps: First, ensure that the prerequisite cation of all significant biological, chemical and, as a result, a food safety hazard can
sanitation standard operating procedures and and physical hazards for each step and each be prevented, eliminated or reduced to
others are in place, and evaluate your oper-
ingredient. You then will need to identify acceptable levels. After the hazards and
measures to prevent these hazards from preventive measures have been determined,
55%
compromising the safety of the finished it is possible to identify the points in the
product. These measures may include using process where the preventive measures can
only approved chemicals, such as food- be applied to prevent, eliminate or reduce
grade lubricants, having detailed product the hazard to an acceptable level.
specifications for chemicals entering the
of MachineryLubrication.com
plant, inspecting trucks used to ship the
Critical Limits for Critical
visitors use food-grade lubricants
at their plant, according to a
finished product, properly labeling and Control Points
recent survey storing all chemicals, and training employees A critical limit is defined as the maximum
who handle chemicals. or minimum value to which a physical,
ML
biological or chemical hazard must be sible personnel signing an acknowledgement. Validation of the HACCP plan will demon-
controlled at a critical control point to If a corrective action is required that has strate that it prevents, eliminates or reduces
prevent, eliminate or reduce to an acceptable not been previously identified in the HACCP all identified microbiological, chemical
level the occurrence of the identified food plan, this should be documented as well. It and physical hazards to a regulated and/or
safety hazard. In the case of lubricants, the may be necessary for the product to be held commercially feasible level. The responsibility
FDA has set this limit at zero parts per million for further investigation. This investigation for this validation rests on the regulated
for non-food-grade lubricant contamination. may include product testing, consultation industry. The validation assembles the data
with a third party or processing authority, or to prove that the HACCP plan developed and
Monitoring Procedures a thorough records review. implemented by a company will control the
Monitoring is essential to an HACCP process and prevent food safety hazards.
system. It can warn of an impending loss Record-keeping Procedures A reassessment should be performed at
of control so action can be taken before a Accurate and complete records are least annually to determine if the HACCP
critical limit is exceeded. Monitoring gener- important because they serve as written docu- system is adequate. A reassessment is also
ally will be more effective if the personnel mentation of compliance with the HACCP necessary any time new hazards have been
responsible for monitoring understand its plan. These records will allow you to trace the identified or when changes have occurred
purpose and importance, and are clearly history of an ingredient, finished product or in the process, ingredients, raw materials,
identified and properly trained. Monitoring in-process operation should problems arise. vendor, product volume, personnel, pack-
procedures usually relate to online processes. They can also help you identify trends in an aging, distribution or any other factor that
operation that could result in a deviation. could affect the hazard analysis.
Corrective Actions HACCP systems should include records for
In conclusion, as the FDA continues its
efforts to fully implement the Food Safety
Once the HACCP plan is implemented, critical control points, establishment of critical
Modernization Act, companies that manu-
corrective actions must be taken any time a limits, how deviations were handled and the
facture food and beverage products must
critical limit is not met. These actions should results of verification activities. These records
prepare for the changing requirements. If
include determining the disposition of a must contain the product identification, crit-
they fail to comply, their plant managers
non-compliant product, correcting the cause ical criteria, time and date of the observation,
could face hefty fines, criminal prosecution
of the non-compliance to prevent a repeat, and the monitors and reviewers signatures.
or even imprisonment.
examining the process or product again at the
control point to ensure the results are within the Verification Procedures About the Author
limits, and maintaining a record of the correc- The HACCP system should be assessed
Loren Green is a senior technical consultant
tive actions and results of the applicable testing. periodically to ensure it is working correctly.
with Noria Corporation, focusing on machinery
Under HACCP, the actions to be taken in Among the points to evaluate would lubrication and maintenance in support of
the event a critical limit is not met at a critical include the monitoring equipments cali- Norias Lubrication Program Development
control point must be established in advance. bration process, any corrective actions, (LPD). He is a mechanical engineer who holds
Personnel responsible for monitoring the and observations of monitors and moni- a Machine Lubrication Technician (MLT) Level
critical control points should understand the toring activity. A periodic evaluation of II certification and a Machine Lubricant Analyst
process and be trained on how to perform employees is also recommended to ensure (MLA) Level III certification through the Inter-
the corrective actions. All corrective actions that corrective actions are performed and national Council for Machinery Lubrication
should also be documented, with the respon- documented properly. (ICML). Contact Loren at lgreen@noria.com.

