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Tribojournal
your global specialist
2012
– A masterpiece in the Oosterschelde estuary– Efficientgenerationofcleancompressedair– High-precisionmachinetooloperation– Analysisservicefortrouble-freeoperation
Tribojournal 1/2012
A masterpiece in the Oosterschelde estuaryLubricationandsealingfunctionsfullyretainedafter25yearsofservice
WorkingwithcleancompressedairNew,fullysyntheticcompressoroilshaveproventheirworthinpractice
Newserviceforoperatorsofwindturbines Bearinggreaseconditionanalysesfortrouble-freeandreliableoperation
Precision,efficiency,sustainabilitySpecialitylubricantsformachinetoolscontributetohigherproductivity andlowerlifecyclecosts Tailor-made,reliableandgoodfortheenvironmentNewsterntubeoilexpandstherangeofreadilybiodegradableoilsforthemaritime and offshore industry
All-roundlubricantforexcellentwearprotectionKlüberfoodNH194-6000isahigh-performancefluidgreaseforhigherprocessreliability
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We thank the company DECKEL MAHO Seebach GmbH for their kind support and provision of pictures.
Tribojournal 1/2012 32
Newwaysofkeeping you informed
Dr. Michael KolkHeadofMarketingandApplicationEngineeringKlüber Lubrication München KG
Dear reader
WhenwepublishedourfirsteditionofTribojournaljustovertenyearsago,addedcustomervaluewastheobjectivewehadinmind,aswithallprod- uctsandservicesweoffer.Thisobjectivehasn‘tchanged.Inthecurrentedition,forexample,youcanfindoutwheretolookforpotentialtoreduceoperatingcosts,howmodernspecialitylubricantscanhelpyouattainenvironmentaltargets,andwhichpioneeringnewproductscanenablemore reliable production processes.
Aswithallourservicesandspecialitylubricants,wewillcontinuetotakenewpathswithourpublications,theTribojournalbeingoneofthem,inresponsetoyoursuggestionsandinordertomeetyourwishes.Wetalkedtoourcustomers,askingthemwhichsourcestheyuseandwhichinfor- mationchannelstheyprefer.Wefoundthatdigitalmediaarepreferredbymanyandthatourwebsiteisbyfarthemostfrequentlyusedsourceforinfor- mationonKlüberLubrication.Sowedecidedtosetupanelectronicinforma-tionserviceinplaceofourtraditional,printedcustomerjournal.
This enables us to – provideyouwithaquickandstraightforwardoverview–it‘suptoyou tochoosethetopicsyou‘reinterestedin
– offeryouaconvenientwayofobtainingin-depthinformationontopics ofyourchoiceandcontactingus
– giveyouexactlytheinformationyouneed Naturally,wewouldbeverypleasedtokeepyouinterestedasakeenreader.Whynotregisterforthenewmediumrightaway? www.klueber.com/en/News/Newsletter/.
IwishyouaninterestingreadofthislasteditionofTribojournal
Dr. Michael Kolk
Tribojournal 1/2012
The main difference to the building of a dam, as had origi- nally been planned, is that the Oosterschelde Estuary has not been turned into an inland body of water by the storm surge barrier and, therefore, the natural tidal action was not cut off. This means that mussels and oyster breeding have survived.
Piet Maljaars:Exactly–andassoonasastormiscomingon,wecancloseeverythingoff.Whenthesealevelrisesmorethan3metresabovetheAmsterdamNAPlevel,whichmeansabovethemeansealeveloftheNorthSea,thenit‘stimetooperatethesluicegates.
Building a storm surge barrier with gates was technically much more demanding than building a dam. Can you ex- plain what makes the barrier so special?
Piet Maljaars:Well,buildingthestormsurgebarrierwasahugechallengeforallcompaniesinvolved.Afterall,itconsistsof62mov-inggatesweighingbetween250and400tonseach.That’senor- mous.Consequently,therequirementspertainingtothehydraulicsystemthatmovesthesegatesareextremelyhigh.Thesameappliestothebearingswhichareanabsolutenecessitytomovethegatesatall.Notleast,alsothelubricanthastowithstandextremeconditionsinsidethebearings.Allthosefactorshadtobetakenintoconsiderationduringtheplanningandbuilding.Therewerenorealempiricalvaluesfromearlierprojects.Soitisevenmoregratifyingthatuptothepresentdayeverythinghasbeenrunningsosmoothly.
Foraquarterofacentury,astormsurgebarrieron the North Sea coast of the Netherlands has beenprotectinglandandpeoplefromthesea–safelyandreliably.Thebuildingisstillregardedamasterpiecenowadaysbecause,withtheplan-ningaswellaswiththebuilding,virtuallyeverystepwasastepintounknownterritory.AgreatexampleofanotableEuropeancooperation.
Shortlybeforethe25thanniversaryofthebarrier‘sinaugurationon4October2011,representativesofthecompaniesinvolvedaswellasrepresenta-tivesoftherelevantauthoritycametogetheragain:PietMaljaars,ClusterCoordinatorattheRijkswater- staat(DutchWaterAuthority),Erik-JanDriessenfromKlüberLubrication,aswellasEllisvandenHout from SKF Netherlands and Peter Schmehr fromSKFGermanysharedfascinatinginsightsonthepastcooperation,thepresentperformanceofthestormsurgebarrierandprospectsforthefuture.
Would you say now, 25 years after its opening, that the storm surge barrier has been an all-around success?
Piet Maljaars:AttheOosterschelde,theDeltawerkenhavein- deedachievedwhattheysteppeduptodoaftertheflooddisasterin1953.Notonlyhasareliableprotectionbeeninstalledforthepeople,whohavebeenabletoliveandworkheresafelyeversince.Anothergoalwastoprotectthefloraandfaunaandmaintaintheecologicalbalance.Mussels,oystersandmanyotheranimalsareheremoreplentifulnowthanever.FortheNetherlands,thestormsurgebarrierisofvitalimportance.Today,thestructureandthesurroundingnaturereserveexistinharmonioussymbiosis.
