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 Contents
8COVER STORY
Using Ultrasound to Improve Lubrication Practices
By using ultrasound technology, lubrication technicians can combine standard time-based maintenance with
condition-based predictive maintenance to gain a clearer picture of whats happening inside their equipment.
January-February 2015

2 AS I SEE IT
Recognizing the Causes and Hazards of Silt Lock
Because of its lack of warning or predictability, silt lock is responsible
30 PERSPECTIVE
Machine Modifications That Increase Reliability
Retrofitting machines requires management support and an alloca-
for some of the most devastating and destructive catastrophes in tion of resources, but the return can be several times the investment.

36
mechanical machinery. Find out how to control the risks.

4
IN THE TRENCHES
FROM THE FIELD The Hard Truth About Particle Contamination
How Cold Temperatures Affect Your Lubricants While you may already be aware that dirt is harder than most metals
found in machines, do you know how much harder it is?

40
Cold temperatures can have dramatic effects on your lubricants and
machinery. It is important to know the possible consequences before

16
you start up equipment on a cold morning. GEAR LUBRICATION
How to Prevent Foaming and Air Dispersions
LUBE-TIPS in Industrial Gear Oils
Our readers offer advice on a host of lubrication-related issues,
Common methods to estimate the air release and foaming properties
including tips on selecting the right grease.

20
of lubricating oils do not provide reliable information for industrial
gear oils. Learn how a special test can deliver more accurate results.

48
INDUSTRY FOCUS
Strategies for Managing the Wave CERTIFICATION NEWS
of Retiring Workers ICML Marks 14 Years of Industry Success
With the changing workforce climate, organizations must
Following 14 years of consistent growth, the International Council
understand the dynamics of near and long-term turnover as well
for Machinery Lubrication has become the world leader in the
as the best tactics for capturing knowledge from plant workers

50
certification of lubrication technicians and oil analysts.
approaching retirement.

28LESSONS IN LUBRICATION
Follow the Trend for Successful Oil Analysis
Trending data in oil analysis reports provides a powerful means
BACK PAGE BASICS
Advantages of Contracting Out
Your Lubrication Program
of recognizing when an oil property is moving in an unhealthy or If you do not have immediate access to skilled, trained and certified
threatening direction. lubrication technicians, it may be time to contract out this function.

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AS I SEE IT
J IM F ITCH | N ORIA C ORPORATION
RECOGNIZING the Causes
and Hazards of SILT LOCK
D o you know about silt lock?
This common condition
causes motion impediment
failure in certain machines. While this type
of failure usually doesnt involve wear or
permanent internal damage to the machine,
it is sudden and abrupt. Silt lock is the result
of solid contamination and is amplified by
other conditions that must be controlled
where possible. It is most often associated
with hydraulic systems and produces
seizure or jamming of components.
Because of its lack of warning or predict-
ability, silt lock is responsible for some of the
most devastating and destructive catastro-
phes in mechanical machinery. These
include mechanical casualties, prolonged
production losses and even loss of human
life. Silt lock has been found to be the root
cause of countless failures related to aircraft,
spacecraft, passenger cars, elevators,
turbine generators, tower cranes, etc.
Obliteration-Prone
Electrohydraulic Valves
Electrohydraulic valves are used exten-
sively in modern hydraulic systems. They
couple the immediate response of electrical
control with the high power of hydraulics. In
other words, they rapidly convert electrical
energy to powerful and responsive mechan-
ical energy. Because the structure of these
valves is generally more complicated and
intricate than ordinary control valves, they
are less tolerant to solid contamination.
Typical examples of such valves include
solenoid, pulse-width modulated (PWM),
proportional control and servo valves. For
2 | January - February 2015 | www.machinerylubrication.com
example, electrohydraulic valves are critical
to steam turbine performance and include
steam throttle valves, trip solenoid valves
and intercept valves. In gas turbine service,
you might have an inlet guide vane valve (on
peaking units) and/or a gas control valve (in
base load units).
As shown in Figure 1, silt particles less
than 10 microns can enter the clearances
between the spool and bore in the leakage
path. This obliteration of the clearance
space can result in increasing static friction
of the spool when the valve is actuated. This
can cause a stick-slip movement, which is
also known as a hard-over condition. Servo
valves are particularly prone to this form of
contaminant failure due to their high
performance demands. For instance, a
stick-slip of valve movement in commercial
aircraft hydraulics might result in the loss of
critical control during a landing sequence.
Critical Risk Factors
Particles generally dont act alone in
causing silt-induced motion impediment
failures. Most often it is a team effort that
increases both the magnitude and
frequency of the risk. These risk factors are
described below:
Particle Size and Clearance
As with contaminant wear, particle size
matters. Very large particles cant enter the
working clearance and are swept aside. Very
small particles pass through the clearance
without restriction. However, clear-
ance-sized particles cause the highest risk.
This is seen in Figure 2 where 10-micron
particles exhibited greater static friction in
Hydraulics
Silt
Lands
High
Pressure
Low
Pressure
Spool
Silt Particles Seed
Particle
Bore
Figure 1. Silt particles migrate into the
clearances between a valves spool and bore,
increasing friction when the valve is actuated.
spool valves compared to particles that
were 30 microns and 0-5 microns.
In valves, silt lock generally occurs as a
result of an eccentric position of the spool
as it rests in the bore. Due to the weight of
the spool, the annular clearance varies from
submicron in the bottom position to 10-50
microns in the space above. A single tramp
particle may be all thats needed to seed the
obliteration process, as shown in Figure 1.
This primary particle narrows the clear-
ance, allowing the smaller and more highly
populated secondary particles to load into
the clearance space. These secondary parti-
cles are the silt that causes the high static
friction (stick-slip or complete seizure),
resulting in motion impediment failure.
Dwell Time
Many valves are in constant motion,
while others remain at rest until needed.

These may be governor valves in a turbine elec-
trohydraulic control (EHC) system or landing
gear hydraulic valves in commercial aircraft.
When a valve remains stationary, the fluid
leakage path across the silt land (the zone where
silt particles pile up) is exposed to more and
more particles. Given enough dwell time, the
particle buildup (obliteration) is sufficient to
arrest movement of the valve and cause motion
impediment failure. The influence of dwell time
can be observed in Figure 2.
Most aircraft valves mitigate the dwell time/
obliteration risk by keeping the valve spool flut-
tering, a design condition called dither.
Nonetheless, as most seasoned airline pilots
will tell you, these valves are still known to stick
on occasion. Television audiences were able to
see an example of contaminant-induced valve
stiction a few years ago on Americas Funniest
Home Videos. A life-sized hydraulic Abraham
Lincoln was shown moving erratically during a
showing of Disneyworlds Hall of Presidents.
Oil Pressure Differential
Oil is always trying to move from high to low
pressure. In typical electrohydraulic valves, the
annular space between the spool and the bore
is all that separates high pressure from low
pressure. Oil leaks through this pathway at a
higher velocity with increasing operating pres-
sures. This results in more particles being
exposed to the silt lands and more packing
force on the particles, causing static friction.
Water Contamination
Free and emulsified water in oil will prefer-
entially occlude to most solid particles such as
dirt. The hydrogen bonding in the water mole-
cules causes strong attractive forces similar to
the clumping of wet sand. Laboratory studies
have shown that moisture sharply aggravates
birds-nest obliteration in valves, orifices,
glances and other tight-clearance flow paths.
Varnish and Sludge
Varnish is a soft, gummy deposit that collects
on internal machine surfaces. It tends to be
more acute on metal surfaces that are cooler
than the oil. Varnish condenses on these cool
surfaces, producing a sticky residue. Electrohy-
draulic valve surfaces are a common destination
for varnish insolubles in oil. Nearby particles
can get stuck on these adherent surfaces. This
condition is known as the fly paper effect (see
Figure 3). The synergistic result greatly increases
the risk of silt lock and stiction.
Silt Lock Risk Increases
with Dwell Time
60
Force required to free valve (pounds)
50
(Clearance-sized
particles)
40
30
20
10
0
0 10 20
Spool dwell time (minutes)
Figure 2. Clearance-sized particles produce
the highest risk of silt lock.
Figure 3. Fly paper particles
Controlling the Silt Lock Risk
Maintenance and reliability professionals
dont have the convenient ability to redesign
machinery or even change operating demands
to reduce the risk of silt lock. However, they
can influence the conditions to which the
machine and its components are exposed.
This would include controlling particle
contamination (exclusion and removal), water
contamination and varnish potential. With
suitable diligence, not only is the risk of silt
lock significantly reduced, so too is the risk of
wear and corrosion mode failures.
About the Author
Jim Fitch has a wealth of in the trenches expe-
rience in lubrication, oil analysis, tribology and
machinery failure investigations. Over the past two
decades, he has presented hundreds of courses on
these subjects. Jim has published more than 200
technical articles, papers and publications. He
serves as a U.S. delegate to the ISO tribology and
oil analysis working group. Since 2002, he has been
director and board member of the International
Council for Machinery Lubrication. He is the CEO
and a co-founder of Noria Corporation. Contact
Jim at jfitch@noria.com.
Machinery
Lubrication
PUBLISHER
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GROUP PUBLISHER
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EDITOR-IN-CHIEF
Jason Sowards - jsowards@noria.com
Particle Size SENIOR EDITOR
Jim Fitch - jfitch@noria.com
>10 m TECHNICAL WRITERS
Jeremy Wright - jwright@noria.com
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800-597-5460, ext. 224
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CORRESPONDENCE
You may address articles, case studies,
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Editor-in-chief
MACHINERY LUBRICATION
Noria Corporation
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Email address: jsowards@noria.com
MACHINERY LUBRICATION Volume 15 - Issue 1 January-February
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Copyright 2015 Noria Corporation. Noria, Machinery Lubrication
and associated logos are trademarks of Noria Corporation. All rights
reserved. Reproduction in whole or in part in any form or medium
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Machinery Lubrication is an independently produced publication of
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and articles submitted for personal and commercial use. The opinions
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CONTENT NOTICE: The recommendations and information provided in
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January - February 2015 |3

