NTM Corp: Mobil SHC Presentation on power cost reduction using mobil shc - customer deck 120330

Where industrial productivity begins.TM

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Industrial Synthetics

Mobil SHC:

Energy Efficiency

kasjacaNTM Corp 2012

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Content Overview

• Industrial Maintenance Budget

• Energy Efficiency Management

• Opportunities for Mobil SHC

• Seven (7) advantages of Synthetics

o Advantage in Focus

• Engineering Activity on Energy Efficiency

o Methodology

o Tools

o Benefits Presentation

• Mobil SHC Lubricants for different applications

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Percentage Breakdown of an Industrial Maintenance BudgetSource: Society of Tribologists and Lubrication Engineers (www.stle.org)

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Breakdown of the labor and materials in an Industrial Maintenance Budget

Percentage Breakdown of an Industrial Maintenance Budget

Portions of the maintenance budget directly influenced by plant lubricant practice

Source: Society of Tribologists and Lubrication Engineers (www.stle.org)

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Energy Cost – A New PerspectiveSource: http://www.machinerylubrication.com/Read/214/lubricant-enery-savings

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Builder recommendation

Significant component failures and unplanned equipment shutdowns

Extreme temperatures

High load, high or very low speed

Short oil drain intervals

Short grease re-lubrication intervals

High energy consumption

High spare parts consumption

Environmental issues (less waste oil)

Risk of food contamination

Opportunities for usage of synthetic lubricants

Mobil SHC vs. Mineral Lubricants

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7 Advantages ofSynthetics

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1) Excellent viscosity/temperature properties and shear stability

2) Good low temperature property

3) Good high temperature oxidation and thermal stability

4) Low volatility

5) Good Traction property

6) Compatibility with mineral oils

7) Longer oil life

Seven (7) advantages of Synthetics

High Energy Consumption

Short Drain Interval

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Advantage in Focus:#7 – Longer oil life – up to 6 times better than mineral oil

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Monitoring of Oil Condition – Signum Oil Analysis Program

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• In today’s industry, condition-based maintenance practices have gained widespread acceptance.

• Key industry leaders increasingly realize that oil analysis is a critical component in any equipment monitoring program.

Condition – Based Monitoring

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FlexibilityPerform many tasks more efficiently with Signum Oil Analysis online capabilities.

ExpertiseThrough global Original Equipment Manufacturer (OEM) relationships and hands-on lubrication experience, ExxonMobil supports your maintenance activities.

QualityMake decisions with confidence by leveraging the quality assurance offered by ExxonMobil.

Informative reports on the condition of lubricants and equipment

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1. Establish Goals and Metrics

2. Obtain Management Commitment

3. Train and Educate Personnel

4. Identify Equipment and Sample Frequencies

5. Implement the Program

6. Respond to the Analysis Results

7. Measure Program Results Versus Goals and Metrics

8. Review and Modify Program

9. Document Savings

Steps to Establish and Maintain a Successful Oil Analysis Program

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General Approach on Monitoring of Oil Condition

TrialRunning Hours (RH)

0 2000 4000 6000 8000

1 S S/C

2 S/C

3 S/C

4 S/C

Legend:• S – Oil Sample taken for analysis• C – Oil Changed as part of maintenance

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Advantage in Focus:#5 – Good Traction Coefficient

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Under conditions of an EHL contact energy is required to shear the lubricant film

Traction coefficient is a measure of this energy

Traction coefficient depends on molecular shape

Some synthetics have significantly lower traction coefficients than mineral oils

Traction coefficients

Good Traction (Friction) Properties5

Mineral oil

Synthetic oil

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Focus on Advantage #5 – Good Traction Properties

Synthetic Oil

Mineral Oil

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Good Traction (Friction) Properties5Mobil SHC 600

Sump Temp 75C

Efficiency 76%

Incr

easi

ng

tem

per

atu

re

Note: Results can vary slightly from batch to batch

Competitive Synthetic runs hotter than the mineral oil product & nearly 8C hotter than Mobil SHC 600

Mineral

82°C

74%

82C

74%

Competitive Synthetic

83C

74%

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Mineral Grease, MAX Temp = 58C (136F) Mobilith SHC, MAX Temp = 44C (111F)

Good Traction (Friction) Properties

Thermographs of FE-8 test rig bearing

Lower traction builds a better film, leading to lower bearing temperatures

5In

crea

sin

g t

emp

erat

ure

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Mineral

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0 5 10 15 20 25 30

%Slide-Roll Ratio

Trac

tio

n C

oef

fici

ent

1. Start of meshing cyclePositive sliding

Pressure

1

Traction in Meshing Gear Teeth

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Mineral

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0 5 10 15 20 25 30

%Slide-Roll Ratio

Trac

tio

n C

oef

fici

ent

2. Pitch lineZero sliding

Pressure

2

1


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Mineral

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0.08

0 5 10 15 20 25 30%Slide-Roll Ratio

Trac

tio

n C

oef

fici

ent

1 3

2


Pressure


Pressure

3. End of meshing cycleNegative sliding

Pressure


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Mineral

Mobil SHC


Pressure


Pressure

3. End of meshing cycleNegative sliding

Pressure

Mobil SHC saves energy over most of the meshing

cycle

0.08

0

0.01

0.02

0.03

0.04

0.05

0.06

0.07

0 5 10 15 20 25 30%Slide-Roll Ratio

Trac

tio

n C

oef

fici

ent

1 3

2


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Good traction properties improve lubrication

Good Traction Coefficient means..