TRAINING AND CERTIFICATION Lubrication Programs
Newcrest Minings Cadia Valley

Operations
WINS GILL AWARD
B y Suzy Hitchcock, ICML
Newcrest Minings Cadia Valley Gill Award Criteria
Operations in Australia has been
Designed to motivate companies to
selected as the recipient of the 2016
Augustus H. Gill Award by the International improve machine reliability and mainte-
Council for Machinery Lubrication (ICML) for nance quality through the application of
excellence in oil analysis. oil analysis, the Augustus H. Gill Award
Lubrication specialist Greg Romer accepted has specific criteria for potential recipients.
the award on behalf of Cadia at the Reliable These include:
Plant Conference & Exhibition in Columbus, Commitment to education
Ohio. Romer credited Newcrests culture of Maintenance culture and management
providing opportunities to not only develop support
personally but also professionally as a big
factor in the success of the program. Newcrests Performance measurements used
award-winning program has had significant Proactive/predictive maintenance
benefits for the company and the site in terms Newcrests Greg Romer accepted the Use of standardized procedures
of savings, both through maintenance practices Augustus H. Gill Award from the International
and inventory management. Council for Machinery Lubrication at the Technology integration
The implementation of sound condition Reliable Plant Conference & Exhibition.
Contamination control
monitoring practices demonstrates time and clear goals, key performance indicators (KPIs)
again that precision-based maintenance is and task allocations. Specialized training in Lubrication management
the future of business models, Romer stated. lubrication and oil analysis was undertaken Oil analysis methods and strategies
Without the support of key mentoring figures with accompanying certification. By 2012,
Use of information technology
(within Cadia Valley Operations), identifying a recruitment program had been initiated,
key individuals and making awards like this a targeting non-trade personnel. These new Continuous improvement
reality, the opportunities to strive for contin- lubrication technicians were trained with Both the Augustus H. Gill and John R.
uous improvement are never appreciated. industry best practices learned and tested by
Battle awards are open to organizations
Cadia began its efforts toward improved way of Noria training and ICML certification.
worldwide independent of any involvement
lubrication practices in 2009. An onsite audit For the remainder of the sites workforce,
with ICML. To avoid bias, ICML has chosen a
was performed, the results correlated, and a plan including the skilled tradespeople, supervisors,
policy by which it does not nominate compa-
created. Changes were then made, including the superintendents and contract labor, training
nies. Instead, nominations must come from
appointment of an asset manager. The reliability in best practices was developed in-house. The
department soon experienced growth with two role of the lubrication technicians was then the companies directly via an application.
lubrication specialists hired in 2011. more clearly defined with procedures created If you know of an organization that
The lube specialists were tasked with based on the required tasks. deserves to be recognized for its
mapping the entire lubrication program. This Our team has demonstrated profession- machinery lubrication or oil analysis
led to the development of work procedures, alism, structure and sustainability, Romer program, encourage them to apply for an
in-house training, inventory consolidation, said. Cadia is not unique in its approach or ICML award.
identification of business risks and optimization success. What allows this site to stand proud To submit a nomination for one of
of a preventive maintenance (PM) strategy. A is the support from the management and ICMLs recognition of excellence awards,
working committee was also established with leadership of the site. visit www.lubecouncil.org.
CERTIFICATION NEWS
RECENT RECIPIENTS OF ICML CERTIFICATIONS

THE INTERNATIONAL COUNCIL FOR MACHINERY LUBRICATION (ICML) CONTINUES TO
provide skill certification testing for professionals in the areas of oil analysis and machinery lubri-
cation. The organization offers three certifications: Machine Lubricant Analyst (MLA), Machine
Lubrication Technician (MLT) and Laboratory Lubricant Analyst (LLA). ICML congratulates the
following individuals who recently achieved certified status in one of the three certification areas.
Abubaker Elsiddig Elmahi Razanakolona Harison Fidele, C&W Services Delgrosso S.P.A.
Suliman, MLA I MLT I & MLA I Brian Cook, MLT I Giovannino Atzori, MLT I
Elamin Osman Elamin Rvoharinjaka Tanjona Alidera,
Cargill Domtar
Mohammed, MLA I MLT I & MLA I
Ian Lorentzen, MLT I Bobby Hanson, MLT I
Jin Hongbin, MLA I Soatianiana Jean Yves, MLT I
Vitor Assis Leal, MLT I Richard Hoyt, MLT I
L. Viraraghavan, MLA II & MLA I
Tadahy Jean Eddit, MLA I & Cementos BSA Doosan Infracore
ACA BIO
MLT I Sandrino Cabrera Peralta, Dae Ho Kim, MLA II
Ariel Meinardi, MLT I Tiandrazana Ahail, MLT I & MLA II
Martn Bravi, MLT I MLA I DRAX Biomass
Cenovus Energy Shawn Baughman, MLT I
Aerzen Williams Joseph Martial, MLA
Cory Randall, MLA I
Scott Leitch, MLT I I & MLT I DSME
AGL Americas Styrenics Centralia College Sung Bum Hong, MLA II Need to take
John Higgins, MLA I Timothy Stacy, MLT I Tyson Lucas, MLT I
DuPont an exam?
Mark Baines, MLA I Anglo American CertainTeed Gypsum Brittany Chambers, MLT I ICML regularly holds exam
Johannes Ferreira, MLA I John Dale, MLT I Cody Welch, MLT I & MLA I sessions throughout the
Albemarle Corp.
Richard Wolstenholme, MLT I CH2M Corey Hall, MLT I United States and the
Cole Bradley, MLT I
Tobias van Rhyn, MLA I Paul Horigan III, MLT I David Prusack, MLT I world. Upcoming dates
Jake Miller, MLT I
Werner Combrinck, MLA I Jason Milhoan, MLT I and locations for ICML
Samuel Garrett, MLT I Chemours
ArcelorMittal Energy Solutions exams can be found at
ALS Ashton West, MLT I
Justin Nichols, MLA I Chris Hardcastle, MLA I www.lubecouncil.org.
Michael Holloway, MLA I Dan Grant, MLT I
Ash Grove Cement Jacob Logue, MLT I Entergy
Ambatovy
Andriamahandry Nofy Malala, Chris Gauldin, MLA I China Petroleum Colton Smith, MLA I
MLT I & MLA I Axion Energy Liu Benzu, MLA I Eskom
Andrianoniarivo Ratsimihara Facundo Diaz Falu, MLT II Zhang Hao, MLA I Siphiwe Molly Sithole, MLA I
Robert, MLA I
Beijing Runcheck Oil City of Chandler Euro Motor Service
ICML Certifications
Augustin Mampoina Tojosoa Joe Maestas, MLT I
Condition Monitoring Marco Della Tommasina, MLT I
Ranjatoson, MLT I & MLA I
Technology LLA I
Lahady Jos Harrison Ferdi- CNOOC Euxinio Industrial
Cui Chao, MLA I L aboratory Lubricant
nand, MLA I Chen Demin, MLA I Martin Heriberto Garcia
Gu Qian, MLA I A nalyst Level I
Maminandrasana Jean COFAC Sotelo, MLT II
Zhu Hong, MLA I
Francois, MLT I & MLA I Manuel Sumpf, MLA II Fernandes Autohandel MLA I
Maraina Lusaac Jean Beijing Dotate
Commercial Motors Faid Ilfaz Khodabaks, MLA I M achine Lubricant
Brisinelh, MLT I & MLA I Fan Gang, MLA I
Carlos Miliani, MLA I
A nalyst Level I
Rabemanana Andriama- Bel-Ray Filtramax
honosoa Tanteliniana, MLA I Glenn Kalber, MLT I Constellium Wade Gillard, MLT I MLA II
Rakotomalala Andriantsoa, Delbert Griffin, MLT I M achine Lubricant
BHP Billiton Finning
MLT I & MLA I James Whitley, MLT I A nalyst Level II
Camila Veronica Orellana Julio Cesar Sepulveda Solis,
Rakotomanga Rija Mandimby, Michael Taylor, MLT I
Sotelo, MLA II MLA II
MLT I & MLA I MLA III
Rakotonirina Fidiniaina Serge, Michael Lepe, MLA II Continental Building FloSolve
Products M achine Lubricant
MLA I BMG World Nicolaas Scheepers, MLA I
Ralaivao Tolojanahary Pierre, Kevin Hutcheson, MLT I A nalyst Level III
Brian Bauer, MLT I Fluid Specialty Services
MLA I Francisco Martinez, MLT I Costa Rican Institute MLT I
Anderson Benites Zelaya,
Ralalanjatovo Faliniaina, MLT of Electricity
I & MLA I Boise Paper MLA I M achine Lubrication
Jocseline Maria Hidalgo
Benjamin Brown, MLT I & Carlos Martin Mejia Garay, Technician Level I
Ranarivelo Herinomenjana- Porras, LLA I
MLA I MLA I
hary, MLT I & MLA I
Randrianarivelo Abela Valison,
Chris Payne, MLT I CRH Canada Javier Alberto Chavarria MLT II
Taylor Roberts, MLT I & MLA I Shawn Berube, MLT I Salazar, MLA I M achine Lubrication
MLA I
Ratovohery Franck Tsiory, Bunge Dale Technical Services Fuchs Technician Level II
MLA I Paulo Merlim, MLT I Jimmy Zednick, LLA II Timothy Vaughan, MLA I