A masterpiece in the Oosterschelde estuaryLubricationandsealingfunctionsfullyretained after25yearsofservice
Tribojournal 1/2012 54
How many times have the gates had to be closed for safety reasons over the past 25 years?
Piet Maljaars: Wehavehadtoclosethegates26times.24timesbecauseofastormsurge,andtwicebecauseithadrainedsomuch.ByclosingthegatesandpumpingoutthewaterfromthepoldersintotheOosterschelde,thewaterlevelbehindthebarriercanbeheldlowartificially.
What exactly happens in the event of an emergency? Do the gates close automatically?
Piet Maljaars:Therearetwooperatingmodes.Thefirstisthemanualone.That’swhatweprefer,because,intheend,aftertakingallaspectsintoaccount,mancanstillmakethebestdeci- sions.Thenthereisthefullyautomaticmodedesignedfortheeventthatno-onecangettothecontrolcentreintime.Thewholebarriercanbeclosedinjustoneandahalfhours–withoutanypowerfromtheelectricitygrid.Thismeanswecanoperatethegatesinatotallyself-sufficientwayintheeventofanemergency.Andtomakesurethateverythingrunssmoothlyintheeventofanemergency,wecarryoutacompletetestrunfourtimesayear.
Weather forceasts have become more accurate over the years. Are their data useful for you, and how do you use them for your warning system?
Piet Maljaars:Rijkswaterstaathasitsownmeteorologicalser- vices.Expertsareconstantlyobservingandanalysingthetechni- caldata.Themomenttheyhavegoodreasontofearthatthewaterwillrise2.75metresabovetheAmsterdamlevel,theystartmakingtheircalculations.Thentheteamhastodecidewhethertoclosetheslidesornot.ButthedirectorofthewaterauthorityhereinZeelandalwaysgetsthelastword.
How vital was the input of the companies that were given the opportunity to demonstrate their capabilities here – such as Klüber Lubrication, the German lubrication spe- cialist, and SKF, the Swedish rolling bearing manufacturer – to the success of the project?
Piet Maljaars:Ofcourse,theplanningwasdoneonmanydiffer- entlevels,includingthepoliticalone.Personally,Ihaven’tbeenonboardforsolong,soIcan‘tcommentonitfrommyownex- perience.Forme,itisanextraordinarilygoodsignthatthepro- fessionalcooperationandthegoodpersonalrelationshipbetweenus and the companies still continue up to the present day.
Ellis Jan van den Hout:Suchclosecooperationissomethingoutoftheordinaryalsoforus.Hereonsite,forexample,westillgetinvolvedinthemaintenancework.Rijkswaterstaat,SKF,KlüberLubricationandmanyothersworkhandinhand.AgreatexampleofgoodEuropeancooperation.Specialeffortshadtobemadeforthisspecialprojectandtherehadtobeahugedegreeofcommitmenttowardsthecontractingauthorityonthepartofthecompanies.Ifwehadn‘tgivenlongguaranteeperiods,wecouldn‘thavedoneanybusiness.Theopennesseveryoneevincedtowardseachotherledtosynergiesthatnoonewouldhavethoughtpossiblebeforehand.Theenthusiasmwithwhichevery- oneparticipatedinthedevelopmentofthisbigandtotallynewachievementwasnoticeable.Know-howfromindustry,authori-tiesandthedifferentinterestgroupsallcametogetherhere.
So everyone had to enter unknown territory and actually get involved with a unique project.
Piet Maljaars:Thatwasexactlywhatmadeitsospecial,sounique.
PietMaljaars,Dutch Water Authority
EllisJanvanderHout,SKF Netherlands
Erik-JanDriessen,KlüberLubricationBelgium
PeterSchmehr,SKFGermany
Tribojournal 1/2012
Erik-Jan Driessen:Thecorrosionprotectionwascrucial.Istillknowfromthepast–IhavebeenworkingforKlüberLubricationformorethan20yearsnow–thatwehavealwaysattachedgreatimportancetofulfillingbothfunctions:sealingandlubricating.Naturally,bearingscanneverbedesignedtobecompletelysealediftheyaretowork.Afterall,theyhavetobefreetomove.Sothelubricanthastotakeoverasealingfunctionaswell.
How did you go about choosing the grease, and how come you decided to go for the German provider?
Peter Schmehr: Extensiveandprotractedexaminationsofthecomponentswerenecessary.Wehadtogainafirst-handunder- standingofthecontactofthegreasewiththeothercomponents.Forexample,howwouldtheslidingmaterialandthesteelgowitheachother,likewisethesealthatwouldenclosethebearinglater?
Everysinglecomponenthadtobecompatiblewiththegrease.Afteralltheteststherewerejustfourtypesofgreaseleftthatwetheninvestigatedmoreclosely.TheKlüberproductattainedthebestresults.SowesuggestedKlüberLubricationastherightpartner.Infurthertests,atSKFandalsoatKlüber,wevalidatedonceagainthebesttypeoflubricant.
Erik-Jan Driessen:Keepingthebalancebetweentherequire-mentsofprotectingandlubricatingwasthemostdifficulttask,butwemanagedit.Theprotectivefunctionhadtokeepgoingformany,manyyearsandthelubricationfunctionhadtobeavailablewheneverneeded.
And what, in your opinion, were the biggest challenges?
Piet Maljaars: The compression of the seabed so that the piles couldbefirmlyanchoredwasonething.Then,ofcourse,wehadtodealwiththespecificlocalcircumstances,suchasthechang- ingofthetides.Andthesizeoftheprojectrequiredthedeliveryofgiganticvolumesofconcrete.Thebeststeelbearingswereneededforthegatesaswellasaspecialitylubricantthatwasabletofulfilitslubricationpurposereliablyandonalong-termbasisandthatwas,furthermore,capableofpreventingcorrosionbytheseawater.Andthen,ofcourse,therewasalsotheprecisionwithwhicheverythinghadtobeperformed.Thegateshadtobefittedtoveryfinetolerances.Intheend,itwasallthelittledetailstogetherthatresultedintheimpressiveoverallresult.Andtheverybestthingisthat25yearsafteritsopening,thewholethingstillworkswiththesameprecisionasonthefirstday.
