LMT Sept/Oct 2012

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ContentsSEPTEMBER/OCTOBER 2012 • VOL 13, NO. 5 • www.LMTinfo.com

ACHIEVING EFFICIENCIES THROUGH PRACTICES & PRODUCTS

EQUIPMENT-SPECIFIC LUBE SERIESFEATURES

8 Compressor Lubrication Part IV-B: Lubrication of Dynamic Compressors Compressor trains represent some of a site’s most complicated and costly equipment. Understanding their various lubrication-related quirks is key to keeping these moneymakers doing what they do best. Ray Thibault, Contributing Editor

17 Bearing Monitoring Keeps Coal Safely On The Move Here’s how proactive condition monitoring is helping a well-known energy-services provider defuse a process safety challenge. Jane Alexander, Editor, with Patrick Parvin, SPM Instrument, Inc.

DELIVERING THE GOODS22 The Anatomy Of A Centralized Lubrication System: Lubrication Controllers & Signal Devices Controls and signal devices are required to complete centralized lube systems. � e types used depend on budgets, the levels of system protection needed and other factors. Ken Bannister, Contributing Editor

MAINTENANCE LOG

DEPARTMENTS6 From Our Perspective

26 Problem Solvers

30 Supplier Index

©Ke

ller—

Foto

lia.co

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SEPTEMBER/OCTOBER 2012 www.LMTinfo.com | 3

www.LMTinfo.com

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September/October 2012 • Volume 13, No. 5

ARTHUR L. RICEPresident/CEO

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KENNETH E. BANNISTERRAY THIBAULT, CLS, OMA I & II

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Lubrication Management & Technology (ISSN 1941-4447) is published bi-monthly except Mar/Apr by Applied Technology Publications, Inc., 1300 S. Grove Avenue, Suite 105, Barrington, IL 60010. Periodical postage paid at Barrington, IL and additional o� ces. Arthur L. Rice, III, President/CEO. Circulation records are maintained at Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Lubrication Management & Technology copyright 2012. No part of this publication may be reproduced or transmitted without written permission from the publisher. Annual subscription rates for nonquali� ed people: North America, $140; all others, $280 (air). No subscription agency is authorized by us to solicit or take orders for subscriptions. Postmaster: Please send address changes to Lubrication Management & Technology, Creative Data, 440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440. Please indicate position, title, company name, company address. For other circulation information call (630) 739-0900. Canadian Publications Agreement No. 40886011. Canada Post returns: IMEX, Station A, P.O. Box 54, Windsor, ON N9A 6J5, or email: [email protected]. Submissions Policy: Lubrication Management & Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.

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4 | LUBRICATION MANAGEMENT & TECHNOLOGY SEPTEMBER/OCTOBER 2012


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FROM OUR PERSPECTIVE

Ken Bannister, Contributing Editor

Who doesn’t remember the late comedian Rodney Dangerfield, whose humor was based on getting “no respect,” regard-

less of his efforts? Dangerfield’s lament used to be a common refrain in countless maintenance departments. Recently, with the emergence of reliability groups making sense of data and years of collected history, as well as the use of—and respect for—certified personnel in the condition monitoring sciences, that tune has grown fainter.

In my opinion, however, the lube side of the equation continues to be viewed largely as an “anyone can do it” function. Even though “doing it” ineffectively can cause up to 70% of all mechanical failures, lubrication still gets no (or little) respect.

This past summer, I was honored to speak at an international condition monitoring excel-lence conference. While there, I learned, through an attendee survey (representing the manufac-turing, mining, oil & gas, utilities and transpor-tation industries) that oil analysis is the number one preferred condition monitoring technique in the Pacific Rim of Australia and New Zealand (with 29% of the respondent vote). Vibration analysis came in second, with 25%. Infrared thermography ranked third, with 20%. Fewer than a handful of respondents acknowledged having formal lube programs or certified lubri-cation professionals at their sites. In contrast, every attending company had numerous certi-fied vibration analysts and thermographers in their maintenance and reliability departments. (Ironically, several attendees privately admitted that even though they supported an oil analysis program, many oil changes were still activated on a calendar basis, not on condition.)

Based on my experience, these findings aren’t out of line. They are, sadly, reflective of industry worldwide—including here in North America.

Sometimes we have to find a catalyst to make people pay attention to the positive effects of GLP (Good Lubrication Practices). My confer-

ence presentation discussed just such a catalyst: the fact that all Australian corporations must now pay a carbon tax based on their CO2 emissions.

The good news I shared with the attendees is that the use of lubricants and lubricant-delivery methods and systems can deliver up to 18% energy reduction through decreased electrical energy consumption that converts directly into a CO2 reduction at the rate of 0.526 kgCO2 units for every 1kWh saved (Carbon Trust – UK grid electricity conversion – 2011). That’s a “threefor” in my book: 1) increased asset/component life-cycle/reliability; 2) reduced energy consump-tion; and 3) a reduced carbon footprint. All of these goals and more can be obtained for almost no capital outlay. Needless to say, such benefits cast a respectful light on GLP, and my audience’s attention could not have been higher.