CERTIFICATION NEWS
Fushun Petrochemical Jeld-Wen Noria Kevin Vickers, MLT I MLA I

Guo Zhijun, MLA I Rhyan Barnett, MLT I Gustavo Huicochea Luciano Silva, MLA I
Sappi
Hernandez, MLT II Madson Silva, MLA I
General Dynamics JR Simplot Peter Hammond, MLT II
Maicon Mateus Lopes Melo,
James Crabtree, MLA I Brandon Nelson, MLT I Novelis Corp.
Saputo MLT I
Michael Miera, MLT I Nolan Williamson, MLT I
General Mills Jude Fernando, MLA I Marcio Braga, MLT I
Stuart Nichols, MLT I
Donald Barton, MLT I Kapstone Paper Peter Mckenzie, MLA I Paulo Ricardo Souza, MLA I
Johnny Brooks, MLT I NV Energy Rafael Silva, MLA I
Georgia Pacific Schulz Group
Sherman Smith, MLT I Rishikesh Velkar, MLA I Reginaldo Neves Ferreira,
James Hebert, MLT I Joey Curl, MLT I
John Sikes, MLT I Kirkland Lake Gold Oelcheck MLT I
Siemens Romulo Muniz, MLA I
Michael Williams, MLA I Trent ODonnell, MLA I Arne Simon, MLA II
Karl Luber, MLA II Vinicius Silvino Moreira,
Carmen Demel, MLA II
Gerdau Korea Midland Power
Carolin Ellerbrock, MLA II SKF MLT I
Anderson Teixeira Mancilha, Gil Won Yang, MLA II
Christopher Wolter, MLA II Nelver Daniel Sanchez Barba, Warlen Faustino Dias, MLT I
MLT I Yu Beom Won, MLA II
Florian Aigner, MLA II MLA I
Tamiris de Souza Marchetti, Ventas Tecnicas
LafargeHolcim Stefan Feichtenschlager,
MLA I Solvay Manuel Balboa Navarrete,
Greg Jenkins, MLT I MLA II
Mitchell Friedman, MLT I Ben Amos, MLT I MLA II
Glencore
Richard Micheal, MLT I Oleotec Corey Best, MLT I
Kevin Gill, MLA I Visy Industries
Mario Norberto Salazar
Lehigh Hanson Starcon Anthony Gott, MLA I
Huber Engineered Woods Eagleston, LLA I
Walter Asher, MLT I Ricardo Gutierrez, MLT I
Nathaniel Weaver, MLT I Vivo Energy
Onyx Dynamic Balancing
Thomas Crillo, MLT I Logan Aluminum Sun Products Dinafitiavana Herimanitra
Services
Travis Gidcumb, MLA I Michael Talbot, MLA I Andriamiharivelo, MLT I &
Hyundai Vinay Sharma, MLA II
Hong Gyu Jeon, MLA II MLA I
Lubrication Engineers SunCoke Energy
Owens Corning
Brody Perloff, MLA I Jonathan Reynolds, MLA I VT Group
Hyundai Steel Anthony Pittman, MLT I
Jong-hyeong Kim, MLA II John McDonald, MLT I Bryan Gonyeau, MLT I Brenda McQuitty, LLA II
Suncor Energy
Mallinckrodt Pharmaceuticals Drew Rice, MLT I Azuma Hashimoto, MLA II Westlake Chemical Co.
Indian Oil Corp.
Joshua Edenfield, MLT I Glen Miller, MLT I Benjamin Kernan, MLA II Aaron Hinson, MLT II
Abinash Kumar, MLT I
Henry Hill III, MLT I Colin Haley, MLA II Devin Snyder, MLT I
Arjun G. Singh Tuteja, MLT I Max Holder Jacob Pease, MLT I Imed Ben Amor, MLA II Josh Wille, MLT I & II
Industrial Lubrication Rainer Schairer, MLA II Leslie Ricca, MLT I Shane Elligson, MLA II Michael Cooper, MLT I
Services Mecoil Micah Davidson, MLT I Siddharth Gupta, MLA II Will Anderson, MLT I
Brad McLendon, MLT I Fabio Baracani, MLT I Michael Taylor, MLT I William Kung, MLA II
Dustin Owens, MLT I Travis Huff, MLT I WestRock
Michelin Synergia Winfred Vick, MLT I
Industrial Sealing & Burney Lang, MLT I Oxy USA Claudio Ruggieri, MLT I
Lubrication Justin Bender, MLA I Wade Dunn, MLA I Weyerhaeuser
David Consiglio, MLT I TestOil Albert Stigall, MLT I
Ray-Allen Hoedebeck, MLT I
Pall Corp. Evan Reddish, MLA I Andrew Free, MLT I
International Paper Mighty Construction Tian Yonghong, MLA I Rebecca Tharp, MLA I Anthony Huffman, MLA I
Ahmad Moore, MLT I Everton Eastwood, MLT I
PCA Texas Pride Fuels Brandin Frost, MLT I