FROM THE FIELD
J EREMY W RIGHT | N ORIA C ORPORATION
HOW COLD Temperatures
Affect Your LUBRICANTS
A s winter weather settles in
across much of the United
States with cold fronts
creeping in from the north, have you ever
thought about the effects these tempera-
ture changes can have on your equipments
reliability? All machines and lubricants
have practical limits when it comes to
operating temperatures. Often the focus is
only on the upper limit, since high
temperatures can wreak havoc on the
health of the lubricant and the machine, as
well as cause safety concerns in some
cases. However, rarely do you hear
someone discussing the lower limits.
At extremely low temperatures, such as
those experienced during the startup of
equipment found outside on a cold winter
morning, the fluid within the housing can
reach a point where it actually congeals and
will no longer flow. This limit is called the
pour point. In circulating systems, the
viscosity becomes so high at this point that
the oil flow is restricted. Components will
then starve of lubrication, which leads to
an early metal-on-metal death.
Of course, circulating systems arent the
only ones that rely on oil flow. Imagine how
a splash-lubricated gearbox handles a cool,
thick fluid. When these gearboxes are
designed properly and using the correct
fluid viscosity, oil is brought up to the gear
tooth interface and even to the shaft bear-
ings and other reduction stages higher in
the sump as the gearset runs through the oil
sump level. When the oil viscosity is
increased to the point where it will no
longer flow, the submerged gear will push
4 | January - February 2015 | www.machinerylubrication.com
Viscosit y
congealed chunks of lubricant out of the
way and will not lift it to the other compo-
nents within the housing that desperately
need to be lubricated. Another side effect
of the increased viscosity is a higher startup
56%
torque. This increased load may be enough
to cause a catastrophic failure or at least
consume a massive amount of energy
because of the excessive friction.
The effects on viscosity are not the only
of Lube-Tips subscribers
attacks the lubricant must endure from the
say cold temperatures have
cold. In extreme cases, blended base oils can caused problems for the
begin to separate into different phases. This lubricants at their plant
separation process is called stratification.
The additives are also susceptible to
becoming insoluble at colder temperatures.
When they become insoluble, additives tend
to gravitationally separate from the base oil
and form deposits at the bottom of the
sump. If the equipment requires these addi-
tives and they are in the form of a sludge or
deposit at the bottom of the sump, the lubri-
cants performance will be hindered and the
machine could be damaged.
What is considered cold? Most base
oils and greases are able to withstand
moderate temperature dips to 0 degrees C
and many to minus 10 degrees C without
much decrease in performance. However,
at minus 20 degrees C and beyond, some
lubricants become unsuitable and begin to
reach their pour point. The pour point is
dictated by the base oil quality as well as
the presence of certain additives. A good
rule of thumb is to always select a lubri-
cant with a pour point that is at least 10
degrees C lower than your lowest expected
startup temperature.
 FROM THE FIELD
At temperatures lower than minus 20 degrees C, simple mineral
base oils will no longer perform sufficiently, so alternatives must be
found. Polyalphaolefin (PAO) synthetic oils are among the front
runners in performance for base oils at cold extremes of minus 20
degrees C and lower. PAOs do not contain the wax that lower
quality, cheaply refined mineral oils do, and this allows for excellent
flow, even at low temperatures. Some PAOs have pour points as low
as minus 50 degrees C.
One property that aids in a PAOs fight against cold weather is
its high viscosity index. Simply put, viscosity index is the rate at
which the viscosity changes with respect to a temperature change.
Having a higher viscosity index means that the lubricants viscosity
does not change at as high of a rate compared to a lubricant with a
lower viscosity index. This is a good thing. What ends up happening
is the viscosity range that is useful to the machine gets extended
over a much larger temperature distribution.
To evaluate cold-weather performance, several ASTM standard-
ized methods can be used, including tests for pour point,
low-temperature torque and flow pressure for greases. In recent
years, the research and development of lubricants in extreme cold
conditions has come a long way. Lubricants are now being devel-
oped specifically for cold-weather applications.
Even though proper lubricant selection is of the utmost impor-
tance, there are other more fundamental steps that can be taken to
solve your cold-temperature issues. These include heaters, larger
6 | January - February 2015 | www.machinerylubrication.com
Always select a lubricant with
a pour point that is at least 10
degrees C lower than your lowest
expected startup temperature.
feed lines, fewer pipe restrictions in pumping systems, changing
application methods, etc.
Understanding what happens to your lubricants at cold
temperatures is your first line of defense. So the next time you walk
into your plant on a cold morning and prepare to start up the
equipment, please think about the consequences of the cold
temperatures on your lubricants and the machinery.
About the Author
Jeremy Wright is the vice president of technical services for Noria
Corporation. He serves as a senior technical consultant for Lubrication
Program Development projects and as a senior instructor for Norias
Machinery Lubrication I and II training courses. He is a certified main-
tenance reliability professional through the Society for Maintenance and
Reliability Professionals, and holds Machine Lubricant Analyst Level
III and Machine Lubrication Technician Level II certifications through
the International Council for Machinery Lubrication. Contact Jeremy
at jwright@noria.com.
 COVER STORY
Using Ultrasound
TO IMPROVE
Lubrication
PR AC TICE S
B Y A DRIAN MESSER, UE SYSTEMS
Keeping a handle on lubrication
seems easy enough. All you need to
do is to make sure the right lubri-
cant is used in the right amount and at the
right time. Unfortunately, its not that simple.
It has been estimated that 60 to 90 percent
of all bearing failures are lubrication related.
Bearing failures most often lead to unplanned
downtime, which can impact production as
well as affect all related components around
the bearing. Downtime is costly. While the
cost varies by incident and by plant, it can
add up.
As the most common cause of bearing
failure, lubrication is serious business. For
many years, this serious business has
been conducted in a way that makes perfect
sense on the surface but in fact borders on
being haphazard.
Many technicians have relied on preven-
tive, time-based lubrication alone. That is,
every X number of months, the grease gun
comes out, and the bearings are lubricated.
After all, underlubrication can be lethal,
causing equipment failure, costly repairs and
replacements, significant unplanned down-
time, and lost profits. But by relying solely on
time-based lubrication, or even a combina-
tion of planned maintenance and temperature
readings to serve as a proxy for lubrication
8 | January - February 2015 | www.machinerylubrication.com
status, you run the risk of something just as
bad if not worse overlubrication.
Relying on time-based, periodic lubrica-
tion assumes bearings need to be greased at
defined time periods. Often this evolves into
a well-intentioned guessing game at best.
Adding more lubrication to a bearing that is
already adequately greased is a real risk.
By using ultrasound technology (along
with normal practices such as removing old
grease and replacing it with new), technicians
can combine standard time-based mainte-
nance with condition-based predictive
maintenance, gaining in the process both a
clearer picture of whats really going on in
their machines and improved reliability.
How Ultrasound Works
Ultrasonic equipment detects airborne
and structure-borne ultrasounds normally
inaudible to the human ear and electronically
transposes them into audible signals, which
a technician can hear through headphones
and view as decibel (dB) levels on a display
panel. In some instruments, the received
sound can also be viewed on a spectral anal-
ysis screen. With this information, a trained
technician can interpret the bearing condi-
tion in order to determine what, if any,
corrective action is needed.
 ML

www.machinerylubrication.com | January - February 2015 | 9

 COVER STORY
This image shows what happens when This is another time series view of a
too much lubricant is applied. Notice the recorded ultrasound from a bearing in
increase in amplitude or the noise level the process of being lubricated.
when lubricant continues to be applied.
Ultrasound technology has many advantages:
It can be used in virtually any environment.
Learning to use it is relatively simple.
The technology is fairly inexpensive.
Modern ultrasonic equipment makes it easy to track trends
and store historical data.
Ultrasonic technology has proven to be extremely reliable in
predictive maintenance, saving thousands of dollars and hours
of lost productivity.
Airborne and structure-borne ultrasound instruments are an
extension of the users sense of hearing. Just like vibration feels what
you cant feel and infrared cameras see what you cant see, ultra-
sound hears what you cant hear. Noise in a typical plant environment
(machines running, production equipment running, etc.) can prevent
you from being able to hear other sounds such as compressed air
leaks or electrical discharges like corona, tracking or arcing.
Ultrasound instruments sense or listen for high-frequency
Screen shots of a good bearing (left) and a failing bearing (right)
10 January - February 2015 | www.machinerylubrication.com
The image above is a time series view of
a recorded ultrasound from a bearing in
the process of being lubricated. Notice the
before noise or amplitude at the beginning
and then once the bearing was properly
lubricated at the end.
sounds that are not heard in the audible range by normal human
hearing. These high-frequency sounds are detected by the instru-
ment and translated into an audible sound that is heard in the
headset by the inspector. The decibel level is then indicated on the
instruments display.
Condition Monitoring and Ultrasound
Traditional inspection of electrical components has been
performed using an infrared camera. Users of this technology rely
on images showing temperature changes that may represent elec-
trical anomalies such as tracking and arcing. For mechanical
inspection, vibration analysis has been the conventional method
for condition monitoring of rotating equipment. Vibration anal-
ysis produces a visual spectrum or time waveform that reveals any
fault harmonics. If the goal is to have a truly world-class predic-
tive maintenance (PdM) program, the use of multiple technologies
is recommended for various inspections. Just as a physician uses
multiple tools to diagnose aches, pains and abnormalities, main-
tenance professionals should take the same approach when it
comes to the assets they are responsible for in their facilities.
In addition to infrared and vibration, ultrasound can be used
to complement other PdM technologies. Airborne and struc-
ture-borne ultrasound can give the user an image to analyze in
order to diagnose and confirm mechanical and electrical condi-
tions. The concept of ultrasound imaging involves recording
sounds heard via the ultrasound instrument and then playing
back those recorded sounds in spectrum analysis software. This
can provide the inspector with the audible sound heard in the
field during the inspection and a visual image or spectrum of the
recorded ultrasound. This method can help to reduce the subjec-
tivity of only relying on changes in the decibel level and in the
sound tone or quality heard by the inspector.

How Ultrasound Produces Better

Lubrication Practices
Ultrasonic technology helps the lube tech take a lot of the
guesswork out of lubrication. Ultrasound is a localized signal,
which means that when a sensing probe is applied to a bearing, it
will not be affected by crosstalk and will allow the technician to
hear and monitor the condition of each bearing. Ultrasound
looks at each bearing individually, much the same way medical
ultrasound can detect exactly which artery is clogged or which
vein is leaking.
How does ultrasound work in regard to lubrication? The first
step is to establish both a baseline decibel level and a sound
sample. This is ideally done when moving through a route for the
first time by comparing dB levels and sound qualities of similar
bearings. Anomalies will be easily identified. Once baselines are
established, each bearing can be trended over time for any
changes in either amplitude or sound quality.
Generally speaking, when the amplitude of a bearing exceeds 8
dB and there is no difference in the sound quality established at
the baseline, the bearing needs to be lubricated. To prevent over-
lubrication, the technician should apply the proper lubricant a
little at a time until the dB level drops.
Many organizations set up their condition-based lubrication
programs by incorporating a two-stage approach. The reliability
inspector uses a relatively sophisticated ultrasound instrument to
monitor and trend bearings. A report of bearings in need of lubrica-
tion is produced. The lube tech then uses a specialized ultrasound
instrument that alerts the tech when to stop adding grease.
To improve efficiencies, it is good practice for the technician to
note when the equipment was last greased and how much grease
was applied in order to calculate roughly how much lubricant is
www.machinerylubrication.com | January - February 2015 | 11
 A

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COVER STORY
used per week. By utilizing ultrasound to lubricate each and every
time, the technician produces historical data that can be employed
as a guide to help determine whether the lubrication schedule can
be modified to save man-hours and if the manufacturers
suggested lubricant amount is accurate. If less is needed, theres
cost-saving potential.
While most of this article has focused on the dangers of under-
lubrication and overlubrication, ultrasound is just as reliable in
picking up other potential bearing failure conditions. A technician
using ultrasound can hear telltale grinding sounds and other
anomalies, which are often accompanied by an amplitude
increase. In regard to lubrication, the advantage of ultrasound is
that it is able to isolate bearings and determine their individual
needs, thus reducing the possibility that some bearings are too
dry and preventing others from overlubrication.
Why Use Ultrasound?
It is always a daunting proposition to make a new investment in
technology. Will it pay off? Will your staff actually have an easy
time using it? Is it a flash in the pan or a truly reliable modality that
will stand the test of time?
Although more plants are utilizing ultrasound and adopting a
predictive or proactive approach rather than a reactive mindset,
there are still many that are figuratively using crystal balls and
outdated methodologies. The end result is poor reliability, unnec-
essary man-hours, downtime, and lost productivity and profit.
While ultrasound cant cure all reliability ills, it has proven itself in
a wide variety of settings to be a valuable and powerful diagnostic
tool that technicians should add to their toolkits.
 ML

When it comes to something as important to reliability as lubri-

cation, the real question becomes, Can you afford not to use
ultrasound technology? Consider the plant that went from almost
30 bearing failures a year before using ultrasound to having no
bearing failures for three years once ultrasound was added to its
maintenance arsenal. Its no coincidence. Ultrasound works.

Ultrasound-assisted Lubrication
When it comes to lubrication practices in plants, there are three
scenarios that could be considered as good, better and best. A
good scenario would be to follow the manufacturers recommen-
dations as to the frequency, type of lubricant and amount of
lubricant to be applied to a certain piece of equipment. A better
scenario would be to still make use of the timed interval, but instead
of lubricating with just a grease gun, utilize an ultrasound instru-
ment while greasing. This will at least allow the lube techs to know
when they have added enough grease or when too much grease has
been applied. Another benefit is that the individual lubricating the
equipment can listen to the bearing while greasing it. This enables
the inspector to hear if other bearing defects are present that lubri-
cation may not help. In a sense, the lubricators become fault
finders. If a bearing does not sound normal or has an increased
decibel level, that bearing can be documented and complementary Using an ultrasound instrument while greasing allows technicians to
vibration or ultrasound data can be collected to determine what know when they have added enough grease or when too much grease
the issue/defect is. has been applied.
 COVER STORY

Finally, the best scenario is to viewed in spectrum analysis software. Although this is a fairly new
use an ultrasound instrument technique, the use of ultrasound for both mechanical and electrical
with data storage and data inspections is growing. The spectrum analysis of recorded ultra-
management software to create sounds can enhance diagnostic accuracy and reduce the subjectivity
routes. Data such as decibel of only comparing decibel levels or simply what is heard by the
levels and sound files can be inspector in the headset.
recorded periodically. How often Adding ultrasound to mechanical inspections can also allow for
the readings are taken should be better use of other tools such as vibration analysis. If there are too
This overlay shows recorded ultrasound based on an asset criticality many assets to monitor with vibration, ultrasound can be included
files of four motor outboard points on assessment. Once a baseline has to complement the vibration analysis program. Critical assets can
identical motors. One has an obvious been established, a low-level benefit from having both vibration and ultrasound data collected.
bearing defect. alarm can be set for when a lack For noncritical assets, which may not necessitate the time to collect
of lubrication condition has been vibration data but still need to be monitored, ultrasound data can
detected for a bearing. A high-level alarm is also set to indicate quickly and easily be used.
when a bearing has reached the point of initial failure. Another reason to complement a vibration program with ultra-
If lubrication is not the solution to the problem, a more detailed sound is if the vibration analysts time is limited. A vibration route
test would be required to identify the specific defect, such as an can be very time-consuming, but ultrasound can help reduce the
inner or outer race bearing fault. When a point along a route has time it takes to collect vibration data. Ultrasound can be used first,
been determined to be lacking lubrication, an inspector can go to and once the decibel level has risen to trigger an alarm, vibration
that point and apply lubricant until the decibel level drops back can further diagnose the problem and the reason for the increase in
down to the baseline level. noise level.
The beauty of adding ultrasound to an existing predictive main-
Other Ultrasound Applications tenance and reliability program is that it can be used for many
Ultrasound imaging or recording is a new concept that involves different applications. Typically, those who are starting out on a
using a special instrument to analyze ultrasounds, which are then reliability journey or are just beginning to utilize the technology will
employ ultrasound for compressed air and gas leak detection.
Tremendous energy savings can be realized through the use of ultra-
sound for both steam trap and compressed air/gas inspections.
Based on these savings, the maintenance and reliability department
can gain buy-in from both management and floor personnel. The
savings associated with the energy-conservation efforts can then
be reinvested in the program by means of additional tools, training,
certification courses or even manpower.
The same method for energy-conservation applications can also
be used for electrical and mechanical applications. This is what
makes ultrasound a versatile and easy-to-use tool for both the
well-established maintenance and reliability programs, and those
that are just beginning their journey.