Moving GLP forward requires understanding, measurement and communication (all hall-marks of a world-class organization). A signifi-cant step toward GLP and achieving respect is the training of lube, maintenance and reliability personnel in the area of industrial lubrication and the promoting of accreditation through any of three international bodies: ICML (Interna-tional Council for Machinery Lubrication), the largest international certifying body at this time; STLE (Society of Tribologists and Lubrication Engineers); and ISO (International Organiza-tion for Standardization).

Only with qualified and knowledgeable personnel will the practice of GLP ever be able to gain traction—and finally silence the “no respect” refrain that lubrication has lived with for so long.

On a lighter note, take a look at the innovative work that you and your department are doing and consider entering the “2012 Maintenance & Reli-ability Innovator of the Year” award competition. It can be a team effort. Details and entry forms are available at www.reliabilityinnovator.com. Good Luck! LMT

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Ray ThibaultCLS, OMA I, OMA II, MLT, MLT II, MLA II, MLA III

Contributing Editor

Lubrication Of

Dynamic Compressors

Tools and techniques to optimize equipment reliability...

Part IV-B:

Compressor trains represent some of a site’s most complicated and

costly equipment. Understanding their various lubrication-related quirks

is key to keeping these moneymakers doing what they do best.

(Author’s Note: Much of the information in this series is based on the practical knowledge of real-world lubrication professionals. Once such expert is Mark Kavanaugh, who has over 42 years of experience in large manufacturing operations, and is currently responsible for coordinating the lubrication of thousands of pieces of rotating equipment in a refi nery. Mark is certifi ed as a CLS, MTL I and MLA II.)


EQUIPMENT-SPECIFIC LUBE SERIES

NOTE: Again, as mentioned in Part IV (A), air-compressor lubrication is not part of this discussion. It was, however, the focus of an article in the May/June 2009 issue of LMT (www.mt-online.com/thibault).

Dynamic

Reciprocating

Positive Displacement

Straight Lobe

CompressorsRotary Screw

Sliding VaneCentrifugalLiquid Piston

Axial

Inert Hydrocarbon Chemically Reactive

Nitrogen Methane Oxygen

Hydrogen Ethane Halogens

Helium Propane Hydrogen Chloride

Carbon Monoxide Butane Hydrogen Sulfi de

Carbon Dioxide Propylene Nitrogen Oxide

Ammonia Butylene Sulfur Dioxide

Air Natural Gas Others

Table I. Classifi cation of Compressed Gases

Dynamic

Reciprocating

Positive Displacement

Straight Lobe

CompressorsRotary Screw

Sliding VaneCentrifugalLiquid Piston

Axial

Let’s start with a recap:

Per the discussion in

Part IV (A) of this

article, “Lubrication

of Positive Displacement

Compressors” (pgs. 8-14,

LMT, July/August 2012),

a compressor’s lot in life is to

increase the pressure of a gas

to the point where it can be

used in an industrial facility.

Rated by discharge pressure

(psi) and capacity in cubic

feet/minute (cfm), compres-

sors fall into two major

groups: positive displace-

ment and dynamic (Fig. 1).

The types of units in these

two groups, along with the

specifi c gases they compress

(see Table I), call for differ-

ent lube strategies. In this

article installment, we’ll

review the dynamic side of

the compressor family tree,

specifi cally the centrifugal

and axial branches.

Fig. 1. Compressors types are classifi ed into one of two major groups: positive displacement and dynamic.

10 | LUBRICATION MANAGEMENT & TEChNOLOGy SEPTEMBER/OCTOBER 2012


Centrifugal compressorsCentrifugal compressors, like that illustrated in Fig. 2, deliver gases at higher fl ow rates than positive displacement compressors, but at lower pressures. They’re used exten-sively in the refi ning and petrochemical industry because there is no contact between the gas and the lubricant—meaning that centrifugal compressors produce oil-free gas. Reactive gases can also be compressed without coming in contact with the lubricant.

Operation… The typical centrifugal compressor relies on the rotating blades (or vanes) of an impeller to accelerate a gas and, thus, create pressure. The impeller sits in a volute—a widening chamber connected to a gas discharge line. Gas that enters the compressor is swept up by the impeller vanes and moved from the center to the outside by centrifugal force, causing an increase in gas velocity. When the gas leaves the impeller and enters the volute, it slows down as the chamber widens. This slow-down converts velocity or kinetic energy to pressure. (Not shown in Fig. 3 are stationary diffuser plates that initially slow down the gas from the impeller and direct it into the volute.)

To achieve desired pressures, most centrifugal compres-

sors are designed as multi-stage units. (The cutaway in Fig. 2 refl ects a fi ve-stage design.) In a multi-stage unit, the impel-lers are all mounted on the same shaft along with a volute for each impeller and one suction- and one discharge-line. Gases aren’t cooled between stages, as they would be in a reciprocating compressor. Typical multi-stage operating pressures are in the range of 100-150 psi.