One element is of special importance: the lubricant that is used for the bearings of the gates has not had to be exchanged until today. The requirements were very high and it was a big challenge to find the perfect solution.
Ellis Jan van den Hout:Thelubricationcapacityofthegreasewasascrucialasitsresistancetowater.Thebearingshavetobeprotectedinthebestpossibleway,butprotectionfromcorrosionalsohastobeensured.Saltwaterisextremelyaggressive.Ifany- thinghasahighlydestructiveinfluenceonthelubrication,it‘ssaltwater.Sothebestprecautionisabsolutelyessential.
Thestormsurgebarrierprotectspeopleaswellasplantsandanimals-aperfectsymbiosisofnatureandtechnology
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Tribojournal 1/2012 76
Ithasalwaysbeenourdefinedgoaltofindpreciselytherightsolutionforthecustomer.Inthiscase,oneofthebigchallengeswastowarrantaservicelifeoftenyears.Alubricantthatwouldhavetobereplacedafterfiveyearswouldhaveincurredmuchhigheroverallcoststhantheextracostofourlubricant.Thepro- cessofexchangingthelubricantaloneisverypricey–andthatdoesn‘tevenincludethecostofthegrease.
So, Klüber’s specialty lubricant should not be considered a typical C-component but an actual design element?
Erik-Jan Driessen:Exactly.Evenwith14,000kilogramsoflubricanttheone-timecostofpurchaseisn’tthecriticalfactorbuttheadditionalvaluefortheoperatingcompanyoverthewholeoperatingperiod.Imean,wecannotjustpumpouttheoldgreaseandpumpinthenewone.Everythingwouldhavetobecom- pletelydismantled.Thecostswouldprobablybeimmense.Butatthemomenttherearenosignsthatanyexchangemightbenecessary. So the decision for Klüber Lubrication in terms of a long-terminvestmentprotectionhasprovedtoberight!
The lubrication at the Oosterschelde storm surge barrier is subject to regular sampling. Can you describe this process?
Erik-Jan Driessen: The free movement of the cardan suspen-sionsismeasuredeveryyear,andonceeveryfiveyearstheamountofgreaseischecked.Greasesampleshavebeentakenfromthebearingsandanalysedinthelaboratorythreetimessofar–with-out any cause for complaint.
The lubricant is simply too good.
Erik-Jan Driessen:IntheOosterscheldestormsurgebarrierprojecteverythingjustworkedoutreallywell.Thiscannotsimplybeexplainedbythewell-engineeredtechnologyoftheindividualcomponents.Icanonlyrepeat:everythingwenttogetherperfectlyandwasperfectlycoordinated,too.
Has the lubricant been improved in the meantime? Or is the product offered today still the same as it was 25 years ago?
Erik-Jan Driessen:Both.Theproductthatwasusedbackthenstillexists.Butofcoursealotofnewproductshavebeendevel- opedinthemeantime.Thepermanentlyincreasingrequirementsfromthedifferentindustriesrequirespecialtylubricantswithahighfunctionalandeconomicaleffectiveness.Therefore,atKlüberLubrication,weattachutmostimportancetoinnovation.
The Oosterschelde storm surge barrier became a prestige project for the companies involved. Is it still the same today? Are those who were and still are involved still proud to say: We were part of it?
Piet Maljaars:Yes,theOosterscheldestormsurgebarrierisanexcellenttestimonial.ThevastnumberofcompanybrochureswithpicturesoftheDeltawerkenisproofofthis.
Erik-Jan Driessen:ForKlüberLubricationIcansay:weareproudthatwegottobeinvolved.Anachievementandaresultthatcarriesweight.
Peter Schmehr:AlsoforSKF,itwasandstillisahighlyprestigiousproject.
Finally a personal question: 4 October is the 25th anniver-sary of the storm surge barrier – is it a special date for you?
Piet Maljaars:TheOosterscheldestormsurgebarrierwasapioneeringproject25yearsago.Becauseofthatitisstillsome- thingspecialtoday.Soattheanniversarytheinternationalnet- workforprotectivewaterweirsgatheredhereforaseminar.Apartfromthat,4Octoberwasaworkingdayjustlikeanyother.
Thebarrierconsistsof62movinggates,whichcanbelockedeithermanuallyor automatically
Tribojournal 1/2012
Workingwithcleancompressedair New,fullysyntheticcompressoroilshaveproven theirworthinpractice
Twokeyfactorsplayamajorroleincompressedairgeneration:highavailabilityofcleancompressedairandcompressedairgenerationatreasonablecost.Newly-developedsyntheticcompressoroilshaveproventheirworthinpractice.Longoillife- time,highefficiencyandaverylowoilcontentinthecompressedaircombinetoreduceoperatingcosts considerably.
Compressedairisthefourthenergyutilityafterelectricity,gasandwater.Fewproductionlinesintheworldwouldrunwithoutit.Themajorityofcompressedairisprovidedbyoil-injectedscrewcompressorsandthecompressoroilsplayamajorroleingener- atingcleancompressedairinanenergy-efficientway.Theyaccountfor less than one percent of the cost of compressor operation; however,therightoilhelpssaveaconsiderablepartofthetotalcost.Theoilhasthreekeyfunctions:Firstitensuresthattherotorsandrotorbearingsinthecompressorarelubricated,secondit dissipates the heat of the compression process and third it formsasealingfilmatthesealedgebetweentherotorandthecompressorcasing.
Forefficientandtrouble-freeproduction,anoilwithlongservicelifeandgoodtemperaturebehaviourwithlowresidualcontentinthecompressedairisrequired.However,thereareconsiderabledifferencesbetweentheperformancesofdifferentcompressoroils.Awell-formulatedsyntheticproducthasconsiderableadvan- tagesovermineraloil-basedproductsandstandsoutinparti- cularforoptimumoxidationprotection,goodadhesionandlowresidueformation.Thenewly-developedsyntheticoilsoftheKlüberSummitSHseriesandtheNSFH1-registeredKlüberSummit FG series made by Klüber Lubrication stand out because oftheirconsiderablyincreasedperformancecomparedtocon- ventional compressor oils.