14 January - February 2015 | www.machinerylubrication.com

 THE LUBE-TIPS SECTION OF MACHINERY LUBRICATION
MAGAZINE FEATURES INNOVATIVE ideas submitted by our readers.
Additional tips can be found in our Lube-Tips email newsletter. If you have a tip
to share, email it to us at editor@noria.com. To receive the Lube-Tips newsletter,
subscribe now at www.MachineryLubrication.com/page/subscriptions.
Another Source of Contamination
The best oil top-up containers should be used with care.
Container nozzles with O-rings can keep dirt from getting inside
the container, but any oil left on the outside of the nozzle tip after
use will collect airborne contaminants. Operators should close
nozzles after use and wipe them clean. Otherwise, dirt on the
outside of the nozzle will be carried into the equipment in the
stream of oil being dispensed.
Simple Tip for Better Oil Sampling
When taking an oil sample using a vampire- or thief-type vacuum
pump, try bending or crimping the sample hose before extracting
from the point of entry. This stops the sudden suction of air and oil
in the hose from dragging any airborne contaminants back into
your clean sample.
Monitor Excessive Moisture in Stored Gearboxes
Humidity-indicating cards that show color changes at different
relative humidity levels (10 to 100 percent) can be used inside large
spare gearboxes and similar stored machines. Use a clear plastic
sight glass and a flashlight to inspect the cards periodically for
excessive moisture. Bags of desiccant can be placed in the same
gearboxes to adsorb moisture that has ingressed. The gearboxes
should be marked as not ready for use.
Working Smart with Filters
When using a kidney-loop cart to filter oil, plumb the carts
filters in series. As the primary filter catches debris and starts to
plug, the pressure drop across the filter increases. This increase in
pressure differential tends to push previously captured debris
through the filter. The secondary filter ends up having a lower pres-
sure differential because most of the debris is captured by the
primary filter.
16 | January - February 2015 | www.machinerylubrication.com
This lower pressure differential will allow the secondary filter to
retain more of the debris that it captures. The secondary filter also
acts as a safety filter in case the primary filter ruptures. In
cost-sensitive applications, the secondary filter can be placed in the
primary position after the primary filter plugs, and a new filter can
be placed in the secondary position.
Advice for Cleaning
Oil Spills
Avoid using clay-based
oil-dry products to clean up
spills. They can cause dust
and contamination risks.
Instead, consider using
absorbent pads.
How to Inspect New Bearings
Carefully inspect new bearings upon arrival for any obvious
damage that may have occurred during shipping, storage or manu-
facturing, as well as to determine if all parts are present. Bearings
have been known to ship from the factory missing roller elements
and other parts. Also, check for factory lubricant. Lack of lubricant
from the factory can cause rust.
Point-and-Shoot Oil Analysis
With a digital camera, photograph your oil samples and store
the images in a trending software for comparison. This will require
the use of a transparent sample bottle. Record a new oil sample
and use it as a baseline. Set the bottle against a white background
like a sheet of paper to maintain a consistent color comparison.
You can also use the camera in other ways, including to record
images of the machine and sampling point as a means of identi-
fying it in the software, or to record abnormalities such as
excessive leakages for easy location by mechanics. Photos are
immediate and speak volumes, so use them to good effect in
reports and trending software.
Selecting the Right Grease
To improve the reliability of grease-lubricated couplings, use
only greases formulated for that purpose. General-purpose greases
often have thickeners that are heavier than the oil. When subjected
to the continuous and extreme forces of a spinning coupling, the
thickeners in general-purpose greases can centrifuge to the outside,
leaving the oil on the inside. Unfortunately, the outside is where the
oil is needed. The thickeners in coupling greases are equal in weight
or lighter than the oil, ensuring that the wearing parts in the
coupling are well-lubricated.
 NOW ON MACHINERYLUBRICATION.COM
FIND MORE GREAT ARTICLES AND CONTENT FROM Machinery Lubrication magazine
online. From Web exclusives and industry news to videos, white papers, buyers guides and more,
everything that relates to machinery lubrication is available now on www.MachineryLubrication.com.

Read this article on the ML site to become How to Improve Desiccant

3 Ways to Detect Cavitation
Wear in Hydraulic Systems
Abnormal noise, high fluid temperature
and slow operation are good indicators
of cavitation in hydraulic systems. As with
everything else, early detection is the best
way to prevent equipment failure and
subsequent downtime. Discover why it is
important to be proactive and look for
these indicators by reading this article on
the ML site.
How to Handle Used Engine Oil
During normal use, impurities such as
dirt, metal catalysts, water and chemi-
cals can become mixed in with oil,
so in time, the oil no longer
performs well. Eventually,
this used oil must be
replaced with new or
re-refined oil to
lubricate the
engine properly.
familiar with how to properly handle and
dispose of the used oil.
Choosing a High-temperature
Lubricant
Many factors affect lubricant selection.
With respect to temperature, the major
contributors are viscosity, thermal degra-
dation and oxidation. Check out this
article on the ML site to find out why the
only real solution for extremely high-tem-
perature lubrication problems is to
re-evaluate the system and environment to
design a situation where the lubricant can
have a fighting chance.
Advice for Quality Oil Sampling
While most people recognize the value
of oil analysis, many do not understand
why oil sampling procedures are so crit-
ical. If sampling is not performed correctly,
the integrity of the oil sample can be
affected. Access this 2-minute, 15-second
video at www.MachineryLubrication.com
to comprehend the importance of proper
oil sampling techniques as well as the two
main objectives you must achieve to obtain
a quality, representative sample.
Breather Life
Desiccant breathers can be attached to
any reservoir, drum of oil or piece of equip-
ment that needs clean, dry air going into it.
In humid or wet environments, these
breathers may not last very long. Access this
1-minute, 51-second video at www.Machin-
eryLubrication.com to learn how breathers
work along with some simple things you
can do to increase their service life.
FEATURED WHITE PAPERS
MachineryLubrication.com is the place
to turn for white papers on a host of
lubrication-related topics. Heres a
sampling of the latest white papers that
are currently available for download:
Creating Alignment for Your
Ultrasound Team
The Trifecta of Motor Maintenance
Cost Effective Wear Metal/
Condition Monitoring Analyzer
Continuing Evolution of Food
Grade Lubricants
Check out the full list of white papers by
visiting www.MachineryLubrication.com
and clicking on the White Papers link.

46%
of lubrication professionals cite
obsolescence as the primary reason
machinery is replaced at their plant,
according to a recent survey at
MachineryLubrication.com

www.machinerylubrication.com | January - February 2015 | 17

 1 1
PRODUCT NEWS PENETRATING LUBRICANT/
P
RUST INHIBITOR
R
Berkebile Oils Protection First Class (PFC) penetrating
lubricant and rust inhibitor incorporates a woolwax
lanolin formula that has been classified as non-hazard-
ous and non-toxic. Although it is solvent-free, PFC is
designed to spray easily and to stick to surfaces. After
application, the lubricant remains soft and pliable and
forms a protective, friction-reducing film. Even in harsh
arctic conditions, the lubricant wont freeze but will
retain its lubricating characteristics, protecting metallic
surfaces and allowing machinery, chains and moving
parts to operate smoothly.
Berkebile Oil
www.berkebileoil.com 800-732-9235

2 OIL CONDITION
OI
MONITORING SENSOR
MO
The Cactus is a miniaturized smart sensor that monitors
in real time the aging of oils in service thanks to the contin-
uous measurement of a fluids viscosity, density, relative 3
humidity (water activity) and temperature. It quantifies
the efficiency of the lubrication process by measuring the
actual thickness of the lubricant film while the machine
is running. The device can be installed online, embedded
onto larger systems or used in a lab for quality control.
Avenisense
www.avenisense.com 33(0)4-5708-0225

3 VIDEO BORESCOPE
VI
The GE Mentor Visual iQ VideoProbe was created to
enh
enhance visual inspections of equipment across sev-
eral industries. Featuring 3-D phase measurement and
analysis along with Wi-Fi connectivity, the video bore-
scope comes equipped with a touchscreen interface,
on-screen keyboard and ergonomic buttons. The Quick
Change probes and tip optics speed the inspection
process by allowing technicians to identify more indi-
cations and collect more data. The 3-D phase measure-
ment capabilities help determine indication depth and
size for pitting, cracking and corrosion.
GE
6
www.ge.com 888-332-3848

4 KARL FISCHER TITRATOR

KA
JM SSciences AquaCounter AQ-300 is a Karl Fischer cou-
lom
om
lometric titrator with six built-in calculation modes to
accommodate solid, liquid and gas samples. It allows
instant recall of data for up to 20 samples and includes
a fritless cell option. A built-in detector monitors titra-
tion status. Four files with preset conditions can also be
stored in memory. The AQ-300 comes with a complete
accessories kit, free software for transferring results to
a computer and an RS-232 cable.
JM Science
www.jmscience.com 800-495-1678

18 January - February 2015 | www.machinerylubrication.com

 2
5
OIL SAMPLE CONDITIONER
OI
Cannon Instruments Thermoelectric Sample Condi-
Ca
tioner (TESC) System is designed to automate the oil
ti
conditioning and testing process according to ASTM
D2983. Incorporating a Brookfield DV2T digital viscom-
eter and thermoelectrically controlled sample chamber,
the TESC System provides preheating, room tempera-
ture stabilization, cooling of the sample to the test tem-
perature, and testing of the conditioned samples final
viscosity. Thermal test history and final viscosity mea-
surements are recorded at multiple spindle speeds and
accessible for export into various software programs
upon completion.
Cannon Instrument Co.
www.cannoninstrument.com 800-676-6232

OIL VIEWING DEVICE

OI
The Maxton MaxView oil viewing device is a convenient
Th
tool for sampling and evaluating hydraulic fluid for con-
too
taminants, oxidation levels and general oil condition. It
4 5 allows ferrous metals, dirt and debris in oil to be dis-
covered in seconds. Simply dip the collection end to the
bottom of the tank, compress the spring action at the
tip to allow oil to flow into the viewing area and pull out
the oil sample. The device assembles quickly by thread-
ing the three pieces together.
Maxton
maxtonvalve.com 775-782-1700

VEGETABLE-BASED STRAIGHT OILS

V
VE
Qu
QualiChems
Q new Eqo-Max series oils are a family of
llow-viscosity vegetable-based straight oils for severe
low
cutting and grinding applications on stainless steels,
titanium and other alloys. The technology in the oils
is derived from carefully selected base stocks to pro-
vide optimized viscosity, lubricity, oxidative stability
and high-pressure performance. The premium oils
are formulated to eliminate foaming when running in
high-pressure coolant delivery systems at 1,000 pounds
per square inch or higher.
7 QualiChem
www.qualichem.com 540-375-6700

8
OIL TEST GAUGE
OI
The Rapid Oil Test Gauge from Geserco is a new digital
oil tester for quickly determining water in oil and base
number values up to 100. It enables measurements to be
taken within three minutes and incorporates a large digi-
tal display that gives step-by-step operating instructions
and test results. Other features include immediate evalu-
ation of test results, an audible alarm for excess water in
oil and low base number, and automatic time-stamping