Fig. 2. Typical centrifugal compressor design

Fig. 3. The basic operating principle behind centrifugal compressorsprinciple behind centrifugal compressors

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Lubrication. . .

The major lubricated components in a centrifugal com-pressor train include:

n Drivern Electric motorn Turbinen Couplingn Compressorn Radial bearingsn Sleeven Tilt pad radialn Thrust bearingsn Angular contact balln Tilt pad

Centrifugal compressors can have large lubrication systems consisting of an oil reservoir, pump, filter, cooler and oil lines. The oil is then pumped to the lubricated parts, which are both radial and thrust bearings. Most centrifugal compressors are lubricated with high quality ISO 32 turbine oil. Some compressors may call for an ISO 46. If a step-up

gear is present and lubricated with the same oil as the bear-ings, ISO 68 turbine oil may be recommended. (NOTE: High-speed air compressors, in some cases, are lubricated with synthetics. This was discussed in the previously refer-enced 2009 LMT article on air compressor oils.)

Some compressors rely on a seal-oil system along with a seal at the end of the shaft to prevent gas from leaking beyond it. This is particularly true when compressing envi-ronmentally toxic gases.

A seal-oil system consists of an oil-collection area, oil supply-line with a check valve, oil return-line, gas return-line, head tank and a seal-oil reservoir. During operation, oil is pumped via the oil supply-line through the seal. Because the pressure of the oil is greater than the pressure of the gas, the oil flowing through the seal keeps the gas from leaking. Oil (carrying the absorbed gas) is pumped to a compart-ment in the reservoir, at which point the gas is separated and returns to the compressor. The gas-free oil then returns to the seal-oil system. As a safety precaution in the event of pump failure, a separate head tank supplies enough oil on a pump shutdown to allow the compressor to be shut down without a gas leak. Most seal-oil systems use the same oil to lubricate the bearings. The oil from the head tank is NOT used to lubricate the bearings.

Axial compressors Operation…Axial compressors are used where high volumes of gas at low pressure are needed. Capable of producing up to 1,000,000 ft3/minute, they incorporate a series of rotating and stationary (or fixed) blades (as illustrated in Fig. 4).

In axial units, the rotating blades accelerate gas that comes in contact with the stationary blades, which change the direction of flow—resulting in a lower velocity, but a higher pressure. Each series of rotating and fixed blades is a stage. (Some axial-flow designs have up to 20 stages.)

Axial compressors are used in gas turbines to provide compressed air during the combustion process. They are also used in large air-separation, blast-furnace-air and other applications where a high volume of air is required.

Lubrication…Bearings—both radial and thrust—on axial compressors are lubricated with high-quality ISO 32 turbine oil.

Basic troubleshooting techniquesAs discussed in Part IV (A) of this series, successful compressor troubleshooting calls for a strong knowledge of machine component design, operating parameters, lubrication requirements and OEM guidelines. In-depth troubleshooting is usually a one-on-one proposition, with a troubleshooter required to look deeply into each piece of the puzzle.

Fig. 4. Typical axial compressor incorporating a series of rotating and stationary blades


Keep in mind that certain troubleshooting principles hold true for all com-pressor types. The following recaps basic guidelines, regardless of the group into which a compressor falls—either positive displacement or dynamic.

Temperature. Changes in temperature from an established norm are reliable indicators of changes in machine condition. Daily temperature inspections should, at least, include: suction and discharge of gas, gas interstage coolers, afterstage coolers, lube-oil coolers, cooling water, mechanical seals, crankcase and bearing oils. Periodic checks of bearings, valves and cylinder head temps are advisable.

Levels. Liquid levels in compressor components must be monitored diligently. Correct crankcase, bearing housing, reservoir oil levels, feed rates on cylinder injec-tors and circulating oil systems must be kept constant. Compressed gas receivers, intercoolers, aftercoolers and process piping must be drained and kept liquid-free. Free water should be drained from oil reservoirs and oil filter housings daily.

Pressures. All compressors are designed to operate in specific pressure ranges; this is one governing factor determining what type of compressor is used in what service. Pressure differentials between suction, interstage and discharge gases must be tracked and variances out of the norm investigated. Bearing, mechanical seal and oil filter pressures should be checked, at least daily. Air compressor inlet filter differential pres-sure should be checked daily.

Changes in vibration or sound. Knocks, pings, rattles or ticks should be inves-tigated as soon as possible after detection.

Oil analysis should be conducted on no less than a quarterly basis—and on a monthly basis in severe services. Tests should include: viscosity, particle counts, wear metals, water content and FTIR or Ruler for remaining useful oil life. Modifications to this basic test slate will be required, depending on compressor type and service.