Allan (Chris) Harley, MLT I
Minera Centinela Emmitt Dendy, MLT I & MLA I Michael Kolek, MLA I Brandon Swanson, MLA I
Calvin Smith, MLT I
Robin Aguirre Opazo, MLA II Jason Gunter, MLT I & MLA I Christy Heath, MLA I
Ernest Sullivan, MLT I Tribologik
Everett Stokes, MLT I Kevin Harrison, MLT I & MLA I Corbin Tolen, MLT I
Mosaic Co. Frederick Moore, MLA I
Joshua Davis, MLT I David Vanegas-Lytle, MLT I
Aaron Crosbie, MLA I Petronas
Matthew Torchia, MLT I UAMPS John Richardson, MLT I
Alexander Dally, MLA I Francesco Bellino, MLT I
Michael Wooten, MLT I Kenyon Savage, MLT I Keely Dolan, MLT I
Angela Halladay, MLA I Mariangela Valentino, MLT I
Neal Crout, MLT I Kevin Beedle, MLT I
Brian Deschytza, MLA I Vale
PF Resolu Lloyd Lester, MLT I
William Paschal, MLT I Garrett Hinck, MLA I Alexandre Isac de Campos,
Hatim Benazzouz, MLT I & Luis Landeros, MLA I
Intertek Jamie Blaczczok, MLA I MLT I
MLA I Nathan Douglas Toney, MLT
Sreekumar Puzhankara, Jeff Stapleton, MLA I Antonio Carlos Soares, MLA I
Joel Mercier, MLT I II & MLA I
MLA II Nita Larson, MLA I Charlyton Sousa, MLA I
Rene Turgeon, MLT I Niels Kristensen, MLT I
Shawn Rempel, MLA I Claudio Zamana, MLA I
Vivek Veliyamparambath, Tim Rochon, MLT I
Terrance Sturm, MLA I Robert Crawford, MLA I
MLA II Cleber Junio da Silva, MLT I
Pollard Banknote Ryan Dunn, MLA I
National Oilwell Varco David Cruz, MLA I
J.D. Irving Christopher Pollins, MLT I Edvaldo Marciano Vascon- Ryan Hokema, MLT I
Mark Smith, MLA I
Aimee Van Wart, MLT I Gerald Maniacco, MLT I celos, MLT I
Patrick Kinsey, MLA I Wolf Creek Nuclear
Jeremie Richard, MLT I
Zehan Han, MLA I Pure Lubricants Emanuel Edilson Jr., MLA I Operating Corp.
Nicholas Lawson, MLT I &
D. Hemalatha, MLA II Glauciany Raquel Oliveira, Matthew Dekat, MLA I
MLA I NB Power MLA I
Nicholas Meekins, MLT I Robert Peacock, MLT I & Rio Tinto Xcel Energy
Ivan Santos, MLA I
Robert Richard, MLT I MLA I Chad Toleafoa, MLT I Glen Green, MLA I
Jackson Santos, MLA I
Thomas Parsons, MLT I Timothy Cox, MLA I
Sabic Jairo Jose Drumond Andrade, Z3 Technical &
Jacobs New Covert Generating Co. Allan Way, MLT I MLT I Commercial Consulting
David Gillis, MLA I Kevin Palmore, MLA I Dustin Hickey, MLT I Leonardo Andre Carvalho, Jose Maria Zatarin, MLT I

Global Training Calendar
October MACHINERY LUBRICATION II MACHINERY LUBRICATION I
Point Lisas, Trinidad October 24 26, 2017 Villahermosa, Mexico November 6 11, 2017
MACHINERY LUBRICATION I
Alexandria , Egypt October 1 4, 2017 OIL ANALYSIS I ADVANCED MACHINERY LUBRICATION
Johannesburg, South Africa October 24 25, 2017 Daegu, South Korea November 13 16, 2017
Firenze, Italy October 11 13, 2017 OIL ANALYSIS II
Guangzhou, Guangdong Province, China November 14 16, 2017
Johannesburg, South Africa October 26, 2017
2001 LUBRIFICATION DE MACHINERIE 1
FUNDAMENTALS OF MACHINERY LUBRICATION
Montreal, Canada October 17 19, 2017 OIL ANALYSIS III Buenos Aires, Argentina November 14 16, 2017
MACHINERY LUBRICATION I Johannesburg, South Africa October 27, 2017
PRACTICAL OIL ANALYSIS
Johannesburg, South Africa October 23 26, 2017 November Dhaka, Bangladesh November 20 22, 2017
OIL ANALYSIS I HOW TO READ AN OIL ANALYSIS REPORT MACHINERY LUBRICATION II
Rotterdam, Netherlands October 24 26, 2017 Villahermosa, Mexico November 6 11, 2017 Kingston, Jamaica November 21 23, 2017
ICML certification testing is available for most of the courses listed.