8
of results. The device also comes with built-in memory
for recording up to 90 test results.
Geserco
www.geserco.fr 33(0)5-5634-9229

www.machinerylubrication.com | January - February 2015 | 19

 INDUSTRY FOCUS

Strategies for Managing

Retiring Workers
the Wave of

B Y BRUCE WESNER, L IFE C YCLE ENGINEERING

Senior leaders across a broad array of industries A higher cycle of turnover is the new reality. More than 90
continue to highlight retirements, turnover and succes- percent of millennials (persons born between 1977 and 1998)
sion planning as key issues confronting their expect to stay in a job for less than three years. How will your
organizations. Much has been written and reported on the company manage the turnover of key positions every few years as
impending retirement wave of baby boomer workers as one of opposed to every decade?
those areas of concern. Organizations must understand the dynamics of near and long-
As new generations enter the workforce and older generations term turnover, including how younger generations of workers will
remain at work longer, employers must evolve to meet new employee impact how you recruit, train and operate, along with the tactics
needs. Most solutions involve recruiting tactics for attracting new, for capturing knowledge from workers approaching retirement
younger talent to industry ranks through collaboration with local before they leave.
colleges and technical schools, but what about proactively
managing the actual turnover in the workplace? Whats the broader
plan for transferring the tribal knowledge of departing workers to GENERATION X MILLENNIALS
their replacements? Born 1965-1976 Born 1977-1998
There are two challenges a turnover strategy must address. The 51 million 75 million
first involves the sheer magnitude of baby boomer retirements - Accept diversity - Celebrate diversity
underway and on the horizon. Approximately 10,000 baby boomers - Pragmatic/practical - Optimistic/realistic
are retiring every day. At many companies, more than 50 percent of - Self-reliant/individualistic - Self-inventive/individualistic
the workforce will be retiring in the next three to five years. Most of - Reject rules - Rewrite the rules
these personnel are in key management and supervisory positions - Killer life - Killer lifestyle
with extensive tenure, tribal knowledge and the secrets or tricks to - Mistrust institutions - Irrelevance of institutions
keeping the workplace on pace. How will their knowledge make it - PC - Internet
to their replacements? - Use technology - Assume technology
The second challenge involves the next generation of workers and - Multi-task - Multi-task fast
their perspectives on employment and tenure. Demographic and - Latch-key kids - Nurtured
trend studies show that the future will bring fewer loyal workers who - Friends arent family - Friends are family
dedicate their entire careers to a single workplace. Portable 401(k)s, Mentoring Dos Mentoring Dos
the extinction of pensions and other golden handcuff benefits are Casual, friendly work Structured, supportive work
among the many factors influencing career mobility. Skilled young environment environment
production and manufacturing industry workers are also in high Involvement Personalized work
demand, so the likelihood of more frequent job-swapping is real. Flexibility and freedom Interactive relationship
Generations X and Y made up more than 60 percent of the work- A place to learn Be prepared for demands,
high expectations
force in 2012, and that number will continue to rise. Job tenure fell
from 9.2 years in 1983 to less than one-half that (4.1 years) in 2008, Source: The Learning Caf and American Demographics
and the recent recession likely cut that number further. Enterprising Museum

20 | January - February 2015 | www.machinerylubrication.com

 ML

Dynamics of Near and Long-term Turnover

To prepare for these changes, companies must first consider
their aging workforce and focus on how to capture the tribal knowl-
edge that these workers possess. They must also look at millennials.
How do they fit into the workplace? How can you engage them and
what are they seeking to attain job satisfaction?
Organizations need to assess their company culture. Culture is
sustained by structures, systems and style of leadership. It is the
way we do things around here, and is taught to the newcomers.
In order to better engage the next generation of workers, you
must eliminate some of the rigid constraints that past organiza-
tional structures may have created. The chart on the previous
page offers a contrasting perspective on the differences between
the generation X and millennial workforce.

Capturing Knowledge from Workers Before

They Leave
Within any organization, the most effective method for estab-
lishing a repeatable and more easily adopted operating culture is
to develop standard best-practice business operations, and
maintenance processes and procedures. It is critical to ensure
that high expectations and associated accountability standards
are set for procedural compliance and to continuously improve
these processes.
An example at a power generation facility might be the
synchronization of electrical turbine generators. Is this accom-
plished by each shift and supervisor with a standardized set of
www.machinerylubrication.com | January - February 2015 | 21
 INDUSTRY FOCUS
procedures and checklists or is it done a little differently each
time based on the personalized styles of those in charge? How
would it be accomplished next month if those supervisors or
technicians were no longer with the organization?
Evolving from a culture of tribal knowledge and informal oper-
ating practices to one of standardized process adherence, practices
and procedures involves commitment and accountability from the
22 January - February 2015 | www.machinerylubrication.com
leadership team. Sharing knowledge, documenting inherent best
practices and eliminating the knowledge is job security mentality
will require time and significant behavioral change.
The following initiatives can be useful in creating more stan-
dardized work practices and reducing the damaging effects of
high turnover:
Identify critical work and procedures
that are currently being accomplished
with tribal knowledge or without the
benefit of documented standard oper-
ating procedures.
Capture knowledge and data for this
critical work from existing employees
and transform that knowledge into
institutionalized training programs
and documented procedures.
Establish training programs that drive
accountability and ensure all employees
have the skills, competency and knowl-
edge to perform the assigned tasks as
well as the ability to record data from
those tasks.
Develop continuously evolving standard
operating procedures that are followed
via checklists and supervisory oversight.
Utilize an enterprise asset management
system that allows managers to make
decisions and plans based on factual
information, captured data and trends
rather than gut feel or the experience of
employees who may no longer be around.
It takes time to shift from a culture of Thats
the way weve always done it, to Heres
precisely how and why we do it this way. This
will require a commitment from leadership to be
engaged and visible with workers.
A survey of corporate boards once defined
the No. 1 reason senior executives are termi-
nated as the inability to affect change
within their organizations. Likewise,
changing the operating culture within your
organization to ensure the transitions that
take place when personnel leave will be a
critical factor in meeting goals and objec-
tives through this coming wave of retirements
and into the next generation of more
frequent employee turnover.
 BOOKSTORE
WELCOME TO MACHINERY
NERY LUBRICATIONS For descriptions, complete table of contents and excerpts from
BOOKSTORE, designed to spotlight lubrication- these and other lubrication-related books, and to order online,
plete listing of books of
related books. For a complete visit store.noria.com or call 1-800-597-5460, ext. 204
interest to lubrication professionals,
ofessionals, check out the
Bookstore at store.noria.com.
com.

Lubrication Fundamentals Oil Analysis Basics

Second Edition Second Edition
Authors: D.M. Pirro and A.A. Wessol Publisher: Noria Corporation
This newly revised and expanded The new second edition includes
reference book emphasizes the more detailed information on oil
need for lubrication and careful sampling, filtration and contam-
lubricant selection. Thoroughly inant removal, base oils and
updated and rewritten, the second additives, water-in-oil contamina-
edition of Lubrication Fundamentals tion and removal, ASTM standards,
discusses product basics, machine glycol testing, flash point tests, and
elements that require lubrication, 14 additional oil analysis tests.
methods of application, lubri-
cation, lubricant storage and
handling, lubricant conservation and much more.
Lubrication Awareness Poster Set
Publisher: Noria Corporation
This set of five posters effectively uses humorous illustrations
Lubrication Basics for Machinery and bulleted tips and pointers to communicate critical lubrica-
Operators Training Video tion advice. Posters included in the set are Home Sweet Home,
Format: DVD Keep Our Machines Clean, Overgreasing Doesnt Pay, Use the
Publisher: Noria Corporation Correct Oil and Watch Your Aim.
Train your team on the basics of lubrication and how to recog-
nize early signs of lubrication-related
problems with this convenient video
training DVD. Your operators
will learn the basics of oper-
ator-based lubrication
inspections and gain the
knowledge to ensure that
routine inspections and
top-offs are performed with
precision and accuracy. Handbook of Lubrication and
Tribology - Volume II: Theory
Automotive Lubricants and Testing and Design - Second Edition
Authors: Simon C. Tung and George E. Totten Author: Robert W. Bruce
This book provides a compre- Sponsored by the Society of
hensive overview of various Tribologists and Lubrication Engi-
lubrication aspects of a typical neers, this handbook incorporates
powertrain system, including the up-to-date, peer-reviewed infor-
engine, transmission, driveline mation for tackling tribological
and other components. It also problems and improving lubri-
covers lubrication fundamentals cants and tribological systems. It
and lubricant testing methods demonstrates how the principles
that are influenced by lubricant of tribology can address cost
additive formulation and engine savings, energy conservation and
hardware changes. environmental protection.

24 January - February 2015 | www.machinerylubrication.com

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

1. In typical use, atomic emission spectroscopy (AES)

(or elemental analysis) has which significant limitation?
A) It cannot detect the most important wear metals.
B) It can only detect wear debris particles less than approximately 5
microns in size.
C) It can only detect wear debris particles less than 12 microns in size.
D) It can only detect additive elements.
E) It can only detect large iron wear debris.

2. Oil sampling frequencies may be affected by:

A) Machinery age
B) Machine criticality
C) Fluid (oil) age
D) Operating conditions
E) All of the above

3. A beta ratio of 200 means that the filter

is how efficient?
A) 200 percent
B) 99.5 percent
C) 98.7 percent
D) 90 percent
E) 50 percent

efficiency equals (199/200) x 100 or 99.5 percent.

The percent capture efficiency is ((beta 1)/beta) x 100. In this case, beta is 200, so the
3. B
conditions require more sampling.
factors such as high loads, extreme temperatures, harsh environments, etc. Severe operating
is because the worse it gets, the faster it deteriorates. Operating conditions can include many
sampling is required. More frequent sampling is also needed when the oil becomes old. This
the high failure probability in these periods. The more critical the machine, the more frequent
More frequent sampling is required when the equipment is new and old. This is because of
2. E
raphy is required to quantify and identify the source of large particles.
indication of particles in the oil analysis report. Running other test methods such as ferrog-
spectrometer. This is why you can see some visible particles in a sample bottle and get no
less than approximately 5 microns in size depending on particle composition and the type of
The major limitation of atomic emission spectroscopy is that it can only measure particles
1. B
Answers

www.machinerylubrication.com | January - February 2015 | 25

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LESSONS IN LUBRICATION
B ENNETT F ITCH | N ORIA C ORPORATION
FOLLOW the TREND for
Successful OIL ANALYSIS
S etting cautionary and critical
limits (or targets) for oil anal-
ysis results is essential and
irreplaceable as groundwork in an oil
analysis program. Its what helps answer
one of the most commonly asked ques-
tions: Is the oil still good? Nevertheless,
the data changes observed, even if they
are within the established limits, can still
prove to be valuable. In these conditions,
trending oil analysis data is where the
value is gained and will help answer what
might be the next question asked: When
will my oil go bad?
If you think about it, simply obtaining a
snapshot of data from an oil sample is
essentially worthless without something
to which to compare it. This is why
trending data in oil analysis reports is so
beneficial. It not only allows you to deter-
mine if the current oil properties are
unfavorable but also if they will become
unfavorable in the near future. Indeed,
quality trending provides a powerful
means of recognizing when an oil prop-
erty is moving in an unhealthy or
threatening direction.
The most effective way to follow a trend
is to consistently collect representative oil
samples and track the data from the results
by plotting them on a property-versus-time
graph. The property can be anything
from the remaining additives within the oil
to the base oils changing properties or the
number and types of particles.
It is imperative that oil samples are care-
fully collected and that all variables are
28 | January - February 2015 | www.machinerylubrication.com
74%
of lubrication professionals say
their plant trends oil analysis
data, based on a recent poll at
MachineryLubrication.com
minimized or at least addressed. Among
the factors that can influence the results
include sample location consistency, service
life of the machine and oil, makeup oil
rates, changes in environmental or oper-
ating conditions, oil formulation changes,
testing procedure consistency, etc.
The key to success with trending is to
learn from the past. This includes others
past failures, not just those of your
machines. Start by identifying when certain
oil properties have typically been healthy
and use this as the standard. Also, take
HUMAN POPULATION
GROWTH
Site of Growth Earth
Variables Enhancing Modern medicine,
Growth Industrial Revolution,
technology, migration
Variables Suppressing Disease/plagues, war,
Growth natural disasters
Result of Extreme To be determined
Population
Oil Analysis
note of when a change in an oil property
has previously led to a machine issue or
failure. You must develop the awareness to
recognize when a change in a particular
property could eventually lead to a problem
with the machine.
Looking Back at the Past
The worlds population growth offers a
good example of the types of trends that
can exist within machinery. The earths
population has been growing for thousands
of years, but it wasnt until around 1800
that it reached 1 billion people. While this
was a major milestone, it only took approx-
imately 120 more years to double to 2
billion. Less than 100 years later, the popu-
lation is rapidly approaching 8 billion
people. Many factors have influenced this
recent trend, such as the Industrial Revolu-
tion and advanced medicine. Figure 1
shows how this rise in population would
appear on a graph.
PARTICLE CONTAMINATION
GROWTH
Lubricated machine
Lack of wear protection,
misalignment, improper
ventilation and filtration control
Proper lubrication, quality
machine design, proper
ventilation and filtration control
Machine failure
 This trend can be compared to the growth of particle contami-