Troubleshooting specifics for dynamic designs…Centrifugal and axial compressors are usually large, very costly, precision machines. Most are computer-controlled, with software that monitors both operating param-eters (i.e., pressure, flow, temperatures, etc.), and machine conditions (i.e., vibration, bearing and seal-oil pressures and temperatures, oil-reservoir levels, etc.). Trouble-shooting these units is a significant undertaking: It typically involves sifting through mounds of data and conducting in-depth hands-on inspections during outages.

Oil analysis for centrifugal and axial compressors should include annual ferrography, filter-debris and varnish tests. The large circulating-lube and seal-oil systems found in these types of units usually respond well to filter upgrades (higher beta ratios and lower micron ratings). Consult the compressor OEM and lubricant manufacturer before attempting any changes.

Oil analysis should be conducted on a quarterly basis.

Monthly oil analysis is recommended in severe services.




ConclusionAs noted in Parts IV (A) and (B), compressors are among the most important (and complex) types of equipment in a plant. Being proactive and reliability-conscious is key to minimizing their failures. This article focused on how various compressor types operate, the correct lubricants to use and valuable trouble-shooting tips. Review these points—and keep them handy. They’ll help improve the uptime of some of the hardest working “moneymakers” at your site.

Coming upPart V of this series covers best practice for improving run time and minimizing shutdowns of blowers and fans. LMT

Ray Thibault is based in Cypress (Houston), TX. An STLE-Certifi ed Lubrication Specialist and Oil Monitoring Analyst, he conducts extensive training for opera-tions around the world. Telephone: (281) 250-0279. Email: [email protected].


Being proactive and

reliability-conscious is key

to minimizing compressor

failures at your site.

Keep this advice handy.

Table II. Summary of Compressor Lubricants

Compressor Type Lubricated Component Lubricant

Reciprocating Cylinder Mineral Oil ISO 100-680 Diester ISO 100-150 PAG 100-320 Frame Journal Bearings Mineral Oil ISO 100-150

Rotary Screw Speed Gear Mineral ISO 32-68 Flooded* Roller Radial & Thrust Bearings PAO 32-68 PAG 68-150 PAG/Ester 32-68 Diester 32-68

Dry Radial and Roller Thrust Bearings Mineral Oil ISO 32-100 Timing Gear Sliding Vane Rolling Element Bearings Mineral Oil AW 32-150 Sliding Vanes

Rotary Lobe Rolling Element Bearings Mineral Oil R&O or Timing Gear AW ISO 150-220 Liquid Piston Rolling Element Bearings Mineral Oil ISO 32-68

Centrifugal Radial and Thrust Journal Bearings Mineral Oil ISO 32-46 Radial and Thrust Rolling Element PAO ISO 32-46 Bearings PAG /Ester 32 (Air Compressor)

Axial Radial and Thrust Journal Bearings Mineral Oil ISO 32 Radial and Thrust Rolling Element PAO ISO 32 Bearings

*The wide selection of lubricants for fl ooded screw compressors is based on the type of gas processed.

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MAINTENANCE LOG


Conveyor systems aren’t just subject to considerable wear. Even in

normal use, they can face the risk of fi re due to equipment failure

or ignition of the materials being transported. In Amarillo, TX,

energy-services provider Savage is successfully employing state-

of-the-art online condition monitoring on a coal-conveyor system to

help eliminate that concern and ensure safe and uninterrupted supply

of fuel to Xcel Energy’s Harrington Generating Station.

Jane Alexander, Editorwith

Patrick Parvin, SPM Instrument, Inc.

Bearing Monitoring Keeps Coal Safely

On The Move

Here’s how proactive condition monitoring

is helping an energy-services provider

defuse a process safety challenge.©

JOS

EPPI

— F

OTOL

IA.C

OM

This article originally appeared in the March 2012 issue of Maintenance Technology.

MAINTENANCE LOG


The challenge of PRB coalThe coal-conveyor system plays an important part in the operation of the Harrington Generating Station: A reliable and trouble-free supply of fuel is critical to secure energy production. The Harrington plant, owned and operated by Xcel Energy, gets its coal primarily from the Powder River Basin (PRB) in Wyoming. A special property of the PRB coal is its propensity to self-ignite. Another characteristic of this coal is its friability, creating combustible dust that can penetrate into bearings and other parts of the conveyor system.

While PRB coal has become popular—based, in large part, on its low cost and low sulfur content—that popularity comes at a price. The potential for spontaneous combustion calls for safe operation and maintenance in coal transportation systems and stockyards. Good housekeeping practices, such as properly managing coal stock piles, limiting dust accumu-lation, preventing spills and conducting regular cleanups are extremely important. For the Savage maintenance department, handling PRB coal has introduced extraordinary hazards. Careful management of these hazards is a must. A mechanical fault in the bearing of a roller, for instance, could cause ignition of the belt or coal. Friction between a seized roller and the belt could also lead to fire. The site’s online condition-monitoring program plays an essential role in dealing with the safety issues that come with the handling of PRB coal.