Visit www.lubecouncil.org for certification information and test dates.
Oil Analysis
BACK PAGE BASICS

G arrett B app | N oria C orporation
VOLATILITY
VS.FLASH POINT:
What You Should Know
A number of testing methods

can be used to determine
the performance charac-
teristics of a lubricating oil.
Two common tests that have endured over
time are flash point and volatility. Although
the methods, technology and practices have
changed through the years, both of these
tests are still utilized today and provide viable
ways to assess new and used oils.
Flash Point
The flash point test dates back to the
mid-19th century as one of the earliest iden-
tifiers of an oils physical properties. It was
originally used to determine the fire hazards
of fuels and oils being stored and transported.
The flash point test measures the
tendency of an oil to form a flammable
mixture with air. Once the oil sample is
heated, a flame is exposed to the headspace.
Ignition is the determining point. The lowest
measured temperature at which the oil will
ignite or flash is recorded as its flash point.
If the test is performed over a longer period
of time, the oils fire point can be obtained.
The fire point is when ignition is sustained
for five seconds.
Several methods can be employed to
determine an oils flash point. Each varies
degrees F) and flash points below 93 degrees C (140 to 374 degrees F).
depending on the fluids viscosity and the
chosen technique. Among the ASTM tests C (220 degrees F). ASTM D92, Flash and Fire Points by Cleve-
that are available include ASTM D56, Flash ASTM D93, Flash Point by Pensky-Martens land Open Cup, is another option for obtaining
Point by Tag Closed Cup Tester. It is utilized Closed Cup Tester, is used for petroleum prod- an oils flash point. Although the technology
for viscosities below 5.5 centistokes (cSt) at ucts with a temperature range of 40 to 360 has evolved, the open and closed cup tests of
40 degrees C (104 degrees F), as well as for degrees C (104 to 680 degrees F) and biodiesel today closely resemble the practices of more
viscosities below 9.5 cSt at 25 degrees C (77 with a temperature range of 60 to 190 degrees than 100 years ago. While often seen as a

BACK PAGE BASICS
While the flash point

precursory test of new oil, flash point can also
be utilized in used oil analysis to detect fuel
tells you very little

dilution, base oil cracking and contamination.
Volatility
The Noack volatility test was developed by
about an oils volatility,
an oils volatility can
Dr. Kurt Noack in the 1930s and first used in
Europe. It was introduced as a way to reveal
tell you a lot about its

the evaporation loss of lubricating oils. In
1984, Al Amatuzio began using the test in the
flash point.
United States to determine the performance
of motor oils. Volatility testing became stan-
dard for North America in 1992 with the
creation of the American Petroleum Institutes
SH/International Lubricant Standardization
There are three different procedures as poor oil circulation throughout the engine,
and Approval Committees GF-1 oils, which
for ASTM D5800: Procedure A, which uses greater oil consumption, higher wear rates
set the bar for the current standards in envi-
the Noack evaporative testing equipment; and increased emissions.
ronmental emissions and fuel economy.
Volatization is a term used to describe the Procedure B, which employs the automated
boiling off of lighter molecules in fluids. It non-Woods metal Noack evaporative appa- Tests That Serve a Purpose
ratus; and Procedure C, which utilizes the Flash point and volatility tests serve a
is closely related to oil consumption in auto-
Selby-Noack volatility test equipment. purpose, just for different conditions. They
mobile engines. The test simulates the oils
Procedure A was first introduced in the are also related. After all, for an oil to reach
reaction to internal temperatures associated
1930s using a toxic mixture of compounds its flash point, it must first volatize. While the
with piston rings and cylinder walls.
known as Woods metal for sample heating. flash point tells you very little about an oils
Known as ASTM D5800, the Noack
Woods metal, also called Lipowitzs alloy, volatility, an oils volatility can tell you a lot
volatility test reveals the evaporation loss of
contains bismuth, lead, tin and cadmium. The about its flash point. Volatility testing has
lighter oil molecules and additives at high
toxicity comes from the lead and cadmium. proven that with better base oils, improved
temperatures. Depending on the method,
The Selby-Noack test was developed in emissions and fuel economy will follow.
a measured sample quantity is placed in a
the mid-1990s by Theodore Selby and his Keep in mind that synthetic lubricants
crucible or reaction flask and heated to 250
generally have higher flash points and do not
degrees C (482 degrees F), with constant air colleagues using a noble metal heater. It elim-
begin to evaporate until a much higher
flow drawn through for 60 minutes. Assessing inates the need for Woods metal and utilizes
temperature is reached. On the other hand,
the before and after weight will determine the a collection of evaporated material for later
mineral oils may start to vaporize much earlier
evaporation loss. analysis. This is particularly useful in identifying
than their flash points. If you are dealing with
elements such as phosphorus, which is known
hazardous conditions, a flash point test is a
to lead to premature failure of catalyst systems.
staple that simply must be conducted.
Volatility testing plays an important role in
84%
engine lubrication where high temperatures About the Author
occur quite frequently. Evaporation losses can
Garrett Bapp is a technical consultant with
be seen in the amount of oil consumption or
Noria Corporation, focusing on machinery lubri-
the need for top-ups. This can also result in a cation and maintenance in support of Norias
of lubrication professionals change in the oils properties, as additives may
do not conduct flash point Lubrication Program Development (LPD). He
or volatility testing to evaporate during the volatilization process. is a certified lubrication specialist through the
assess new or used oil, As lighter molecules burn off or evapo- Society of Tribologists and Lubrication Engineers
based on a recent poll at
MachineryLubrication.com rate, heavier molecules remain, causing a shift (STLE) and holds a Machine Lubrication Tech-
in the fluids viscosity. Leaving behind heavier nician (MLT) Level II certification through the
or thicker oil can contribute to reduced fuel International Council for Machinery Lubrication
economy due to added viscous drag as well (ICML). Contact Garrett at gbapp@noria.com.