Quality trending
nation in machinery. Particles produce particles. In fact, one
particle can generate as many as 20 new particles within a machine.

provides a powerful
Of course, this will depend on many variables, such as particle
ingression rates, the filtration rate, the likelihood of wear genera-
tion, etc. Regardless, when particles are the instigator of new
particles being created, the contamination can quickly escalate. means of recognizing
By adding quarterly sampling dates and ISO particle contami-
nation codes to Figure 1, we can illustrate a lubricated machine when an oil property is
that was accidentally introduced to new contaminants and
resulted in increased wear generation. Note the dramatic trend
moving in an unhealthy
toward the most recent dates in Figure 2. When this type of
growth in particle concentration occurs, it will be linked to an
or threatening direction.
imminent machine failure.
In order to predict an impending rapid growth of particle
contamination, oil sampling must be performed frequently enough as frequently or more, it would be much easier to recognize the
to detect a slight uncharacteristic increase. For example, in Figure start of the abnormal increase. Sampling machines for changing oil
1, if the world population is measured every 1,000 years, the results conditions is no different.
would be 0.1 billion, 0.1 billion, 0.1 billion, 0.2 billion, 0.2 billion About the Author
and finally 7 billion. However, if the population is measured twice
Bennett Fitch is a technical consultant with Noria Corporation. He
is a mechanical engineer who holds a Machine Lubricant Analyst (MLA)
Level III certification and a Machine Lubrication Technician (MLT) Level
6 II certification through the International Council for Machinery Lubrica-
tion (ICML). Contact Bennett at bfitch@noria.com.
5

3
Industrial
Revolution
2

The Plague
1

0
8000 4000 3000 2000 1000 0 1000 2000
B.C. B.C. B.C. B.C. B.C. A.D. A.D.

FIGURE 1. The worlds population growth

21/18

19/16

18/15

17/14

16/13

15/12

14/11
Apr-13 Jul-13 Oct-13 Jan-14 Apr-14 July-14 Oct-14 Jan-15

FIGURE 2. An illustration of particle contamination within a machine

www.machinerylubrication.com | January - February 2015 | 29

 Maintenance and Reliabilit y

PERSPECTIVE
A LEJANDRO M EZA | N ORIA C ORPORATION

Machine MODIFICATIONS
That INCREASE Reliability

T he ultimate goal of lubrication excellence is to increase

machine reliability and reduce operating costs. To
achieve this objective, changes must be made at different
levels of the plant, including the technology and hardware that
are currently in use.
Machines may require modifications for a variety of reasons, such
as to improve the accuracy of lubrication procedures, to enable
inspections of the in-service oil and the machinery, to ensure precise
oil analysis and consistent oil sampling, and to enhance the effective-

Two sight-glass options

ness of the contamination control

program. Following is an overview of
these types of modifications.

Lubrication Procedures
It is critical that machines receive the right lubricant in the right
amount at the right frequency. It is also essential that they are
lubricated using clean, ergonomic and safe procedures. To ensure
proper lubrication practices, machines must have the appropriate
accessories installed. This typically involves lubricant-delivery
devices like constant-level oilers, single-point lubricators, grease
fittings, grease purge valves, centralized lube systems, spray
systems, etc. Temperature-management systems, including heaters
and coolers, may also be needed, along with rolling-element
bearing seals and shields, and power-flush quick-connects on
reservoirs and sumps.

Inspections
Oil analysis that is supported by visual inspections of the
in-service oil offers a powerful way to monitor the condition of
the oil and the machine. Simple visual inspections can confirm
that the oil is in good condition or indicate the presence of
contaminants or excessive degradation. Among the devices that

30 | January - February 2015 | www.machinerylubrication.com


24%
of lubrication professionalss say improving the
accuracy of lubrication procedures
the most likely reason forr making machine
modifications at their plant,
poll at MachineryLubrication.com
may be installed to facilitate inspections of
the oil include bottom sediment and water
(BS&W) bowls, which enable quick inspec-
tion of low-lying contaminants and sludge,
and level gauges, which should be located
near fill ports and be large enough to easily
determine the oil level.
From time to time, machines should be
inspected internally to verify that the
lubrication system and machine compo-
nents are free of deposits and excessive
wear. External inspections are also useful
to identify the presence of leaks or
abnormal operating conditions. A number
of machine modifications or accessories
can be employed for this purpose. For
instance, large reservoirs and sumps
should be equipped with inspection
hatches. These hatches, which can be
opened for a visual inspection and then
sealed again, should incorporate lips,
gaskets and compression clamps/bolts to
control accidental dirt entry, ingression
and air movement. Magnetic drain plugs
and other inspection devices enable wear
metals to be examined and removed from
the oil. External modifications can allow
for visual inspections of lube points,
chains, couplings, belts, etc. Minor
hatches or plugs may also be removed to
introduce a camera or borescope.
Oil Analysis
Oil sampling is key to the success of an
oil analysis program. Oil samples obtained
incorrectly will produce faulty technical
reports and an inaccurate machine diag-
nosis. An example of a machine modification
for proper oil sampling would be installing
Retrofitting machines will require full
support from management and an
allocation of resources, but the return
should be several times the investment.
ML
ocedures would be
t, based on a recent
brication.com
a primary sampling port. These ports
should be positioned according to the lubri-
cation systems configuration. Secondary
sampling ports can also be useful for moni-
toring specific components.
Installation of in-line instrumentation will
be necessary for real-time lubricant moni-
toring in large or critical machines. These
types of sensors include fluid pressure
gauges, flow meters, temperature gauges,
free water alarms, low oil level alarms, pres-
sure differential gauges, filter bypass alarms,
air-intake vacuum gauges, etc.
A high-efficiency breather for particles
and moisture
Contamination Control
A well-structured contamination control
program is a strategic element of proactive
maintenance. It addresses and helps to
eliminate the root causes of critical machine
failure modes. A wide range of machine
modifications can be made to enhance
contamination exclusion and removal, such
as incorporating circulating systems with
quality oil filters, high-performance
breathers, hydraulic cylinders equipped
with rod boots to control ingression, reser-
voirs designed with baffling to enable
contaminants to settle or detrain, and A single-point lubricator
return-line diffusers to control tank aera-
be several times the investment. Of course,
tion. Other alternatives would be to install
before any equipment modifications are
dust protection covers where grease fittings
made, it is necessary to assess each machine
are used and offline filters on bath-/
splash-lubricated machines. You may also
based on its criticality and operating condi-
tions. Safety and ergonomics must also be
need to use headspace management equip-
considered. While this may take some time,
ment with large reservoirs.
it will pay off in the long run with increased
Retrofitting machines is a smart strategy
machine reliability.
for reducing operating costs. It will require
full support from management and an allo- About the Author
cation of resources, but the return should Alejandro Meza is a senior technical consul-
tant with Noria Corporation. He has more
than 20 years of experience in the lubricant
industry, technical services, quality assurance,
training, consulting and development in the
United States, Brazil, Mexico and the Americas
region. Contact Alejandro at ameza@noria.com
to learn how Noria can help you make machine
modifications to increase reliability.
www.machinerylubrication.com | January - February 2015 | 31
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Translucent new oil is visually
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 ASK the EXPERTS

Should critical equipment be checked more

often than non-critical equipment?
Critical equipment most definitely should be checked ability and poor reliability and preventive maintenance would be an
more frequently than non-critical equipment. Based on excellent candidate for real-time, continuous online monitoring.
the definition of critical, you are referring to the As the assets attributes become less and less severe, the
machines with the highest importance to you, your company and sampling frequency relaxes, changing from continuous monitoring
your process. These assets deserve the focus of your limited time, to maybe hourly, daily, monthly, quarterly or annually. You may
money and energy. even reach a point where you decide that oil analysis just doesnt
Of course, it is important to know how you define an asset as offer any benefit because the machine has little to no impact on
critical. There are many approaches to determine the criticality of production, safety or the environment. It might be cheap to replace,
an asset. Some plants choose to use a simple 1 to 5 grading scale or you may have easy access to spares.
and subjectively assign numbers, while others utilize large, Criticality is very much a part of making informed decisions on
drawn-out processes and even employ a coaching consultant to scheduling, whether it be a simple sight-glass inspection or as
help make the determination. However, the decision can be complex as a turbine rebuild.
narrowed down to a few key attributes: impact on production,
impact on safety, impact on the environment, replacement cost,
spares or redundancy availability, probability of failure, historical
data on reliability and preventive maintenance.
Most plants are very limited in manpower and money. If there
are only so much of these resources in your bank, you want to be
sure to spend them wisely. In order to make an informed decision
on how to spend, you must have a good grasp of the assets criti-
cality relative to one another.
These criticalities can also be used to help set work prioritiza-
tion. With limited resources, you always want to be working on the
highest priority jobs first. This ranking of jobs is all but impossible
if you dont have an understanding of machine criticality.
Oil sampling is a good example of using criticality to drive
scheduling decisions. Any asset that has a high impact on produc-
tion, safety and the environment; costs more to replace; has little
to no spare parts or redundancy; coupled with a high failure prob-

What role does density play in the overall

performance of lubricants, especially in regard
to hydraulic oil?
Density is a key property not only in lubricants but in all
fluids. It is the measure of the mass of a substance in
relation to a known volume. For example, the density of
water is 62.4 pounds per cubic foot. However, this varies according
to the temperature of the fluid.
Lubricants generally are less dense than water. If the density of
an object is less than that of water, then that object will float. This
is why if you have a moisture problem in your lube system that the
water settles to the bottom of the sump and is drained out first
whenever the plug is pulled or the valve is opened.
This value is also used in some calculations involving viscosity.
Viscosity is the single most important property of a lubricant, so if
any math is to be done using this value, the density must be known.
A common conversion between absolute viscosity to kinematic
viscosity uses the density value. If the density of a fluid changes for
whatever reason, this can introduce errors in converting between

34 January - February 2015 | www.machinerylubrication.com

 both viscosity values.
A common term
used in conjunction
Stay Connected With Noria
with density is specific
Follow us on Twitter
gravity, which is the
relationship of density https://twitter.com/NoriaCorp
to water. Water has a
specific gravity of one,
so if a fluid is heavier
than water, the specific Like us on Facebook
gravity value will be http://www.facebook.com/noriacorp
more than one.
Anything lighter than
water will have a value
that is less than one. Connect with us on LinkedIn
This property of a https://www.linkedin.com/company
fluid is crucial for several attributes of a lubricant. For instance, as the density /noria-corporation
of a lubricant increases, the fluid becomes thicker. This leads to an increase
in the amount of time it takes for particles to settle out of suspension.
The specific gravity of rust falls somewhere between 2.44 to 3.6, so Continue learning with us on YouTube
as the oil thickens, particles such as this settle out much slower in reser- http://www.youtube.com/user/noriacorp
voirs and other areas with dwell time in the fluid. In hydraulic systems,
this can cause failure. These types of systems are very sensitive to any
contamination. Therefore, if the particles are in suspension longer, it
can result in problems such as silt lock, cavitation and corrosion.
In E.C. Fitchs Proactive Maintenance for Mechanical Systems, many other
problems associated with density deviations are given, particularly in
hydraulic systems. These include a greater propensity for cavitation
(both at pump suction and downstream of orifices), decreased pumping
power, increased stress on pumping elements and poor pumpability due
to fluid inertia.
According to Fitch, High-density fluid contributes to better
contamination control by aiding in the suspension, transport and
removal of particulate contaminants. Since the particles are held in
suspension longer, they are more easily removed by filters and other
particle-removal systems, thus making it easier to clean the system.
It is important to note that some fluids used as lubricants are in fact
heavier than water. Most phosphate-ester fluids have a specific gravity
of more than one. In these systems, water would float on top of the oil.
Keep in mind that as density increases, so too does the erosive poten-
tial of the fluid. In high turbulence or high-velocity regions of a system, the
fluid can begin to erode piping, valves or any other surface in its path.
Not only are solid particles affected by the density of a fluid, but so
are contaminants such as air and water. Both of these contaminants
have a marked impact on density. Oxidation influences the density of a
fluid as well. As oxidation progresses, the density of the oil increases.
Overall, density plays a critical role in how a lubricant functions and
how machines perform. Most systems are designed to pump a fluid of a
specific density, so as the density begins to change, the efficiency of the
pump begins to change as well. Understanding the importance of
density and how it relates to your equipment is essential for the reli-
ability and health of your machines.
If you have a question for one of Norias experts, email it to editor@noria.com.
www.machinerylubrication.com | January - February 2015 | 35
 Contamination Control

IN THE TRENCHES
W ES C ASH | N ORIA C ORPORATION

The HARD TRUTH About

Particle CONTAMINATION

I t has been proven that the No. 1 cause of machine failure is

the degradation of component surfaces. These surfaces can
degrade in a variety of ways, but the most destructive is via
particle contamination. While you may already be aware that dirt is
harder than most metals found in machines, do you know how
general methods: Rockwell hardness, Vickers hardness and Mohs
hardness. Although each of these tests is a little different, they all
measure a materials strength by indenting or scratching.