Condition monitoring: a proactive strategySavage implemented its condition-monitoring program to monitor plant machinery and detect potential failure at an early stage. In late 2009 and early 2010, the Intellinova®

online system from SPM Instrument was installed to monitor 40 conveyor and crusher bearings. The condition of these bearings is measured with SPM HD®, a new and advanced shock-pulse measurement technique. Particularly well-suited for low-RPM applications, this new technology can be utilized on rolling-element bearings throughout the range of 1-20,000 RPM. At the Savage Harrington location, the conveyor system runs at approximately 120 RPM.

A prominent feature of the SPM HD technique is its capacity to detect machine problems at a very early stage and provide reliable diagnostic information months before replacement of a damaged part becomes necessary. SPM HD delivers immediate condition evaluation in green-yellow-red and presents measuring results with remarkable detail, giving a clear picture of bearing condition.

Savage’s condition-monitoring program was off to a flying start. Initial readings in June 2010 indicated dete-riorating condition on one of the pulley bearings. With the online monitoring system, Savage personnel were able to keep a watchful eye on development of the damage for a full 15 months before the bearing needed replacement.

As can be seen in the trend graph in Fig. 1, taken from Condmaster® Nova software, the HDm readings (black) were already in the yellow warning zone when measure-ments began. Shortly thereafter, they started to move into the red, but the condition degradation was relatively slow. In September 2011, a significant increase was seen, leading to a decision to replace the bearing in a planned maintenance action. Immediately after replacement, the readings dropped into the green zone.

Fig 1. Trend graph of measurements on the pulley bearing. HDm (black) is a scalar value expressed in decibels. It represents the strongest impact found during the measurement time, and is the primary parameter for asses- sing damage sever-ity. HDc (blue) is a scalar value expres-sed in decibels, representing the level where 200 collisions per second are found. HDc is very useful for determining lubrica-tion condition.


MAINTENANCE LOG

The time signal in Fig. 2 shows that in the late stages of the damage process, the majority of the signals were dominated by damaged rolling elements. The periods between the “bursts” in the time signal are equal to the cage frequency—i.e., how often the rolling element enters the load zone of the bearing.

By September 2011, clear indication of both inner and outer race damages was visible in the Condmaster® Nova spectrums (see Fig. 3, page 20).

Examination of the replaced bearing showed severe damage on both its inner and outer rings, as well as the rolling elements. Still, no secondary damage to the shaft or bearing housing had resulted, and since the bearing was replaced during normal downtime, no loss of production was incurred.

Fig. 2. Time signal from the pulley bearing; signals dominated by damaged rolling elements

With this condition-monitoring technology,

Savage personnel were able to keep a

watchful eye on development of the

damage for a full 15 months before

the bearing needed replacement.


MAINTENANCE LOG


Clear and tangible benefi tsIn general, a majority of industrial accidents happen during cleaning or other maintenance activities. When equipment failures occur during normal production runs, production requirements may call for hurried maintenance efforts to get the machinery back up and running as quickly as possible. This can be an invitation for accidents to happen. In contrast, when maintenance can be carried out only when confi rmed necessary and under planned stops, risks are signifi cantly reduced.

To Savage, the condition-monitoring program brings indisputable benefi ts beyond the ability to provide a reliable delivery of coal to its valued Harrington Generating Station customer. A substantial reduction in equipment failures, improved worker and equipment safety and an increase in plant availability and productivity are results that speak for themselves. Assuring dependable, safe and trouble-free opera-tion of the coal conveyor system is a smart business strategy—in more ways than one.

When asked about the cost savings for this particular bearing change, Mark Kilgore, Operations Manager at the Savage Harrington site, noted, “We could still run if this bearing would have failed during a run, but had it failed outside the normal hours of the maintenance team, we would have had to call them [maintenance] in and this would have been an extra expense.” According to Kilgore, if the bearing had catastrophically failed, it could have caused a fi re. It also could have damaged the belt—one of the longest belts in the plant.

The pulley bearing in question is located about halfway up a conveyor belt system rising over 200 feet from the ground to the top. If the bearing were to overheat, both it and the coal traveling on the belt could catch fi re. That burning coal, in turn, could then fall onto the returning belt below. On its way to the top of the conveyor system, a fi re would pull air in from underneath the conveyor system, fueling an inferno-like situation akin to the inside of a blast furnace. Such an incident clearly could be devastating to workers and equipment alike.

The early detection of potential bearing problems saves users downtime and money. Kilgore sums it up this way: “As we all know, when you have a catastrophic failure, it never happens when it is convenient, and it usually causes severe damage. With this system [SPMs], we are able to catch these problems before complete failure, and we can schedule the repair when it is conve-nient for us.” LMT

Patrick Parvin is Managing Director of SPM Instrument, Inc., based in Eugene, OR. Telephone: (541)687-6869; email: [email protected].