Benefitsofsyntheticcompressoroils
Specialoxidation-resistantcompressoroilsensurereducedmaintenancecosts,highercompressoravailability,reducedtotalcostforoil,oilfiltersandoilseparatorsaswellasreduceddis- posalcosts.Furthermore,therightcompressoroilincreasescompressorperformancewiththesamepowerinputowingtoitshighlubricitybaseoilcombinedwiththeoptimumadditivepack- age.Duringthecompressionprocess,thisproductwillavoiddecomposition,oxidationandresidueformationoftheoil.
Thereareseveralfactorswhichhaveaneffectontheoilinthecompressor:highpressure,continualintakeoffreshair,hightemperatures,considerableshearingforces,particleintrusionand atmospheric humidity.
Tribojournal 1/2012 98
Allthesefactorscauseageingoftheoil,whichshowsmostlyasoxidation.Attemperaturesbetween90°Cand100°Cormoreandundercontinualoxygenintake,organicacidsproducedbyoxidationquicklydecomposetheoil,i.e.theoilagesrapidly.Theconcentrationofsuchacidsisexpressedbytheso-calledneu- tralisationnumber.Thelowerthisvalue,thelowertheextentofoxidation.KlüberSummitproductsensurealowneutralisationnumberthroughcarefullyselectedhigh-qualityadditives.
Condensateproducedbyairhumidityisanotherfactorleadingtohighmaintenancecostsasitmustbeprocessedpriortodisposaltothesewagesystem.Unsuitableoilsorlow-qualityadditivesleadtoemulsificationofthecondensates,makingitimpossibletoseparateoilandwaterinanormalseparator,requiringmore- expensivecondensateseparators,increasingcost.Particularlyinthefood-processingandpharmaceuticalindustries,theoilcon- tentinthecompressedairmustbeaslowaspossibleandcom- pressoroilsmustberegisteredasNSFH1,forexampletheKlüber Summit FG series.
Savingrealmoney
AleadingsausagemanufacturerwashavingtroublewithhisNSFH1compressoroils.Oilservicelifeoflessthan1,000hourscausedhighmaintenancecostsandfrequentdowntime.Follow- ingpreciseanalyses,KlüberLubricationrecommendedon-linecleaningofthecompressorswithKlüberSummitVarnasolvandchangeovertoaKlüberSummitFGoil.Aftercleaning,thecom- pressorcouldbeoperatedupto15Kelvincoolerthanbefore.Additionally,thecoolernolongerrequiredanannualstripandclean.Theoperatinghoursincreasedtomorethan4,000andmaintenancecostsweredecreasedconsiderablywhiletheoilpricewascomparable.
KlüberSummitFGoilswereespeciallydevelopedforcompres-sorsinthefood-processingandpharmaceuticalindustrieswherecompressedaircanhavecontactwiththeendproductduringtheproductionprocess.WithNSFH1registrationandcertifica-tionaccordingtoISO21469,theseoilssupportmanufacturingplantsintheircompliancewithdemandinghygienerequirements.KlüberSummitFGoilsshowverygoodresistancetooxidation,whichmeansthatthepresenceofoxidationresiduesorlacquerin the compressor is minimised.
Oilchangeintervalscanbeextended,e.g.upto5,000operatinghoursinoil-injectedscrew-typecompressors.Besidesreducedmaintenanceandoperatingcosts,thisenableshigheropera-tional reliability.
Anotherexampleisamanufacturerofparticleboards.Compressoroilchangeswererequiredafter2,000operatinghours. KlüberLubricationrecommendedchangingtoaKlüberSummitSHseriesoil.After8,000operatinghours,usedoilanalysisintheKlüberLubricationlaboratoriesrevealedthatadditivedegradationintheoilhadstarted,howevertheoilwouldnothavetobechangedforanother2,000hours.Hence,theoilservicelifeisfivetimeslongerthanwiththepreviously-usedcompressoroil.Summingthetotalcostsforoilchange,disposal,oilfilters,oilseparatorsandmaintenance,thepremiumproductturnsouttobethemostcost-efficientone.
Oil service life in compressors used by a manufacturer of particle boards could bequadrupled
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Tribojournal 1/2012
Thetotalcostcalculationintheaboveexamplerevealsconsider-ablecostsavings.Morecompressedaircanbeproducedwiththesameenergyconsumption(improvedspecificperformance).
KlüberSummitSHoilswereespeciallydevelopedforthelubrica- tionofheavily-loadedaircompressorswithprojectedoilchangeintervalsofupto10,000operatinghours(undernormaloperatingconditions).Theyareneutraltowardsmostelastomersealsusedin air compressors. Special inhibitors keep compressors clean ontheinsidetoavoidcleaningcostsandunplannedcompressordowntime.
Easycompressorcleaning
Mineraloil-basedcompressoroilscancausevarnishandcarbonbuild-up,especiallyinoil-injectedscrewcompressorsandrotaryvanecompressors,whichsettleintheentireoilcircuit.Inhydraulicsystems,mineraloilscancauseglueingofvalvesonhotsurfaces,resultinginhighenergyconsumption,cloggedoilductsandfiltersandhighmaintenancecostsanddowntime.
KlüberSummitVarnasolvmadebyKlüberLubricationisahighlyeffectivecleaningconcentratebasedonesteroilwithcleaningadditives.Itissubstitutedinaconcentrationof10%totheoilfilling60hourspriortothenextoilchangeandrunnormally.Thecleaningconcentratedissolvesresiduesonthesurfaceswhilethecompressorisinoperationandensuresthattheyremaindis- solvedintheoiltobeflushedoutattheoilchange.Thismethodismuchmoreeffectivethanflushingthecompressorwithnormalcompressor oil.
TheoperatorcaneasilydetermineifandwhenanoilchangeisnecessarywiththeKlüberSummitTANKit,whichusesthebreak- downacidsintheoiltoindicatebycolourtheextentofoxidationoftheusedoil.Alternatively,KlüberLubricationcanmakeafullusedoilanalysistodetermineanycontaminationandwearin the unit.