Rockwell Hardness
much harder it is? The Rockwell hardness test method has several scales that are
Before analyzing the differences in the hardness of materials, based on the testers indenting tip. However, they all work similarly.
you must first understand how hardness is measured. A quick A load is applied to the indenter, which then transfers the load to
Internet search for hardness measurements likely would yield three the material being tested. At the conclusion of the test, the inden-
s
ti cl e
ar
lP t
ta us
us
t Me st dD
in g s) Du s) n
o s)
o n D ss) e ar nes a
ilic r dne
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iam nes
Ir ne d
/ L ard L B ar S
/ L Ha L D r d
g H g/ s H mg ohs g / s Ha
0 m hs 0 m oh 0 m
0 oh
50 Mo 50 -7 M 50 -8 M 50 0 M
(5 (6 (7 (1

>1,000 mg
Wear Debris

170 mg
25 mg Wear Debris
Wear Debris
120 mg
Wear Debris

Particles of high compressive strength (hardness) and angularity (sharp edges) cause the greatest damage.

36 | January - February 2015 | www.machinerylubrication.com


tion depth is measured. Most metals are
tested using the C scale, which employs a
diamond tip to aid in the indenting process.
The higher the number in the Rockwell
scale, the harder the substance.
Vickers Hardness
Like the Rockwell scale, the Vickers
hardness test uses a diamond tip and relies
on indenting a surface to measure how
hard it is. The higher the value, the harder
the material. However, the measurement is
a little different. While the Rockwell scale
measures the indention depth, the Vickers
test involves locating the indention and
comparing it with the force required to
achieve it. Once this ratio is determined,
you are left with a measurement of the
materials hardness.
Mohs Hardness
The Mohs hardness scale is a much
older method used primarily by jewelers
and those who are concerned with
minerals. It was based on a scale of 1 to
10, with diamond being at the top (the 10
value). Materials were tested against each
other, and if one scratched the other, it
would be given a higher value. For
instance, gypsum can scratch talc; there-
fore, gypsum would have a higher Mohs
value than talc. Since diamond scratches
ML
everything, it was given the highest value.
The Mohs scale is easy to interpret, but
it lacks the certainty of the other tests. The
difference between a 5 and a 6 on the Mohs
scale cannot truly be determined, whereas
the hardness differences on the Rockwell
and Vickers scales are much more tangible.
Applications
Most bearings are created using a type
of chrome steel. Although there are many
variations of this material, the majority
come in at approximately 60 on the Rock-
well hardness scale (848 on the Vickers
hardness scale). In contrast, quartz has a
Vickers hardness of approximately 1,200 (7

TYPICAL MOHS
PARTICLE TYPE SOURCE SPECIFIC GRAVITY HARDNESS* GENERAL APPEARANCE
Burrs and machining swarf B 69 3-7 Curls, spirals INGRESSION SOURCES
Grindings B,I 69 3-7 Curls, chunks, chips Built in during
B=
manufacture or repair
Abrasives B,I 36 7-9 Sharp-edged chips
Ingested from the
Floor dust B,I 1-5 2-8 Chips, flakes, chunks I=
atmosphere
Road Dust (mostly silica) I 2-6 2-8 Rounded chunks
Generated from
G=
Mill scale I 5 NA Flakes, tree bark appearance within the machine
Coal dust I 1.3 1.5 NA Black, shiny flakes NA = Not available
Ore dust I Various Various Irregular-shaped chunks
Wood Pulp I 0.1 1.3 1.5 - 3 Fibrous *MOHS HARDNESS SCALE
RR ballast dust (limestone) I 2.68 2.8 59 Chips and chunks Scale 1-10
Quarry dust (limestone) I 2.68 2.8 59 Chips and chunks Diamond = 10
Foundry dust I 2.65 7 Chips and chunks Fingernail = 1

Fibers I, G, B Various Various Fibrous

Slag particles (blast furnace) I, G, B 2.65 7 Silica, sharp edges, vitreous
Aluminum oxides I, G, B NA 9 Crystals, colorless
Red iron oxides (rust) I, G, B 2.4 3.6 56 Red-orange crystals
Black iron oxides (magnitite) I, G, B 4 5.2 56 Black/bluish chunks
Copper oxides G, B 6.4 3.5 4 Small, shapeless Aluminum Oxide
Tool steel G, B 78 67 Various shapes Quarry Dust
INCREASING HARDNESS

Forged steel G, B 78 45 Various shapes Road Dust

Tool Steel
Cast iron G, B 6.7 7.9 35 Granular or flake-like
Rust
Mild steel G, B 78 3 Various shapes
Forged Steel
Alloys of copper, bronze G, B 7.4 8.9 14 Various shapes Mild Steel
Alloys of aluminum G, B 2.5 3 13 Various shapes Bronze
Babbitt particles G 7.5 10.5 1 Various shapes, gray Aluminum
Soot G 1.7 2.0 NA Vitreous, brown or black Babbitt

www.machinerylubrication.com | January - February 2015 | 37

 IN THE TRENCHES
on the Mohs scale), which is roughly 1.5
times harder than chrome steel. Quartz was
chosen for comparison because it is one of
the most abundant minerals in soil
(primarily sand). Silica-dioxide crystals are
commonly referred to as quartz and can be
found in most soils. Soils can vary from
region to region, with some more abrasive
than others. For example, the soil around
my house in Oklahoma is classified as clay
loam. This is a common soil type that has a
blend of different levels of sand, clay, silt,
etc. While other minerals in dirt can be
abrasive, it is the silica that cuts the most.
Machines susceptible to dirt ingression
should be outfitted with devices to
prevent these particles from getting
inside the equipment.
38 | January - February 2015 | www.machinerylubrication.com
In areas with high concentrations of sand
in the soil, it is important that machines
86%
susceptible to dirt ingression are outfitted
with devices to prevent these particles from
getting inside the equipment.
Hopefully, you now have a better under-
standing of just how much harder dirt is
than bearing and gear surfaces. Consid-
of lubrication professionals say
ering that steel has a Mohs value of only particle ingression has caused
4.5, the old adage tougher than nails problems for their plants equip-
doesnt sound quite as impressive and ment, based on a recent survey at
MachineryLubrication.com
perhaps should be changed to tougher
than dirt.
About the Author
Wes Cash is a senior technical consultant
with Noria Corporation. He holds a Machine
Lubrication Technician (MLT) Level II certifica-
tion and a Machine Lubricant Analyst (MLA)
Level III certification through the International
Council for Machinery Lubrication (ICML).
Contact Wes at wcash@noria.com.
 IGINDUSTRY
EAR LUBRICATION
FOCUS

Prevent
How to
Foaming and Air
Dispersions
in Industrial
Gear Oils
B Y RDIGER K RETHE, OILDOC
Lubricating oils are not completely free of air. Whether
DISSOLVED AIR UNDISSOLVED AIR
during operation or storage in barrels, oils are constantly
in an exchange process with their air-containing environ- Dissolved into molecule Not dissolved into molecule
structure (mineral-based structure
ment. Even if the oil is free of air bubbles, it will have a proportion oils = approximately 9%)
of dissolved air. This depends primarily on the gas solubility, but
No free air; no bubbles Free air; air bubbles present
pressure and temperature also have an effect. Some mineral oils
present (entrained bubbles in the body of the
can have air content approaching 9 to 11 percent volume at atmo- oil or on the oils surface, i.e., foam)
spheric pressure and room temperature. As long as the air remains
CAUSES
dissolved in the oil, this generally is not a problem.
However, free air bubbles, which usually are caused by Permanent reaction with Generated primarily by entrainment
air from environment of air bubbles, e.g., by immersing
constantly immersing machine parts or through oil returning to by diffusion; air content machine parts, return of the oil
the reservoir, can lead to serious disruptions in equipment opera- primarily depends on into the reservoir, suction of air
tion, including impaired cooling effect, increased oxidation pressure and temperature bubbles, etc.
tendency, shortened oil life, reduced carrying capacity of the
CONSEQUENCES
lubricant film, oil spills, decreased oil pump capacity, lack of
No problems Problems
lubrication, cavitation and microdieseling.
Variations of pressure Greatly increased compressibility,
Foam and Air Release and temperature can
transform dissolved air
affected lubrication and cooling
capabilities, increased oil oxidation,
Oil returning to a reservoir has enough time to separate air in into free air bubbles cavitation, microdieseling, etc.
the form of air bubbles. The main influences on the speed at
which these air bubbles separate from the oil and rise include the TABLE 1. Comparison of dissolved and free air
size of the bubbles, the oils viscosity and the oil temperature. The
amount of dispersing additives, the oils density and any impuri- anti-foam additives, which reduce the surface tension of the oil, i.e.,
ties also play a role. by the well-proportioned addition of silicone-containing compounds
As air bubbles arrive at the surface, surface foam is formed. or oil-soluble polyglycols. Too many anti-foam additives can lead to
Therefore, foam consists of a series of air bubbles, which are each a significant deterioration of the air-release capability.
surrounded by a skin of oil. As a function of the oils surface
tension, this skin of oil can burst more or less rapidly. The time it Operational Causes
takes for the ascended bubbles to burst and achieve complete The possible causes of foam formation in gears can be divided
separation from the oil is mostly dependent on the oils viscosity into two groups: transmission and lubricating oil. If lubricating oil
and temperature, but the content of polar aging products, impuri- mixes with other lubricants or contaminants such as dust or water,
ties and certain additives also have a bearing. The oil property that foaming can result along with oil aging, which leads to the forma-
describes how fast these ascended bubbles burst is called the tion of polar oil-aging products, an increase in viscosity or filtering
foaming behavior. out of anti-foam additives by bypass filters.
As seen in Table 2, air release cannot be improved by additives. Transmissions with short residence times of the oil in the reser-
However, the foaming behavior of lubricating oils can be improved by voir are particularly sensitive to changes. Increased air entry due to
40 | January - February 2015 | www.machinerylubrication.com
 GEAR LUBRICATION

a high oil level may cause high flow velocities of oil injection directly
AIR RELEASE FOAMING BEHAVIOR
into the gear teeth.
In practice, you often see an overlap of several of these factors. At what speed do air bub- At what speed do ascended
While each factor on its own would not be a problem, a combina- bles rise to the surface? bubbles burst?
tion of these factors can lead to increased foaming. This makes it Residence time in the tank
Ascended bubbles should burst
difficult to identify the actual causes. should be higher than
fast to avoid a stable or increasing
the air release to avoid
foam buildup.
Air Release Standards re-intake of air bubbles.