Fig. 3. Spectrums showing clear indications of inner and outer race damage


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DELIVERING THE GOODS

How Controllers WorkA lubrication-system controller is often described as the system’s “brain.” Most controllers are multi-function, stand-alone devices housed in a control panel. The excep-tions to this can be found in single-point lubricators (SPLs) and some smaller electro-mechanical oil-delivery pumps that have built-in circuit-board-style controllers that can be programmed through an LCD touch screen or a series of mechanical switches. These are usually simple control devices that activate the lube pump and speed up or slow down the fl ow rate of the pumped lubricant.

Turning the pump on and off is the controller’s primary function. In the case of a pneumatically powered pump, the controller opens an electrically operated air solenoid valve to allow air into the piston and fi re the pump. With electrically driven piston and gear pumps, the motor is electrically energized, allowing the pumping action to commence. Once the controller receives a signal informing

it that the pump has fired, a given time has elapsed, a lubricant line pressure has been achieved or a distribu-tion block cycle has been completed, the pump’s power source is shut down until the next lubrication cycle commences. (The only exception to this is a recircu-lating-oil system that is powered up on machine startup and runs continually until it is turned off when the machine is idled or shut down.) Lubrication cycles can be controlled by a counter that determines the number of machine or production operations, by a programmed or set timer or by a condition signal—for example, an amperage draw meter indicating energy draw increases on a machine system motor because of a mechanical friction rise due to lack of lubrication. (This is a popular control mechanism that measures the amperage of the conveyor drive and take-up motors to activate and deactivate the “power and free” conveyor chain and pin lubricators used in automotive assembly plants.)

The Anatomy Of A Centralized Lubrication System

Lubrication Controllers And Signal Devices

Ken BannisterContributing Editor

To complete a centralized lubrication system design, the designer must tie the pump and

delivery system together and synchronize their operation with a combination of control and

signal devices. The type of controller and signal devices used will depend on the budget, the

level of system protection required, the type of pump and distribution system employed and

the ability of the host machine to interpret and act upon the control signals.


DELIVERING THE GOODS

A controller’s secondary function is to take an emergency signal, shut down the system and activate an alarm. The alarm can be a simple light or buzzer wired directly to a solenoid in the control panel that, in turn, will activate an alarm email or work order—or both—in the CMMS/EAM maintenance management software.

A controller’s level of sophistication can range from a manual on/off device, to a simple count-driven on/off device, all the way up to a very sophisticated program-mable PLC/computerized PC device. The controller sophistication is usually underwritten by the lube system’s consequence of failure where public safety is a concern—i.e., in the nuclear or chemical industries, etc.—or where production losses are major concerns when lubricated equipment is a production constraint, or where machine failure leads to high downtime.

How Signal Devices Work Signal devices used for control and system protection can be mechanical, hydraulic, pneumatic or electrical in design—and active or passive in operation.

Different delivery-system designs will use controls differ-ently. For example, in most single- or dual-line system designs, the pump must continue to operate until the line pressure has reached an end-of-line line pressure of at least 800 psi, allowing the injectors to fi re. Once attained, a pressure-signal switch informs the controller to shut off the pump, which, in turn, also reverses a fl ow valve allowing the lubricant to return to the reservoir and the injectors to reset. A timer then counts operations or elapsed clock time and tells the controller to start the process all over again. In this system type, the pressure switch can also be coupled to a time-out switch set to signal an alarm state if the system doesn’t achieve its line pressure (due to a broken line or no lubricant) in a specifi ed time period.

Progressive-divider lubrication-delivery systems can employ simple counters attached to the top piston in a primary delivery block. Once every outlet in the block has fi red lubricant, the top pin will have moved in and out of the block once—thus signaling one complete operation of the block. The counter is linked to a controller that actuates the pump based on the number of required block cycles. Progressive blocks also utilize passive hydraulic blocked-line indicators that actuate when hydraulic lock up occurs in a line-blockage situation, causing a pin to “pop” out and indicate which line is blocked, thus speeding up the trouble-shooting process (see Fig. 1).

AvailabilityThe bottom line is that there are many control and protec-tion devices available to the customer. Be sure to consult with your suppliers to ensure that you have the right system and right level of control your systems need.

Coming UpThe November/December issue will address the mainte-nance of automated lubrication systems. LMT

For more information on automated lubrication delivery systems and/or ICML or ISO lubrication certifi cation training, contact Ken Bannister directly. Telephone: (519) 469-9173; email: [email protected].


Fig. 1. Progressive-divider block signal indicators (courtesy EngTech Industries Inc.)

Cycle Pin Indicator

Blocked LineIndicator Pin

Cycle Pin Indicator

Blocked Line

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MT targets the critical technical and business information needs of engineers, managers and technicians who have specifi c interest in and/or responsibility for the reliability, availability, safety, effi ciency and environmental integrity of countless plant equipment systems throughout all industry sectors.