Conclusion
Practicalexamplesshowthatchangeovertofullysyntheticcom- pressor oils made by Klüber Lubrication can be made very easily. Oilservicelifecanbeconsiderablyextendedandcompressorperformance increased to save costs and valuable resources.
Core statements:– Modern compressor oils help save money– Morecompressedairwiththesameenergyconsumption
IfandwhenanoilchangeisrequiredcanbeeasilydeterminedbymeansoftheKlüberSummitTANKit
Robert Corna
SalesManagerCompressors
Klüber Lubrication Deutschland KG
Tribojournal 1/2012 1110
Availabilityiskeytotheoperationofwindturbinesasunplanneddowntimeresultingfromcomponentwearcanbeverycostly.Repairsorbearingexchangearetobeundertakenonlyintimesofplanneddowntimeandshouldbepreventedwheneverpossi- ble. Lubricant analysis can provide helpful information. While used oilanalysisisalreadystandardforgearoils,KlüberLubrication‘sanalysisserviceisnowalsoavailableforlubricantsingenerators,bladesandmainbearingsofwindturbines.The”GreaseConditionAnalysis(GCA)“serviceisnowavailableaspartofKlüberMonitor.
Bearinggreaseconditionanalysesbymeansofstandardisedmethodsonaregularbasisprovideinformationonthecurrentconditionofthegrease.Basedonanalysisresults,thefailure riskofexpensivecomponentsorsystemscanbereducedanduseful life be increased. Grease condition analysis is not only recommendedforstandardconditionmonitoring,butalsopriortochangingovertoanotherbearinggrease.
”KlüberLubricationconsidersthisoffertobeanelementofsus- tainablecustomercare“,saysAri-PekkaHolm,ManagerBusinessUnitWindEnergyatKlüberLubrication.”Ourresponsibilitydoesnotendafterhavingsoldabearinggrease.”
Ournewgreaseconditionanalysisserviceinformsoperatorsonthestatusquoandgivesasignofwarningwheneversomethingiswrong.“
Grease condition analyses made in Klüber Lubrication laborato-riesprovideinformationonseveralaspectsofagrease‘scurrentcondition,includinggeneralgreasecondition,behaviouroftheadditives,oxidation,wearparticles,mixingwithforeignmatterandoxidationandtheextenttowhicholdandnewlubricantaremixedafterchangeovers.Asamplingkitwithdetaileddescriptionis available from Klüber Lubrication.
TheexpertsfromKlüberLubricationwillbeprovidingastraight-forward,clearreportontheresultscontainingrecommendationsonhowtoproceed.GreaseconditionanalysisisavailableforselectedlubricatinggreasesfromKlüberLubrication.
NewserviceforoperatorsofwindturbinesBearinggreaseconditionanalysesfortrouble-freeandreliableoperation
Dipl.-Ing. Alexander Dörner
Service Developer
Klüber Lubrication München KG
Tribojournal 1/2012
Machinetoolstodayshouldbecapableofincreasingtheoverallproductivityofacompanythroughmaxim- isedmachiningspeedsandfeedsandtheassociatedreduction of cycle times. Both the manufacturers and operatorsofmachinetoolsexpectsafeoperationandhighprocessreliabilityaswellasincreasedmachineavailability.Furthermore,thedynamic,globalconsid-erationofcostshasbecomeincreasinglyimportant:conceptssuchaslifecyclecosting(LCC)ortotalcostofownership(TCO)takeintoaccountnotonlythepurchasepriceofamachine,butalsoalladditionalcostsarisingduringitsoperationalservicelifetime.Theseincludenotonlyrecurringexpensesforserviceandmaintenance,spareparts,compressedair,energydemand,lubricantsandtools,butalsopotentialcon- sequentialcoststhatmayarisefromtheoperationofthemachineaswellaseventualdisposalcosts.
Besidestheeconomicaspects,greatemphasisistodayplacedonenvironmentalissues,i.e.theobjec-tive that machine tool operation should pose as little anenvironmentalhazardaspossible.Theglobalavailability of products needed for machine operation istodaygenerallyexpected,asiseffectiveserviceandsupport,tobedeliveredeitherbyqualifiedstaffvisitingtheplant,orbymeansofremotemaintenance.
Lubricantswithoptimisedfrictioncoefficientscanhelpincreaseenergyefficiency
Empiricalstudiesshowthatasmuchas70to85ofamachinetool‘slifecyclecostsisalreadydeterminedduringthedevelopmentstage. Synthetic lubricants can help to minimise these costsbyextendingcostlyrelubricationandoilchangeintervals,orevenbyenablinglifetimelubrication.Atthesametime,theseproducts can improve machine performance.
Precision,efficiency,sustainabilitySpeciality lubricants for machine tools contribute tohigherproductivityandlowerlifecyclecosts
Tribojournal 1/2012 1312
Itpaystoconsiderlubrication atthemachinedesignstage
Empiricalstudiesshowthatasmuchas70to85ofamachine‘slifecyclecostisalreadydeterminedduringitsdesignstage.1)Itisatthispointthatlubricants,whichareoftenoverlookedduetotheirpresumedminorrole,areinfactofextremeimportance:Syntheticspecialitylubricantshaveinmanycasesproventoextendre- lubricationandoilchangeintervals.Quiteoften,theycan even enable lifetime lubrication in an application. Atthesametime,specialitylubricantscanenhancemachineperformanceintermsofimprovedprecision,extendedproductionoutputorreducedrejectrate.KlüberLubricationprovidesawiderangeofhighlyeffective,high-qualityspecialitylubricantsforallmachinetoolapplications.Havingbeendevelopedincloseco- operationwithmanufacturersofmachinetoolsandtheircomponents,thesespecialgreasesandoilsareusedforinitialfillbytheOriginalEquipmentManufacturers(OEMs) and also recommended in lubrication charts provided to the operators.