Several standards exist for the measurement of air-release Large bubbles ascend Small bubbles produce big bubbles
properties: ASTM D3427, ISO 9120 and IP 313. All of these use faster than small bubbles. before bursting.
the same test procedure (the impinger method). Air is blown into In higher viscosity oil, air Higher viscosity oils show higher
the oil sample through a valve at a precise time and pressure. The bubbles rise less quickly. foam stability.
release of dispersed air bubbles is recorded until the volume
Air release cannot be Foaming behavior can be improved
remains unchanged. The air release is defined as the number of improved by additives. by additives.
minutes needed to release the air dispersed in the oil to 0.2
percent volume. Aspiration of air bubbles
promotes pseudo cavi- Surface foam reduces cooling
Air release is an important property for many applications. For
tations; dieseling effect capacity and promotes oil oxidation.
example, minimum air-release requirements are included in the reduces the capacity.
standards for new hydraulic fluids and turbine oils. Modern turbine
oils and hydraulic fluids often have lower air-release values than the An air-oil emulsion distributed over the entire volume of oil leads to
serious problems in plain bearings or hydraulic systems, including
minimum requirements listed in Table 3. Air release is also a key diminished capacity, limited lubrication and cooling, declining oil
property for the condition monitoring of in-service fluids. For highly life, cavitation, microdieseling, etc.
viscous lubricating oils, air release is measured at higher tempera-
tures, e.g., 75 degrees C. TABLE 2. Air release and foaming behavior characteristics

Foaming Standards ISO VG/Type 32 46 68 100 (150) (>320)

The measurement of the foaming characteristics of lubricating Turbine Oil
oil is standardized in ASTM D892 (ISO 6247 and IP 146). Air is DIN 51515, 5 5 6 - - -
pumped into the oil through a spherical, porous stone. Small air ISO 8068
bubbles are created, which form an air-in-oil dispersion. These air Hydraulic Fluid
bubbles rise to the surface where a layer of foam builds up. After five (HLP/HM)
5 10 13 21 32 -
minutes, the air flow is stopped. The volume of foam is measured DIN 51524/2,
ISO 11158
immediately after switching off the air and after 10 minutes.
After the first test sequence at 24 degrees C, a second oil sample Lube Oil
is measured in the same way but at 93.5 degrees C and then at 24 (CLP/CKC)
- - - - - -
degrees C. The test result for each sequence consists of two DIN 51517/3,
ISO 12925/1
numbers, as seen in Table 4. However, DIN 51517/3 includes a foot-
note that seems to discredit ASTM D892 as a test procedure for TABLE 3. Minimum air-release requirements according to various
foaming characteristics of industrial gear oils: international standards
A change of the given test procedure for the foaming characteris-
tics will be done if a new or modified test procedure is standardized. ISO VG/Type 32 46 68 100 (150) (>320)
Certainly the test equipment does not work as well with
Turbine Oil I 450/0
highly viscous oils in comparison to turbine oils or hydraulic
DIN 51515, II 50/0 - -
fluids. One of the reasons could be because the amount of air ISO 8068 III 450/0
pumped into the oil depends on the viscosity. Highly viscous oils
generate a high counter-pressure. The higher the viscosity, the Hydraulic Fluid
I 150/0
(HLP/HM)
lower the amount of entrained air and foaming characteristics. II 75/0 -
DIN 51524/2,
Air entrainment in a gearbox also functions differently than in a III 150/0
ISO 11158
hydraulic system.
Industrial Gear
I 100/0 (100/10)
Flender Foam Test Oil (CLP/CKC)
DIN 51517/3,
II 100/0 (100/10) 150/60
The measurement of foaming characteristics according to III 100/0 (100/10)
ISO 12925/1
Flender is standardized in ISO/DIS 12152. Inside the Flender foam
test rig, a horizontal pair of spur gears rotates at 1,405 revolutions TABLE 4. Foaming characteristics requirements

42 January - February 2015 | www.machinerylubrication.com

 ML
ML

per minute. Lubricant is filled into the apparatus until the spur
gears are covered halfway up the side. The gears start to turn for
five minutes and splash air in the oil like a mixer.
After 90 minutes, any change in the oil phase, oil dispersion and
foam volume are documented. The percentage increase in the oil
volume one minute after stopping the instrument as well as the
percentage increase in the volume of the air-oil dispersion five
minutes after stopping the instrument are two important values in
evaluating and assessing the test.
For the percentage increase in the oil volume one minute after
stopping the instrument, the following rating should be used:
The upper limit of more than a 15-percent increase in the oil
volume one minute after stopping the instrument does not equate
to an actual foaming limit for existing gearboxes. This limit is only
valid for the test instrument and the standardized test procedure. It
FIGURE 1. Foaming characteristics test (ASTM D892) is based on the experiences of Siemens (Flender) in meeting the
requirements of Flender gearboxes.
Up to 5% Good foaming characteristics The percentage increase in the volume of the air-oil dispersion
five minutes after stopping the instrument is limited to a maximum
Up to 10% Satisfactory foaming characteristics
of 10 percent. This limit is required by leading manufacturers of oil
Up to 15% Still acceptable foaming characteristics pumps to avoid cavitation.

Above 15% Unacceptable foaming characteristics Case Study #1: Lifting Gearbox
Excessive foaming in an industrial gearbox containing 1,000
1702513 1702514 1702515 liters of gear oil was observed during operation. Contamination or
mixing of different oils or other fluids is the most common cause.
Foam Reservoir New Oil
Water (Wt.-%) <0.1 <0.1 <0.1
Silicon (ppm) 6 2 0
Kin. Viscosity
145.3 115.2 104.0
(40C, mm2 /s)
Kin. Viscosity
15.27 12.3 11.1
(100C, mm2 /s)
Viscosity Index (VI) 107 97 91
Calcium (ppm) 174 55 0
Phosphorus (ppm) 189 73 25
Zinc (ppm) 106 34 0
Barium (ppm) 1 0 0
Sulfur (ppm) 3,588 3,605 3,481
Acid Number (mgKOH/g) 0.25 0.18 0.19

TABLE 5. Test results from a lifting gearbox

FIGURE 2. Infrared spectra of oil samples from a lifting gearbox

www.machinerylubrication.com | January - February 2015 | 43
 GEAR LUBRICATION

8031962 8021706 8021708 8021706

Gearbox New Oil Filtered Oil New Oil
Water (Wt.-%) <0.1 <0.1 Water (Wt.-%) <0.1 <0.1
Silicon (ppm) 0 9 Silicon (ppm) 2 9
Kin. Viscosity (40C, mm /s) 2
330.9 330.8 Kin. Viscosity (40C, mm /s)
2
330.1 330.8
Kin. Viscosity (100C, mm /s) 2
37.4 38.2 Kin. Viscosity (100C, mm /s)
2
38.1 38.2
Viscosity Index (VI) 162 166 Viscosity Index (VI) 167 166
Boron (ppm) 31 33 Boron (ppm) 31 33
Phosphorus (ppm) 371 414 Phosphorus (ppm) 422 414
Zinc (ppm) 0 0 Zinc (ppm) 0 0
Barium (ppm) 0 0 Barium (ppm) 0 0
Sulfur (ppm) 4,932 5,013 Sulfur (ppm) 4,938 5,013
Foam S1 (ml/ml) 110/110 10/0 Foam S1 (ml/ml) 10/10 10/0

TABLE 6. Oil analysis results of a sample from a filled gearbox TABLE 7. Oil analysis results for a sample of filtered new oil

FIGURE 3. An infrared spectrum of an oil sample from a newly FIGURE 4. An infrared spectrum for a sample of filtered oil
filled gearbox

Therefore, a sample of the new oil was requested. One sample was
taken from the middle of the oil reservoir and another from the
foam. The results are shown in Table 5.
Elemental analysis revealed the cause of the excessive foaming
the oil was contaminated by another fluid. The analysis also
showed differences in additive elements of the new oil, the foam
and the sample from the gearboxs oil reservoir.
Case Study #2: New Oil After Filling a Gearbox Case Study #3: Main Gearbox of a Wind Turbine
When new oil was used to fill a gearbox and the gearbox was
started, the oil showed an increased foaming tendency. The
customer believed the cause of the increased foaming tendency was
the removal of anti-foaming agents due to bypass filtration. To
obtain more information, oil samples from the new oil and from
the oil in the gearbox were analyzed (Table 6).
The results showed the silicon-based anti-foaming agent had
been completely removed. There were also small changes in addi-
tive content. An infrared spectrum of the gearbox sample in
comparison to the fresh oil can be seen in Figure 3.
The spectrum revealed cross-contamination by another fluid. A
fresh oil volume was then filtered to determine if bypass filtration was
the only reason for the foaming or if cross-contamination also had an
effect. After filtration, a sample was taken and analyzed (see Table 7).
The analysis showed that the anti-foaming agent was not
completely removed. A small amount (2 parts per million) remained.
Although the slight changes in the amount of anti-foaming agent
are not visible in the infrared spectrum (Figure 4), a good correla-
tion of the sample before and after filtration is evident.
Some filter manufacturers have even included the Flender foam
test in their testing procedures to avoid problems with removed
anti-foam agents.
A wind turbines main gearbox was initially filled with a mineral
oil. After operating for 25,000 hours, the oil was changed, and a
switch was made to a synthetic polyalphaolefin-based oil. The
new filling started to foam almost immediately. Oil analysis was
utilized to determine whether the gearbox was flushed properly
(see Table 8).
Small changes in the element concentrations were visible. The
infrared spectrum (Figure 5) shows the contamination more clearly.
The brown graph represents the spectrum of the old oil, while the
blue graph is the new oil, and the red graph is the oil from the
gearbox after the oil change.
Case Study #4: Cement Mill Gearboxes
During a scheduled downtime, the oil in two industrial gear-

44 January - February 2015 | www.machinerylubrication.com

 ML

2295772 1504280 2155316 1702513 1702514 1702515

After Oil Gearbox A Gearbox B New Oil
New Oil Old Oil
Change
Oil Usage (hours) 500 210 0
Water (Wt.-%) <0.1 <0.1 <0.1
Water (Wt.-%) <0.1 <0.1 <0.1
Silicon (ppm) 16 25 0
Silicon (ppm) 4 2 3
Kin. Viscosity
332.3 325.1 318.8 Kin. Viscosity
(40C, mm/s) 204.3 200.7 216.1
(40C, mm2/s)
Kin. Viscosity
36.7 36.5 23.4 Kin. Viscosity
(100C, mm/s) 18.8 18.6 18.97
(40C, mm2/s)
Viscosity Index (VI) 157 160 92
Viscosity Index (VI) 101 103 98
Calcium (ppm) 0 0 0
IR-Oxidation (A/cm) 7 11 -
Phosphorus (ppm) 393 432 197
Calcium (ppm) 15 18 18
Zinc (ppm) 3 0 22
Phosphorus (ppm) 175 163 156
Barium (ppm) 0 0 0
Zinc (ppm) 5 6 7
Sulfur (ppm) 3,992 3,857 10,690
Molybdenum (ppm) 859 861 852
Acid Number
0.94 0.99 0.82 Sulfur (ppm) 10,752 10,768 10,690
(mgKOH/g)
Flender Foam (%) 18 - - Acid Number
0.83 0.79 0.85
(mgKOH/g)
TABLE 8. Test results from old and new gear oil
TABLE 9. Test results for new and in-service gear oils from
cement mill gearboxes

FIGURE 5. An infrared spectrum of an oil sample from a wind

turbines main gearbox

boxes was changed. Due to the positive experiences with the oil, the
same oil type was used again. After the oil change in both gear-
boxes, increased foaming was observed. The gearboxes were
stopped again, and the customer complained to the oil manufac-
turer about the bad oil quality. The oil manufacturer took
samples from the foaming oil in both gearboxes and from the new
oil that was delivered (see Table 9).
The elemental analysis results were not unexpected. Only the
viscosity of both gearbox samples was slightly decreased. This
decrease was within the limits for ISO VG 220. However, in compar-
ison to the fresh oil sample from the same batch, it was noticeable.
The infrared-oxidation value was also abnormal and much too high
for this limited usage. The infrared spectrum indicated contamina-
tion with an ester-containing fluid (see Figure 6).
While discussing the results, the customer revealed that a
cleaner had been used. The cleaner contained ester-based compo-
nents, and its viscosity was very low. It became obvious that the
cleaner was the reason for the increased foaming.
FIGURE 6. Part of an infrared spectrum for a contaminated gear oil
In conclusion, the formation of foam or finely dispersed air
bubbles is one of the most frequently discussed phenomena in the
operation of gearboxes. Excessive foaming can lead to serious
operational problems as well as safety and environmental hazards.
Different standardized test procedures are available to esti-
mate the air release and foaming properties of lubricating oils.
However, the common test methods for air release (ISO 9120,
ASTM D3427-12 and IP 313) and foaming properties (ASTM
D892, ISO 6247 and IP 146) do not provide reliable information
for industrial gear oils. Therefore, a special test (Flender foam
test, ISO 12152) has been developed and standardized. This test
delivers much more reliable results and can improve the reliability
of gear oils. The examples given in this article demonstrate the
application of these test procedures and offer an overview of a
variety of foaming problems as well as their causes.

www.machinerylubrication.com | January - February 2015 | 45

 GET to KNOW

Chenevey,
Bob Chenevey is the manager of mechanical systems
for the Upper Occoquan Service Authority (UOSA), a
municipal water-reclamation plant in northern Virginia

UOSA Strive
that processes 54 million gallons of water per day. Before
Cheneveys arrival, the plant had been utilizing oil anal-
ysis and reducing its number of oils. However, over the

for Lubrication
past four years, Chenevey has been part of expanding these
efforts through training, improving the lube room and
consolidating lubricants. The plant now uses desiccant

Perfection
breathers on machinery and has installed shelving and
a bulk storage system with individual filters and pumps.
It has also changed its sampling techniques to allow for
better, more representative oil samples.