THE OLD WAY THE NEW WAY
Detect Lubricant Problems, Faster.

Stop using those old dark, hard-to-read flat sight
glasses. The Luneta Sight Glass provides a crystal- Sight Glass Features
clear, 360-degree undistorted view of in-service oils. Quick 360-degree view of oil
Our Sight Glass is shatterproof, chemically resistant Accurate oil level monitoring
and is made to withstand your harsh environment, Tritan material stronger than bullet-
including extreme temperatures. Youll never want proof glass
to use those hard-to-read sight glasses again! Integrated eyelets for ID tags or other
lubricant information
See the difference at Luneta.com
Volume discounts are available, call

1-888-742-2021 for more information.
Go to noria.com/quicktips/ for more videos.

Why a Lubrication Program?
Mechanical wear and corrosion (chemical degradation) make up approximately 70 percent of industrial machine failures,
costing companies millions of dollars each year. Unfortunately, many companies dont realize their mechanical problems
can be traced back to poor lubrication practices, even though lubrication represents one of the easiest cost categories to
streamline and control. Both wear and corrosion can be mitigated or prevented by proper lubrication practices.
Most organizations conduct maintenance that includes lubrication, but few recognize the serious potential of comprehen-
sive analysis, training and implementation of excellent lubrication practices particularly those that are proactive.
Noria can give your organization an individualized lubrication system, personnel training on best practices and continued
access to a network of industry experts all in one comprehensive program.
... we believe the cost savings

from the avoidance of lost
production and gear failures
could be up to
$1 million a year
Tim Newman, Maintenance Manager,
Simmons Feed Ingredients
1328 East 43rd Court | Tulsa, Oklahoma 74105 | Phone: 800.597.5460 | noria.com
Lubrication Program Development (LPD)
Achieving lubrication excellence translates into major benefits for your company,
but it can be an overwhelming endeavor for busy plants that need effective, sus-
tainable solutions you can use immediately. With Norias Lubrication Program De-
velopment (LPD), we deliver just that. We will guide you through the entire program
to create the individualized, high-performing system you need.
Program Results:
Significant Cost Savings: Operational costs decrease, fewer necessary
repairs, less downtime, more profit
Greater Efficiency: Achieve ROI ahead of schedule, increase life and function-
ality of plant machinery
More Knowledgeable Staff: More skilled maintenance staff, more organized

lubrication tasks, personnel able to handle lubrication issues in-house, major cul-
tural shift to better performance
The Rights of Lubrication

Right Lubricant
Right viscosity, additives, type, grade,
thickener, for every machine
Right Place
Every lube point dont miss any
Right Amount
Precise calculated volume for greases
and oils
Right Time
Precise calculated interval and condi-
tion-based
Right Tools
Inspection, sampling, contamination
control, procedures, etc.
Right People
Background, skills, training,
ownership
Launch Phase
Getting your lubrication program off to
the right start has never been easier.
The launch phase of Norias Lubrication
ICANT SELECTION
Program Development will help you LUBR
S2P
achieve best practice while avoiding S1P
S3P
pitfalls and wasted resources. Youll L RE
SA R1
P C
receive a customized roadmap in line
EP
P S4M S5M
SP
TIO
with your priorities and budget which
D2
DI
R2
AL
N
is designed to rapidly deliver value R
AN
M
NT
D3
5M
S6K
DS
ME
and quick wins with each phase. The
ON
TOR
R3P
launch phase includes:
ENVIR
AGE
D1P
R7
K
D4M
D5
A 540-point Onsite Assessment
R6M
K
R4P
This onsite assessment is an important
step in evaluating the health of your
H8M
lubrication program. A Noria expert A5M
A4P
H3P
ION
spends a full day assessing your current
H7M
A8
K
H9
K
lubrication practices.
ICAT
LUBR
M
A6
A3P
H6
PPL
M
SWOT Analysis - Once the cur- C 5K

ICA
5M
P
A7 H
H2
DA
NT
rent lubrication programs strengths, M M

H4
A2
AN
AN
weaknesses, opportunities and threats

P
C3M C4 M
AL
G
A1 P
IN
YS
are identified, an accurate map for P H1
DL
IS
N
the future is created. You will gain an HA
C2P C1P
understanding of what you are doing
CON
well, where you can and should imme- TAMINATION CONTROL
diately improve, and where there might
be low-hanging fruit that you can take
advantage of immediately.
LPD Sample Chart
Analysis of 40
Program Elements - There are
40 critical elements to lubrication
PLATFORM
LUBRICATION
MANAGEMENT SELECTION
(S)
KPIs
ENVIRONMENTAL RECEPTION
DISPOSAL & STORAGE
(D) (R)
SCORE SCORE SCORE