..lower friction between oil molecules,

..lower energy losses due to friction in lubricated components,

..lesser work on motors driving the equipment,

..lower power consumption on the equipment!!

which leads to..

which leads to..

which leads to..

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0.0

2.0

4.0

6.0

8.0

10.0

Laboratory Tests Gear Manufacturer's Tests Users' Experience

2.2%

5.6%

7.7%

3.8%

4.4%

8.8%

2%

6% 5.8% 6%

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.

Good Traction (Friction) Properties

Lower traction coefficient results in reduced energy consumption

Percent increase in efficiency (2% to 8.8%)5

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Good Traction (Friction) Properties5

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2%350

820

Previous w/ SHC 6XX Previous w/ SHC 6XX

1 Equipment 01 23,380.0 22,912.4 3,740.80 3,665.98 74.82 26,185.60 2 Equipment 02 17,976.0 17,616.5 2,876.16 2,818.64 57.52 20,133.12 3 Equipment 03 14,980.0 14,680.4 2,396.80 2,348.86 47.94 16,777.60 4 Equipment 04 16,716.0 16,381.7 2,674.56 2,621.07 53.49 18,721.92 5 Equipment 05 14,800.0 14,504.0 2,368.00 2,320.64 47.36 16,576.00

TOTAL 98,394.24

Power Consumption (W) Power Cost / Day Savings /

DayAnnual Savings

Target Savings

Working Days / Year

Power Cost / KW-Hr

Average RH/Day

# Equipment ID

Conservative only at least 2% reduction from the information shown in the previous slide..

Each of the 5 subject equipments is driven by a 440-V DC Motor with an average Current of around 70 Amps running at the indicated operating conditions.

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Methodology

1) Gathering of baseline information. Equipments in subject (Brand, Make, Model, Capacity, Maintenance Background, etc..) Maintenance logs, records, maintenance methods and systems.

2) Focus on the Power Equation (P = V * A) This equation is simple but reliable as Current directly affects Power while Voltage,

though fluctuates, can be considered constant. Note that we need to specify if the electric motor to be tested is a DC or AC motor, DC

Motors are best used for this test. This is to eliminate Power Factor Correction, and results can be taken as calculated. This will make our evaluation easier yet reliable.

3) Gather initial values from the existing equipment BEFORE changing to our SHC. This will be

used as baseline data/values. NTM to request verification and acknowledgement of the initial figures customer personnel. We will refer our proposal to these figures.

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Methodology

4) NTM to present the proposal as shown in Slide 17.

5) AFTER the oil is changed to Mobil SHC, monitor Current values at the same times as when the initial values were taken. (i.e., 8AM? 10AM? 2PM? 4PM?, 2x/day? 3x/day, etc..)

6) Plot the values gathered using the same template as the proposal then compute for the new efficiency.

7) Plot the values gathered using the TCO / UCP Templates to show the benefits gained.

8) Present formal report of the documented benefits.

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1) Some equipments have their own Power Meters to be attached on their equipment for specific purposes.

2) Some equipments will indicate Voltage and Current values in its monitor/panel.o Atlas Copco compressors are examples of these. Some

even store values in its memory for monitoring purposes.o Other refrigeration compressors have these features

3) Another reliable tool is to use a Clamp Meter for directly reading Current values.

Tools for measuring important parameters

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Presentation of Documented Benefits

1) Annual Maintenance Cost of:

Lubricants Consumption

Energy Consumption

Parts Replacement

Labor Cost

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Application Product Series / NameAvailable

ViscositiesRemarks

Worm Gears Mobil Glygoyle 460 460Brass and Bronze metallurgy

Enclosed Gears Mobil SHC 60068, 150, 220, 320, 460

Enclosed Bearings Mobil SHC 60068, 150, 220, 320, 460

Open Bearings Mobilith SHC 220

Air Compressors (Screw) Mobil Rarus SHC 1026 68

Air Compressors (Reciprocating)

Mobil Rarus 827, 829 100, 150

Refrigeration Compressors Mobil Gargoyle Arctic SHC 226E 68

OK for Ammonia and Hydrocarbon Refrigerants

Mobil SHC Products for different industrial machinery applications

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The cost of the Right Oil is not the real cost of Lubrication