Thisarticledealswithaspecificitemofcuttingmachinetoollubricationinvolvingcriticaloperatingconditionswithdemandingrequirements:thelubricationoflinearguidesinmachinetools.
The lubrication of drive and guidesystems
Moreandmoreoftoday‘smachinetoolscontainlow- frictionlinearguidesratherthanconventionalslidewaystoenablepositioningoftheworkpieceand/ortool.Motionisnormallyachievedviaballscrews.Thelinearguidesaredesignedasflatguidesorprofiledrailsin- corporatingrecirculatingballsorrollers.
Thespecificrequirementstobemetbythese components–whichalsoinfluencetheselection oflubricant–are:– Highprecision– Highreliability– Lowvibration,nostick-slip– Highspeeds– Highaccelerationleadingtohighdynamicloads
Amultitudeofinfluencingparametersplayaroleintheconstructionandoperationofmachinetooldrivesystems:– Typeoflinearguide– Friction bodies and seals/caps– Operatingconditions– Usefullifeofthelubricantandrelubrication– Otherexternalinfluencingfactors
For Klüber Lubrication, “sustainable industrial production” means long-term, holistic thinking.Three examples for this include: reducing unplanned downtime to a minimum, reducing friction even further and cutting lubricant consumption. The effect: lower energy con- sumption and cost, less CO2 emission, longer maintenance intervals and longer component lifetime. We also aim at continually developing our environmentally-friendly lubricants to pro- tect man and nature, and helping our customers to attain their goals in the fields of environ- mental protection and conserving resources more easily.
Klüber Lubrication: technological innovations for ecologically and economically efficient solutions.
your global specialist
Speciality lubricants for sustainable efficiency.
Tribojournal 1/2012
operatorsiflubricantsarecompatiblewithandresistanttospe- cificmedia.
Oncethe”correct“lubricant,i.e.oneoftherightconsistencyclassandbaseoilviscosity,hasbeenselected,aproperlyper- formedrunning-inprocedurecanhaveadecisiveeffectonlubricationinthelongterm,andhenceontheperformanceoflubricantandcomponent.Forrunning-in,thegreaseshouldbedistributedalongtheguidewayorintheguidebushingbyper- formingseveralfull-lengthstrokes.Subsequentrelubricationisthencompletedwithamaximumof50%oftheinitiallubricationvolume,butpreferablywithsmallervolumesappliedatshorterintervals.
ConclusionItisnotuncommonforlubricants,whicharenormallyconsideredlow-priority”C“components,toassumean”A“functionwithapositive effect on machine tool TCO. To fully utilise the potential providedbyoptimisedlubrication,aglobalapproachisindispen-sableforanysolutiondevelopment:– The lubricant should be considered as a machine element alreadyatthedesignstageofthemachinetool/component.
– Theperformanceofthelubricant,itsapplicationanddosageare taken into account.
– Thechosenlubricantshouldbecompatiblewithotherlubri- cantsandmaterials,e.g.thoseusedfortheseals.
– Thelubricantneedstoberesistanttoanyexternalinfluencesandliquidmedia,suchascoolants.
Withthesepointsinplace,productiontothescheduledplan canbeexpectedwithoutmachinebreakdownorunplanneddowntime.
References:
1)VDIGuideline2884:Purchase,operatingandmaintenanceofproductionequipmentusing
LifeCycleCosting(LCC),December2005
Dipl.-Ing. Stefan Müller
MarketManagerGlassand
Metalworking,Machines,Tools
andInstallations
Klüber Lubrication München KG
Consideringthedesignofinternalandexternalseals,cageguides,lubricant reservoirs and lubricant feed lines it it becomes obvious whythelubricantshouldbeconsideredanimportantmachineelementinitsownrightearlyinthemachinedesignstage.
Consideringthesystemasawhole,thehighrequirementstobemetbylinearguidesresultinequallyhighrequirementstobemetbythelubricants:– Goodanticorrosivebehaviouranddemulsifyingabilityenablingresistancetomedia,andespeciallytocoolinglubricants
– Dampeningofvibrationorshocks,whichisimportante.g. forthemachiningofgreycastiron
– Wearprotectionalsoundermicro-movementconditions– Lowfrictionenablingeasystart-up– Additionalsealingpropertieswhenoperatingincontaminated
environment– Goodcompatibilitywithplastics,elastomersandother
lubricants
Different lubricant compositions to meetdifferentrequirements
Dependingontherequirementsofeachindividualapplications,specialitylubricantsofdifferentcompositionareavailable–e.g.lubricantswithdifferentbaseoilviscositiesmatchingdifferentspeedsandloads(seeFig.1).Differentthickenertypesprovidecharacteristicssuchasimprovedadhesiontometalsurfaces,goodresistancetofluidmediaaswellasimprovedgooddampen- ingeffect.
InitialgreasingoflinearguidesisnormallyprovidedbytheOEMfollowingmanufacture.Relubricationisthenperformedbytheoperatorusingcentralisedlubricationsystemsorlubricantdis- pensers(particularlyforsoftgreases).Itisthereforevitalthatthelubricants used for initial lubrication and relubrication be fully compatiblewithoneanother.Wheremanufacturershavenotpro- videdpertinentinformation,severaltestingmethodscanbeusedtodeterminelubricantcompatibility,e.g.thewaterwashouttest,therollstabilitytestortheSNR-FEB2test.Thesetestsalsotell
Fig. 1:Guideforselectingtherequiredbaseoilviscositiesfordifferinglinear speeds
Linear speed
low
<15m/min
vibration<0.5m/s2
increasedwear
highviscosity(100to500mm2/s)
MICROLUBEGL261/262
medium viscosity(approx.100mm2/s)
KlüberplexBEM41-141/34-132
increased friction heat
lowviscosity(25to70mm2/s)
ISOFLEXNBU15/TOPASNB5051
medium
15to60m/min
vibration < 1m/s2
high
>60m/min
vibration < 2m/s2
Fig. 2:Workedpenetrationistestedtodeterminetheeffectacoolinglubricanthasontheperformanceofagrease.TestsperformedwithISOFLEXNBU15showthereishardlyanydifferencebetweentheoriginalusedgreaseandtheusedgreasecontaining2.5%ofcoolinglubricant.