LUBRICANT HANDLING &
ANALYSIS APPLICATION
(A) (H)
CONTAMINATION
CONTROL
(C)
Management Levels
Management Levels Program
Program Stages
Stages Elements
Elements
Launch Phase Cont.
program success. A score is assigned to each of these elements, comparing your

programs current state to best practice.
25 Priority Next Steps - The 40 critical elements are weighted and prioritized
to determine which actions should be performed first to maximize your investments
and make the biggest reliability and ROI impacts.
Financial Cost Justification - It is inevitable that improving your lubrication

practices will require a financial investment. To help maintenance and plant manage-
ment understand the financial benefits, the costs of the plants current lubrication
practices will be evaluated. Comparing the opportunity costs versus the investment
provides the payback. The internal rate of return (IRR) is 5-year net present value.
Audit and Review Recommendations - To keep a lubrication excellence

program operating at a high level, Noria supplies the information you need to per-
form periodic audits and review each of these elements so your program will remain
on track.
Metrics and KPI Recommendations - Measuring progress and compliance with

your program goals will be critical to program success, as what gets measured gets done.
Dozens of KPI recommendations will be provided for everything from lubricant storage and
handling to contamination control.
Lubrication Program Manager - Planning and tracking progress is key to a success-

ful lubrication program transformation. The online lubrication program manager will support
you throughout your journey, providing plant and corporate-level planning boards, and
priority next steps.
Lubrication Awareness Training - The process of transforming a lubrication

program to best practice requires a high level of communication. This half-day training
ensures those involved in the program are aware of their roles and responsibilities as well
as managements expectations for deployment. In addition, it focuses on the importance of
lubrication excellence and contamination control to help get your team on the same page.
Engineering Phase
During the Engineering Phase, a team
of Noria experts will survey all your
lubricated assets to collect informa-
tion needed to engineer an optimized
lubrication program. From this data,
we strategically engineer every pro-
cedure from a proactive maintenance
mindset, seeking to eliminate the root
causes of machine failure that stem
from poor practices. Each procedure
includes a job plan and complete
description for each task.
Why Procedures?
Work Scope - Procedures clearly
specify the work an individual is ex-
pected to perform.
Consistency - Documented proce-

dures bring uniformity to the lubrica-
tion task while keeping everyone on
the same page.
Best Practices - A procedure

creates the framework for standard-
izing best practice and disseminating
expertise among employees.
Training - Procedures form the

basis for training lubrication person-
nel, serving as a natural curriculum for
task-based training and evaluation.
Engineering Phase Cont.
Engineering Deliverables
Lubricated machine master list in functional hierarchies (location, area,
machine, component, lubrication point)
The lubrication worksheets include links to the full, documented, best-

practice procedure that outlines: completion time, operating state,
frequency, location, materials and tools, purpose, scope, summary
(with volume and optimum lubricant) and detailed steps.
Oil analysis test slates and sampling frequencies for all critical oil-
lubricated assets
Lubrication routes with calculated lubricant volumes and frequencies

(time-based skilled lubrication tasks and inspections)
Manpower assessments
On-condition tasks (top-ups, filtration, oil changes, etc.)
Machine hardware modification recommendations
Lubricant consolidation
Implementation
Implementation involves taking the procedures, guidelines and practices de-
veloped in the Launch and Engineering Phases and integrating them into your
plants lubrication program. Noria supports you with integrating procedures
and pertinent data into your plants CMMS or scheduling software, scoping and
installing lubrication hardware and accessories, safely changing lubricants where
needed, building lubrication routes, managing an oil analysis program, coaching
and developing your team, and establishing key performance indicators (KPIs)
and metrics for sustainable program success.
Customer Support and Partnership

Noria has procurement specialists dedicated solely to managing the ordering,
logistics and delivery of your implementation. Ongoing email, telephone and
web-conference support by our technical team can also be provided.
Vendor Neutrality
Norias vendor neutrality ensures an impartial, unbiased presentation of the require-
ments necessary for hardware implementation. Noria does not recommend one
suppliers products over anothers, maintaining the strictest vendor-neutral integrity.
HELP Training
Norias Hands-on Excellence in Lubrication Program (HELP) is a training program
that facilitates consistent and accurate implementation of the lubrication program.
HELP primarily focuses on demonstrating the hands-on skills necessary to run a
successful program.
Knowledge & Skill - Using task lists, work procedures and job descriptions,
we define and map your organizations knowledge and skill requirements to
perform all tasks.
Knowledge Check Assessment - Provides an overall summary of your

teams current understanding of key lubrication knowledge.
Qualification - Skill competency for each element is assessed and measured.
Just-in-Time Training - We coordinate the trainings to occur when your new

equipment arrives or is available, supporting the program implementation.
(HELP) Training Courses
Max #
Course Attendees Week 1 Week 2 Week 3 Week 4
Lubrication 101 (Classroom) 25 1 day
Hands-on Hardware Modifications 10 2.5 days 0.5 days
Hands-on Lube Room, Lubricant Handling 10 2 days

Hands-on Lubricant Validation and Change Out 10 0.5 days
Hands-on Oil Sampling 10 0.5 days
Hands-on Routine and On-Condition Tasks 10 1.5 days

Hands-on Machine Inspections 10
Oil Analysis, Test Slates and Data Interpretation 10 1 day
Management Training 10 1 day
Machinery Lubrication Level I and Certification 25 3.5 days
Sustain
Maintaining lubrication excellence
beyond Norias Lubrication Program
Development means personnel must
seek continuous improvement. Noria
addresses this need by providing ac-
cess to its technical team for as-needed
consulting, failure investigation, training,
job skills assessments and diagnostic
support.
Monitoring Program Success