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PROBLEM SOLVERS

Advanced Zinc-Free Hydraulic Fluid

According to Shell, its new Shell Tellus S3 M hydraulic fl uid uses advanced zinc-free anti-wear technology to improve pump protection, enhance system effi ciency and provide up to twice the life of the company’s previous zinc-free product. It’s suited for use in factory-based industrial hydraulic applications and severe-duty, extended-operation

applications, as well as outdoor applications in climates with limited temperature variations. The fl uid’s low aquatic toxicity helps reduce its environmental impact. Shell Tellus S3 M meets the requirements of a number of OEM specifi cations,

including, among others, Husky (ISO VG 46), Parker Hannifi n HF-0, HF-1, HF-2, and Eaton 694. It also meets standards ISO 11158 HM fl uids, AFNOR NF-E 48-603, ASTM D6158 (HM mineral oils), DIN 51524-2 (HLP oils) and Swedish Standard SS 15 54 34 AM.

Shell LubricantsHouston, TX


Low-Foaming, High-Performing Metalworking Fluid

NuSoL® Alumax 89 from Chemtool is specifi cally formulated for all operations

on non-ferrous alloys, exotic ferrous alloys (including titani-um), Inconel and Monel, plastics and composites. According to the manufacturer, while NuSoL Alumax 89 provides the excel-lent type of wetting, detergency and boundary lubrication that’s associated with other NuSoL metalworking fl uids, this product incorporates a new performance-enhancing additive package that demonstrates lower foaming characteristics for typical use concentrations (5-15%).

Chemtool, Inc.Rockton, IL

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Unlock the Secrets that let you Tap your True Maintenance Potential

and Maximize Asset Reliability!

Unlock the Secrets that let you Tap your True Maintenance Potential

and Maximize Asset Reliability!World Class organizations know that increased asset reliability, utilization and maintainability, reduced operating costs, downtime, contamination, energy consumption and carbon footprintall commence with a best practice lubrication program!

“Industrial Lubrication Fundamentals”3-Day, On Site, Certifi cation Preparation Training Program

Course design is based on ISO 18436-4 and the ICML body of knowledge and exceeds minimum training requirements to write the ICML, MLT1, MLA1 and ISO LCAT1 International lubrication certifi cation exams. Exams can be arranged to take place at your site immediately following the training.

For more information on this unique training program developed and delivered by internationally accredited lubrication and maintenance expert Ken Bannister, author of the best selling book Lubrication for Industry endorsed by ISO and the ICML as part of their certifi cation Domain of Knowledge Content.Contact ENGTECH Industries Inc at 519.469.9173 or email [email protected]

With over 70% of all mechanical failures attributed to ineffective lubrication practices, you will want to have professionally trained and certifi ed lubrication personnel working on your reliability efforts!

Making Total Tool Management Simple

The makers of WinTool say their product is the only centralized, online tool database capable of

seamlessly interfacing with many of the software programs that a manufacturing site already uses, including CAM, presetters, tool crib management, scheduling and ERP, purchasing, etc. According to the company, this single database not only provides users with online access to an up-to-date record of tool inventory, it helps them eliminate errors and uncertainty by not ordering tools they already have on hand.

WinTool USAArlington, TX

Inline Machine Tool Fluid Filtration And More

According to Eriez, its fully automated mobile SumpDoc™ provides inline coolant

fi ltration and replenishment for machine tools while they run. The fi rst phase of its three-phase process vacuums chips and sludge from dirty sump coolant at a rate of 85 GPM per minute (50 microns). Fine solid particulate is then fi ltered to 3-5 microns and tramp oils are removed to less than 0.5% at fl ow rates of 90-120 GPH. Once clean, the fl uid is analyzed and the SumpDoc is set to deliver a lean, medium or rich coolant mix back to the sump. Depending on the regularity of cleaning, a 200-gal. sump typically can be processed in about two hours. Mounted on a battery-powered pallet jack, the unit comes with onboard hookups and extensions for compressed air, plant water and 120V, single-phase electric.

Eriez Manufacturing Co.Erie, PA



PROBLEM SOLVERS

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Filter Cart Delivers Real-Time Particle Count Readouts

The Tandem Series fi lter carts from Y2K Fluid Power feature an on-board particle

monitor with a real-time readout of the fl uid’s condition to ISO cleanliness standard ISO 4406-1999 (E). This can help eliminate drawing fl uid samples and waiting on results. The unit also has two sets of fi lter elements that allow fi ltering of different grades of fl uid, with no cross-contamination using a single cart.

Y2K Fluid PowerSioux Falls, SD

Expanded Automatic Lubricator Product Lineup

PLI, LLC has added the MEMOLUB® ONE LPS to its line

of reusable automatic lubricator products. The unit features a low-pres-sure 240cc single-point, self-contained design with low environmental impact. According to the PLI, it saves time, money and bearings with precise metered lubricant injection, simple programming and economical, easy-to-change, replaceable lube cartridges. A three-year warranty protects against defects in material or workmanship.

PLI, LLC Racine, WI

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Take a break from a week filled with questions, by attending a week filled with answers.