ISOFLEXNBU15 ISOFLEXNBU15+2.5%coolinglubricant
340 340
320 320
300 300
280 280
260 260
240 240
220 220Wor
ked
pen
etra
tion
1/10
mm
Freshgrease Usedgrease
Examination of resistance to media
Tribojournal 1/2012 1514
Dipl.-Ing. Dirk Fabry
MarketManagerMaritimeund
OffshoreIndustries
Klüber Lubrication München KG
More and more operators and suppliers of mari-timeandoffshoreequipmentareinvolvedinmini- misingtheirimpactontheenvironment.Theseefforts affect the choice of lubricants used in ships,andmachineryingeneral.Withspecialitylubricantsenablingsustainableandprofitablesolutions,KlüberLubricationsupportsshipown-ers,OEMsandoperatorsinreachingtheirenvi-ronmentalgoalsmoreeasily.
KlüberbioRM2-100,thenewreadilybiodegradablesterntubeoil,isdesignedforthelubricationofpropellerbushesandpropellershaftsealsoffixed-pitchandcontrollable-pitchpropellers.Thesyntheticspecialityoilisnon-toxictomarineorganisms–accord- ingtoOECD201,202and203tests–anditsbiodegradabilityisatleast60percentaccordingtotheOECD301Ftest.Aleadingglobalmanufacturerofpropellershaftsealssubjectedthenewsterntubeoiltoadynamicendurancetestonatestrigfittedwiththeoriginalseals,anditpassedsuccessfully.
Justasthefirstoilofthisseries,KlüberbioRM2-150,thenewoilwithviscosity100facilitatessmoothstart-upofpropellers,evenatverylowtemperatures.WhereasKlüberbioRM2-150isdesignedforapplicationinmoderateandwarmerregionsoftheworld,thenewKlüberbioRM2-100copesreliablywiththecolderclimates.BothKlüberbioRM2oilshavealongservicelifeowingtotheirgoodstabilityagainstoxidation,hydrolysisandtemperatures.KlüberbioRM2oilsaremisciblewithmineraloil-basedsterntubeoilsforeasychangeover.
InthedevelopmentofbothKlüberbioRM2oils,KlüberLubricationcooperatedcloselywithitsaffiliatedcompaniesSIMRITandMerkelFreudenbergFluidtechnik,bothleadingsuppliersofshaftsealsandprofiledsealstothemaritimeindustry.LikeKlüberLubrication,thesetwocompaniesbelongtotheFreudenbergGroup.Together,thethreecompaniesarethereforeinauniquepositiontomatchelastomersandlubricatingoilsforthetaxingrequirementsofpro- pellermanufacturersandshipowners.
Tailor-made,reliableandgoodfortheenvironment Newsterntubeoilexpandstherangeofreadilybiodegradableoils for the maritime and offshore industry
Tribojournal 1/2012
All-roundlubricantforexcellentwearprotection KlüberfoodNH194-6000isahigh-performancefluidgrease forhigherprocessreliability
Ithasbeentraditionallyassumedthatlubricantsapprovedbythefood-processingindustryare notveryefficient.KlüberLubricationclearlyprovesthiswrongwithitsspecialitylubricantsforthefood-processing,cosmetics,pharmaceuticalandanimalfeedsindustries.ItslatestdevelopmentKlüberfoodNH194-6000forexampleprovesoncemorethatNSFH1-registeredlubricantsareveryefficient.
Thedevelopmentofthisnewspecialitylubricantarosefromaspecificrequirement:Acustomerneededafood-gradegreasewithparticularlygoodflowcharacteristicsincentrallubricationsystemsofferinggoodwearprotection.”Ourproductdeveloperscreatedthishighlyefficientfluidgreasefromcarefullyselectedrawmaterials“,saysSabinePetri,ProductManageratKlüberLubricationMünchenKG.KlüberfoodNH194-6000standsout,amongotherthings,foritspermanentlysoftconsistencyavoidingcloggedfeedlinesincentrallubricationsystemsandhenceprovidinghighprocessreliability.
Duetoitsspecialcomposition,KlüberfoodNH194-6000offersanunusualcombinationofperformancecharacteristics.Itpro- tectsagainstweareffectivelydespiteitsverysoftconsistency(NLGI000)andattainsloadstage>12intheFZGscuffingloadtestaccordingtoDINISO14635.Atthesametime,itoffersex- cellentwearandcorrosionprotection.”Thisisexceptional“,saysSabinePetri,”asthechoiceusedtobebetweeneithertheoneortheotherinthepast.Thereismore:ourproductdevelopmentteamroundedtheconceptoffwithgoodwaterresistanceandgoodlow-temperaturecharacteristics.KlüberfoodNH194-6000thereforeefficientlyprotectsmachinesandinstallationsagainstwear,eveniftheyaresubjecttofrequentwaterwashdownorlowtemperatures.”
KlüberfoodNH194-6000canbeusedinthefood-processing,cosmetics,pharmaceuticaloranimalfeedindustriesowingtoitsmanifoldperformancecharacteristicsandNSFH1-registration,e.g.forbearingordip-feedlubricationofgeardrives,wormgearsorchains.Thespecialgreasehasproventobeeffectiveinmilk- processingequipmentwhichissubjecttochilltemperatures,and
infood-packageprintingmachines,forwhichKlüberfoodNH194-6000wasdeveloped.However,thisspecialitylubricantisalsosuitableforapplicationsoutsidethefood-processingindustry:itensuressmoothrunningoflinearguidesanddoorhingesinkitchen furniture.
”KlüberfoodNH194-6000iscurrentlygoingthroughthecertifi- cationprocedureaccordingtoISO21469bytheNSFinstitute,ashaveallH1productsfromKlüberLubrication“,addsHelgaThomas,MarketManagerforthepharmaceuticalandchemicalindustries.”Inspectionprocessescurrentlytakeafewmonths,soweconsidertheNSFISO21469sealforKlüberfoodNH194-6000willbeavailablebythemiddleoftheyear.“
Tribojournal 1/2012 1716
TheISO21469standardiswell-establishedandtheworldof H1lubricantshasbecomeinconceivablewithoutit.However,thequestionarisesofwhetherthe”ISO21469Certified“logocanbeinterpretedasasealofqualityineverycase.