Norias extensive knowledge of oil
analysis means clients have access to
world-class monitoring practices. Noria
can support ongoing best practices
by implementing testing and training
to interpret data within the context of
individual plants and goals.
Case Studies from Customers
Lubrication Program
Enables Simmons Feed
to Cut Downtime
by 50 Percent
The Simmons Feed Ingredients plant in Southwest
City, Missouri, brought in Noria consultants to develop
a roadmap for lubrication excellence. After implement-
ing Norias Lubrication Program Development and
training, the facility was able to achieve cleaner oil,
prevent machine failures, avoid lost production and
save up to $1 million a year.
For the Sinclair

Wyoming Refinery,
machinery
lubrication was a
trouble spot until
Noria helped put it in
the spotlight.
Norias onsite training and Lubrica-
tion Program Development helped
transform the Sinclair Wyoming
Refinery into an industry leader for
machinery lubrication. With guidance
from Noria, the refinery was able
to shift to a proactive maintenance
approach and adopt best practices,
significantly impacting its operations
and bottom line.
Improved Lubrication Practices Stop

Machine Failures at TEP
As part of its Lubrication Program Development (LPD), Norias team of
consultants devised a plan of attack to put the Tucson Electric Power
(TEP) generating station in Springerville, Arizona, on the path to lubri-
cation excellence. The plant now sees far fewer equipment problems
due to insufficient or improper lubrication, and its lubrication-related
machine failures have been reduced dramatically.
For More Case Studies Visit

noria.com/serv/customers/
Noria Workforce you get Noria lubrication technicians, a Noria lubrication pro-
gram and Noria expert support.
Solutions
Short-term Services Need help upgrading your lube
Some customers tell us, "Not only do I not have the manpow- room or installing new hardware during a shutdown? We can
er to build the lubrication program, I don't have the manpow- do it all.
er to run it. Can you put a Noria lube tech at our site?" The
Full-time Services Whether you are starting from the
answer is yes. Our technicians are embedded full-time at your
ground up or need highly skilled technicians, Noria Workforce
site so the engineering design can be executed effectively.
Solutions can help. NWS can staff your entire lubrication de-
This provides laser focus to critical tasks and the unceasing
partment, including management, engineers and technicians.
perseverance needed to prevent costly machine repairs and
downtime. When you have Noria Workforce Solutions (NWS), Visit noria.com/serv/workforce-solutions
About Noria
Since 1997, Noria has been
delivering world-class lubrica-
tion programs for a wide variety
of customers and industries,
including power generation,
food and beverage, heavy man-
ufacturing, mining, etc. Major
lubricant manufacturers turn
to Noria to train their teams,
design world-class lubrication
programs and solve lubrication
problems.
As a trusted advisor to the

worlds leading organizations,
Noria has a staff of technical
specialists dedicated to con-
sulting, training and publishing
in the core competencies of tri-
bology, lubrication, oil analysis,
contamination control and ma-
chine reliability. Our services are
disseminated through top-qual-
ity training courses, consulting
services, publications, webi-
nars, videos and books.
Our mission is to inspire

change through education by
providing tools, resources and
expertise so the industrial world
can realize the tremendous
potential that lubrication excel-
lence has to offer.
Customer List
Many of Norias customers view our services as a competitive advantage, so we cant provide a complete list of
everyone with whom we have worked. Heres a small sample of the companies we have helped:
www.noria.com/LPD

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September - October 2017

This issue sponsored by:

Simply put, we give our customers the confidence

Learn More At Noria.com

2 | September - October 2017 | www.machinerylubrication.com

MEDIA PRODUCTION COORDINATOR

MACHINERY LUBRICATION Volume 17 - Issue 5 September-October

SUBSCRIBER SERVICES: The publisher reserves the right to accept or

Copyright 2017 Noria Corporation. Noria, Machinery Lubrication and

CONTENT NOTICE: The recommendations and information provided in

Conspicuously Display managers, often on bulletin boards outside

4 | September - October 2017 | www.machinerylubrication.com

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DEMULSIBILITY RPVOT MPC (RUL 1) (RUL 2)

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$82,000 $79,000 $78,112 $80,688 $80,424

14 | September - October 2017 | www.machinerylubrication.com

HOW DOES YOUR SALARY THIS YEAR WHAT IS YOUR AGE?

YES NO TENURE AND AVERAGE SALARY

www.machinerylubrication.com | September - October 2017 | 15

EDUCATION LEVEL AND AVERAGE SALARY WHAT PROFESSIONAL CERTIFICATIONS

WHAT IS THE TOTAL NUMBER OF

SYNTHETIC WORM GEAR LUBRICANT

PGO & PGO-FGL SERIES

SFGO ULTRA SERIES

To Learn More About Lubriplates Products and Services Visit www.lubriplate.com

<40 HRS. 40 HRS. 41-49 HRS.

50-59 HRS. 60-69 HRS. >70 HRS.

12% 48% 40% 5%

Misalignment leads to increased vibration, premature seal EASY-LASER E-Series

www.machinerylubrication.com | September - October 2017 | 19

WHAT IS RELIABLE PLANT? I am going

With an established and global reputation for technical excellence,

In 2017, more than 1,500 attendees from 47 states, 27 countries and

Visit Conference.ReliablePlant.com for

Individual Individual Group (3-9) Group (10+)

$895 $1,195 $745 $645

With a certificate program Groups get 30% off all workshops

For more information call 1-800-597-5460 or visit Conference.ReliablePlant.com.

Attend. Learn. Apply.

24 | September - October 2017 | www.machinerylubrication.com

when in the raised position. The hose should

Hoses should be installed at the pump

Hoses that are too long may rub on

26 | September - October 2017 | www.machinerylubrication.com

About the Author

www.machinerylubrication.com | September - October 2017 | 27

What is the best cleaning procedure for