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Copyright © 2012 Rockwell Automation. All Rights Reserved. AD RS2290-R1P


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Access LMTfreeinfo.com and enter the circle number of the product in which you are interested, or you can search

even deeper and link directly to the advertiser’s Website.

SEPTEMBER/OCTOBER 2012 • Volume 13, No. 5

Submissions Policy: Lubrication Management & Technology gladly welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications, Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish, and adapt your submission in any medium, including via Internet, on multiple occasions. You are, of course, free to publish your submission yourself or to allow others to republish your submission. Submissions will not be returned.

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AL, DC, DE, FL, GA, MD, MS, NC, NJ, PA, SC, VA, WV 1750 Holmes Drive

West Chester, PA 19382610-793-3093; Fax 610-793-3094

JIM [email protected]

IA, MN, NE, ND, SD1300 South Grove Avenue, Suite 105

Barrington, IL 60010847-382-8100 x116; Fax 847-304-8603

BILL [email protected]

OH, KY, TN135 N. Rocky River Road

Berea, OH 44017440-463-0907; Fax 440-891-1254

JOHN [email protected]

30 | LUBRICATION MANAGEMENT AND TECHNOLOGY SEPTEMBER/OCTOBER 2012

It’s Time To Shine!

We’re Looking For Lube Starz!

It’s Time To Shine!

LubeSta

rzLubeSta

rz©

©

www.LMTinfo.com/LubeStarz

Our Lube Starz Section is all about our readers, the hardest-working lube pros in the universe!

We want to learn who you are, where you work and more about your job. If you’re chosen as the subject of a short, published profi le, you’ll soon be reading about yourself in an upcoming Lube Starz Section in Lubrication Management & Technology and on our Website.

Go to www.LMTinfo.com/LubeStarz and download the profi le form. Fill it out and follow the instructions for submitting it with your photo. That’s all there is to it.


A.T.S. Electro-Lube Int’l Inc. ....................www.atselectrolube.com ................................67 ............ 13Baldor Electric Company ..........................www.baldor.com ............................................80 ...........BCEngtech Industries Inc...............................www.engtechindustries.com .........................75 ............ 27Fluid Defense .............................................oilsafe.com/workfl ow .....................................65 .............. 7Foster Printing Services .............................www.fosterprinting.com ................................76 ............ 28Idcon, Inc. ...................................................www.idcon.com/maintenance-jobs.htm ......74 ............ 26Innovator of the Year .................................www.reliabilityinnovator.com .......................68 ............ 15LUBE-IT/Generation Systems, Inc. ..........www.generationsystems.com ........................70 ............ 19LubeStarz ....................................................www.lmtinfo.com/lubestarz ..........................78 ............ 30MARTS .......................................................www.martsconference.com ...........................71 ............ 21Miller-Stephenson Chemical Co. .............www.miller-stephenson.com.........................62 .............. 4Neil Bloom .................................................www.mt-online.com/rcm ..............................69 ............ 16NSK Corporation ......................................www.nskamericas.com ..................................64 .............. 5Pennzoil ......................................................www.pennzoil.com.........................................66 ............ 11Rockwell Automation ................................www.psug.rockwellautomation.com ............77 ............ 29Shell ............................................................www.shell.com/us ..........................................61 ..........IFCU.S. Tsubaki Power Transmission, LLC ...LongLifeLambda.com ....................................79 ......... IBCUVLM, Inc. ................................................www.uvlm.com ..............................................63 .............. 4

When you’re on a roll, you shouldn’t have to stop for anything.

T H E U L T I M A T E P O W E R T R A N S M I S S I O N T E C H N O L O G Y

Reduce down-time and maintenance costs with Tsubaki Lube-Free LAMBDA® Roller Chain.

To sign up for a SPECIAL RISK FREE TRIAL go to: LongLifeLambda.com

Break free from the chains that keep stopping you. Get long-term operation without additional lubrication with the original and longest-lasting lube-free roller chain. Get going with LAMBDA® lube-free roller chain and keep your operation running longer.

L U B E - F R E E • M A I N T E N A N C E - F R E E • H A S S L E - F R E E • W O R R Y - F R E E

© 2011 U.S. Tsubaki Power Transmission, LLC. All Rights Reserved.

(800) 323-7790

Stop by and check us out atPack Expo International 2012

Oct. 28-31, Chicago, ILBooth # 4648


The Sign of Quality

• Energy Efficient

• Unmatched Quality

• Superior Reliability

• Quickest Delivery Available

For almost 100 years, Baldor•Reliance® has developed a reputation for designing and manufacturing the highest quality industrial electric motors available. Beneath the nameplate of every Baldor•Reliance motor, you will find the best industrial electric motor you can buy.

When reliability counts, accept nothing less than theSign of Quality from Baldor•Reliance.

baldor.com

©2012 Baldor Electric Company


Documents

LMT Sept/Oct 2012