Withaviewtoquality,itisimportanttohaveacompetentcertifi- cationcompanyinspectingtheH1productionprocessesof H1lubricantsupplierswithacomprehensiveandcomprehensibleISO21469certificationprogramme.
Thecertificationprogrammedeter-mines the individual steps to prove impeccable production conditions for H1lubricantsforuseinthefood-pro-cessingandpharmaceuticalindustries.TheindependentNSFinstituteforin- stancerequiresinitscertificationpro- grammeannualauditsofproductionplantsforH1products.Inadditiontoauditsofproductionprocesses,recipedata are inspected for currency and
compliancewithNSFrequirements.TheNSFalsotakessamplesfor chemical analysis.
Incontrasttothat,theISO21469standarditselfisrathergeneral.Therearenosuitableverifiablecriteriaforacertification.There-fore,certificationbasedonthisstandardonpaperaloneisnotsufficientwhenitcomestocomprehensibleandsustainableim- provements of production conditions of H1 lubricants.
Workingwithacompetent,experiencedcertificationcompanythatisacknowledgedworldwidegivestheextraedgeofsecurityandisrecognisableforcustomersatfirstsight.TheNSFawardsaneasilyrecognisable”NSFISO21469Certified“logoforuseonH1lubricantlabels.Itsmajoreffectistoprovideinspectedsecurityforcustomers:thelogostandsforverifiablequalityinspectionsofproduction conditions for H1 lubricants.
Klüber Lubrication deliberately chose the NSF institute for its long-standingexperienceandhighcompetenceinthefieldoffoodanddrinkingwatercertifications.
The European Hygienic Engineering & Design Group (EHEDG) is a consortium of equipment manufacturers, food industries, research institutes as well as public health authorities and was founded in 1989 with the aim to promote hygiene during the processing and packing of food products.
The principal goal of EHEDG is the promotion of safe food by improving hygienic engineering and design in all aspects of food manufacture.
EHEDG actively supports European legislation, which requires that handling, preparation processing and packaging of food is done hygienically using hygienic machinery and in hygienic premises (EC Directive 2006/42/EC for Machinery, EN 1672-2 and EN ISO 14159 Hygiene requirement).
As a member of this organisation, Klüber Lubrication actively supports and contributes to the goals of EHEDG.
KlüberLubricationisnowalso a member of EHEDG
It’sthelittlethingsthatmake all the difference ISO21469certification
Helga Thomas
State-certifiedfoodchemist
MarketManagerPharmaceuticaland
ChemicalIndustries
Klüber Lubrication München KG
Tribojournal 1/2012
AutomotiveEngineeringExposition 23–25MayYokohama,Japan
Techtextil 24–26AprilAtlanta,USA
InnoTrans 18 – 21 SeptemberBerlin,Germany
Newspecialoilforcontinuouswood fibrepanelpresses
KlüberLubricationislaunchingthehigh-temperatureoilKlüberthermCH2-260designedforthelubricationofchainsandsteelbeltsincontinuousfibreboardpresses.Thisoilcom- pletesourrangeofspecialhigh-temperatureoils.DuetoitsnewanduniquerawmaterialsKlüberthermCH2-260offersout-standingperformancecharacteristics.Thisspecialoilshowsexcellentresistancetoevaporationevenattemperaturesas highas250°Candmore.Thedesignofthelubricantensuresthatitformsonlyminimalresiduesandensurescontinuallowfrictioninmachines.Thebenefitsavailableinclude:
– Machinesrequirelesscleaningandmaintenance– Oil and current consumption is reduced– Utilisationofproductioncapacitiesisoptimised
Operatorsbenefitfromsignificantenergyandcostsavings and reliable production processes.
Tradeshows,aplacetomeet
Latestdevelopments,services,andexpertslookingforwardtoansweringyourquestions:TaketheopportunitytomeetKlüberLubricationatoneofthemanytradeshowsweareparticipatinginthisyear.Herearesomeoftheplacesforustomeet:
Youwillfindanoverviewofallthetradeshowsweare participatinginunderwww.klueber.com/News/Events.
Expomin 9 – 13 AprilSantiagodeChile,Chile
IndustriAutomation 15–18MayBudapest,Hungary
BIEMH28May–2JuneBilbao,Spain
SMM 4–7SeptemberHamburg,Germany
HusumWindEnergy 18 – 22 SeptemberHusum,Germany
News
Tribojournal 1/2012 1918
Tribojournal
PublisherandCopyrightKlüber Lubrication München KGGeisenhausenerstraße781379München–Deutschlandphone+49(0)89/7876-0Fax+49(0)89/7876-333E-mail:[email protected]/TJ121002
Reprints,totalorinpart,arepermittedonlypriorconsultationwith Klüber Lubrication München KG and if source is indicated and voucher copy isforwarded.
The contents of these articles are based onourgeneralexperienceandknow-ledgeatthetimeofprinting.Theyserve forgeneralinformationonlyandcanbe nosubstituteforexpertconsulting.Wetherefore do not accept liability for any damageresultingfromusinginformationgainedfromthesearticles.Anyinforma-tiongivenonKlüberproductsdoesnotconstituteanassuranceofproductprop-ertiesorofaproduct’ssuitabilityfora particular application. Our competent staffwillbepleasedtosupportyoubyconsultingyouinallmattersregardinglubrication.Ifrequiredandpossiblewewillbepleasedtoprovideasamplefortesting.
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Innovativetribologicalsolutionsareourpassion.Throughpersonalcontactandconsultation,wehelpourcustomerstobesuccessfulworldwide,inallindustriesandmarkets.Withourambitioustechnicalconceptsandexperienced,competentstaffwehavebeenfulfillingincreasinglydemandingrequirementsbymanufacturingefficienthigh-performancelubricants for more than 80 years.