Q: What types of training
have you taken to get to
your current position?
A: I have taken countless hours of
communication and management
courses to learn how to work with
many different personalities. Ive
also taken writing, project manage-
ment and finance courses, all of
which are needed to be a manager
today. However, some of the most
Name critical training came from the U.S.
Bob Chenevey Department of State when I went
through five months of culture
Age
management, leasing, construction
61 and procurement training. This
Job Title was designed to acclimate me to a
Mechanical Systems life of working with Foreign Service
National employees and contrac-
Manager
tors at overseas embassies. It was a
Company mandatory pass set of courses
Upper Occoquan and tests to ensure that I would be
Service Authority successful working in those
different cultures.
Location
Centreville, Virginia Q: What professional certi-
fications have you attained?
Length of Service A: I used to hold steam engineers
4 years
licenses, but Ive let those lapse
because I simply dont need them. I
still carry a Facilities Management
Administrator and Systems Mainte-
nance Administrator certification
with Building Operation and
Maintenance Institute (BOMI) Inter-
national. That said, I am surrounded
by loads of talent. Here at UOSA, we
have many technicians who are
driven to get certifications, which is
something I respect immensely. We
have a lead mechanic with an Asso-
ciation of Boards Certification
(ABC) Plant Maintenance Technolo-
gists Level I and II certification, and
a lead mechanic who holds a Level I
Machinery Lubrication Technician
certification from the International
Council for Machinery Lubrication.
Other shops have electrical masters
and journeyman licenses as well as
infrared certifications.
Q: Are you planning to obtain
additional training or achieve
higher certifications?
A: I am not personally. However,
the shop base will continue
working to gain further certifica-
tions. Although it is not a
requirement for our mechanics
and electricians to hold certifica-
tions, UOSA has taken the stand
to support our mechanics, electri-
cians, techs and operators with
bonus awards whenever certain
certifications are obtained.
Q: Whats a normal work
day like for you?
A: Im pretty much a 40-hour-
work week person. We have a
good computerized maintenance
management system (CMMS) that
I look at frequently. We have two
lead mechanics who perform all
the mechanical functions, working
primarily with the mechanics, work
orders and repairs to keep the
plant in good condition. I do the
other stuff such as working with
the guys trying to figure out their
training needs, working with
budgets, writing scopes of work,
working with upper and lateral
management, and coordinating
between engineering, maintenance
and our treatment process folks
who handle the plant operation on
a daily basis. We also contract out
much of our heavy maintenance
items, and between the leads and
myself, we provide a great deal of
support to our contractors. Over
the past year or so, Ive been
involved with asset management,
looking into the future and identi-
fying plant needs on critical
equipment through our capital
improvements program. Opera-
tions, maintenance and
engineering work well together
here at UOSA, and we are
successful because of that.

46 January - February 2015

Q: What is the amount and range of equipment that
you help service through lubrication/oil analysis tasks?
A: When I came here, I made the decision to test only equipment
that had more than 1 gallon of oil. For equipment with 1 gallon
and less, it made sense to change the oil rather than test it. This
left more than 300 pieces of equipment for oil analysis, ranging
from air compressors and blowers to large engines and a wide
variety of high-viscosity gearboxes. We have large centrifuges,
two bio-solids dryers, filter presses, a cogeneration plant,
digesters, bio-reactor equipment, a granular activated carbon
(GAC) regeneration system, emergency generators, 37 clarifiers
and countless pumps. Within that, there is plenty of mechanical
equipment for us to maintain.
Q: On what lubrication-related projects are you
currently working?
A: We just bought a bulk storage system with individual pumps
and filters. Were not expanding, just continuing to consolidate
our lubricants. This year we committed to using a filter cart for
high-viscosity oils. Since we have 37 clarifiers with unfiltered oil,
it makes sense to perform an annual cleaning. Each of these clar-
ifiers holds as much as 18 gallons of oil. Thats an expensive
Q: How does your company view machinery lubrica-
endeavor when an analysis comes back as marginal. We know
we can clean it and get it back to normal using the filter cart. We
tion in terms of importance and overall business
are looking at a payback of a single year in oil savings and strategy?
extending the life of the oil by at least two years. Once our A: On a scale of 1 to 10, probably in the 3 to 4 range, but not
mechanics start seeing the benefits of cleaning vs. replacement, because they dont care. Its because theyve delegated it to our
well work toward smaller carts to perform cleaning on some of level. Lubrication is a function of the mechanics and technicians
our other smaller gearboxes and drives. understanding the importance of good practices and knowledge.
My manager knows that its important, and he is completely
Q: What have been some of the biggest project supportive of anything we do, encouraging us to continue, move
successes in which youve played a part? forward and strive for lubrication perfection.
A: Within UOSA, I think our cogeneration plant is certainly the
most lucrative. We use bio-gas produced from our digesters to
Q: What do you see as some of the more important
generate 845 kilowatts 24 hours a day, seven days a week with an trends taking place in the lubrication and oil
uptime of more than 90 percent in the past year. Its a small plant, analysis field?
but its about 20 percent of our overall power demand. Over the A: I think filtering is key to a good program. I believe emphasis
course of a year, thats a substantial savings. Since Ive been here, needs to be placed on filtering before changing the oil. At least
weve started a new GAC regeneration furnace, a new centrifuge then you can get all you can out of the oil until it no longer has the
and a new bio-solids dryer. For me, it was a matter of sitting physical and chemical properties to reliably lubricate.
through design and review meetings so that as a team, UOSA
could ensure a good end product. Q: What has made your company decide to put more
emphasis on machinery lubrication?
A: Many of us have attended conferences where best practices
Be Featured in the Next and proper lubrication have been the focal point. We all know
Get to Know Section that good, clean oil helps make bearings and wear surfaces
happy. Its been a long haul though. Some of this can get expen-
WOULD YOU LIKE TO BE FEATURED IN THE sive, between sampling, sampling equipment, filtration and
NEXT GET TO KNOW section or know someone training. I think you have to first figure out the real need. How
who should be profiled in an upcoming issue of many failures have you had due to improper lubrication, or is it a
Machinery Lubrication magazine? Nominate yourself matter of increasing the life of your oil? This is how we are ratio-
or fellow lubrication professionals by emailing a photo nalizing it. If a plant is having a lot of failures, then there is
and contact information to editor@noria.com. something wrong with the maintenance program in general. For
us, we want to simply extend the life.

www.machinerylubrication.com | January - February 2015 | 47

 CERTIFICATION NEWS
ICML Marks 14 YEARS
of INDUSTRY SUCCESS
B Y SUZY HITCHCOCK, ICML
In 2001, when the International Council for Machinery
Lubrication (ICML) offered its first certification exam,
few could have envisioned the organization becoming
the world leader in the certification of lubrication technicians and
oil analysts. However, following 14 years of consistent and
impressive growth, ICML has now administered more than 21,000
exams to practitioners from more than 100 different countries.
Exams are currently offered in English, Spanish, Portuguese,
Korean, Japanese, Chinese, French, Italian, German and Russian.
The organization is also looking to translate its exams into addi-
tional languages to ensure qualified individuals are able to test
their skills equally.
Thanks to ICMLs rapid global expansion and successful track
record, its certification programs in effect have become world stan-
dards on the certification of technicians, with thousands of
companies worldwide using its credentials for skill-based hiring and
promoting. The International Organization for Standardization
(ISO) has even incorporated ICMLs certification programs as the
basis for its two international standards on the certification of oil
analysis personnel. ICMLs Machine Lubrication Technician (MLT)
and Machine Lubricant Analyst (MLA) programs were pioneered
into ISO 18436-4 for field-based personnel, while ICMLs Labora-
tory Lubricant Analyst (LLA) program was expanded and forged
into ISO 18436-5 for laboratory-based personnel.
Over the years, ICML has continued to support lubrication
standards development, with its volunteers being active in various
committees and working groups responsible for standards
relating to the application of lubrication and oil analysis best
practices. ICML serves as a voice for industry to advocate for
necessary standards and welcomes suggestions for specific issues
needing standardization.
Besides certification and standards development, ICML helps
to dignify the careers of lubrication practitioners by recognizing
excellence in industry and identifying future industry mentors
through its awards programs. The Augustus H. Gill and John R.
Battle awards, which are presented for excellence in oil analysis
and lubrication, recognize end-user programs around the world
and bring global prestige and respect to lubrication champions
and their teams. The focus of the awards is not just to identify
48 | January - February 2015 | www.machinerylubrication.com
Lubrication Programs
award recipients but to encourage excellence and create a means
to share best practices among user organizations on a global
scale. The awards are open to companies worldwide at no cost to
the applicants and are independent of any involvement by the
applicant companies in any area of ICML activity. The awards
criteria serve as a roadmap for organizations in their journey to
world-class lubrication and oil analysis initiatives.
Most importantly, ICML has become a global community of
lubrication and oil analysis practitioners who are deserving of
recognition and support. The organizations volunteers have a
passion to do right by its members and have an incredible commit-
ment to make ICML work.
It has been said that industry rides on a precious and delicate
film of oil. Just how much this film of oil influences economic health,
job stability and the environment is becoming more and more
evident. Industry is increasingly open to a more proactive approach
to maintenance in order to improve asset reliability and produc-
tivity. It is also awakening to the fact that none of these initiatives
really matters if the individual performing lubrication tasks is not
properly trained and supported. ICMLs mission is to help more
people understand and appreciate this crucial role.
For more information on ICMLs certification programs and
how to join the organization, visit www.lubecouncil.org.
About ICML
THE INTERNATIONAL COUNCIL FOR MACHINERY
LUBRICATION IS A VENDOR-NEUTRAL, not-for-
profit organization founded to facilitate growth and
development of machine lubrication as a technical field
of endeavor. Among its various activities, ICML offers
skill certification testing for individuals in the fields of
machine condition monitoring, lubrication and oil anal-
ysis. ICML is an independently chartered organization
consisting of both paid professional staff members and
volunteer advisors. It provides lubrication and oil analysis
standard development support, scholarship, skill-based
testing and certification, and recognition of excellence.
CERTIFICATION NEWS
Abu Dhabi Gas Industries
Lala Khunte, MLA I & MLA II
Advanced Technology
Services
Dennis Kraffert, MLT I
Alinta Energy
Benjamin Cope, MLA II
AMRRI
Bob Brahm, MLA I & MLT I
ArcelorMittal
Darlene Richmond, MLA I
Ardent Mills
Derick Lindsey, MLT I
Ashland Specialty
Ingredients
Keaton Dunigan, MLA II
AV Technology
Paul Dinneen, MLA II
Mark Needham, MLA II
Ryan Watson, MLA I
Robert Williams, MLA I
Barrick
Jason Harris, MLA II
Bristol-Myers Squibb
Gualberto Santana, MLT I
Ruben Torres, MLT I
Capron Oil Management &
Engineering Solutions
Kartik Chandra Sekhar, MLA I
Carter, Holt & Harvey
Michael Clifford, MLT I
Cerro Verde
Walter Augusto Isley
Fernandez Erazo, MLA II
CF Industries
Raymond Stoulp, MLT I
Coca-Cola
Carlos Alessandro Barbosa,
MLT I
Colfax Fluid Handling
Alvaro Romo Gardeazabal,
MLA I
Cosan Limited
Paulo Roberto da Silva Jr.,
MLT I
CRE Philippines
Erwin Bernal, MLT I
DTZ
Matthew Artis, MLA I
RECENT RECIPIENTS OF ICML CERTIFICATIONS
THE INTERNATIONAL COUNCIL FOR MACHINERY LUBRICATION (ICML) WOULD LIKE
TO CONGRATULATE PROFESSIONALS worldwide who have recently achieved certified status
through ICMLs certification programs. ICML offers certification in the areas of oil analysis and
machinery lubrication. The following is a list of recently certified professionals in the area of
machinery lubrication who have attained their status as a certified Machine Lubricant Analyst
(MLA), Machine Lubrication Technician (MLT) or Laboratory Lubricant Analyst (LLA).
David Cochran, MLA I
Brandon Cyprych, MLA I
Chris Hancock, MLA I
Jerry Tom, MLA I
Dynamic Mechanical
Greg Telfer, MLA I
Enviva
David Bradford, MLT I
Jacob Griffies, MLT I
Casey Raiford, MLT I
Fluor Driver
Sergiy Samylin, MLT I
Shawn Wilson, MLT I
Robert Woolridge, MLT I
Fonterra
Eugene Davis, MLT I
Fuchs
Alexander Franke, MLA II
Fundacion Tekniker
Asier Osoro Urizar, LLA I
Estibaliz Askasibar Ardantza,
LLA I
Irune Arizmendiarrieta, LLA I
Leire Legaristi Litago, LLA I
Vanesa Gonzales Gonzalez,
LLA I
GE Energy
Angel Munoz Fraile, MLA I
Javier Martinez Guembe,
MLA I
Georgia Pacific
Aaron Hinson, MLT I
Glencore
Joshua Jansen, MLA I
Hindustan Petroleum Corp.
Abhijit Sarkar, MLT I
Hinton Pulp
Clayton Arlidge, MLT I
Rommel Loutan, MLT I
Bryan Ollenberg, MLT I
Max Plamondon, MLT I
Holcim
Jose Maria Ervin Dio, MLT I
IK4-Tekniker
Sarai Garrido Elustondo, LLA I
Marcos Gil Calvo, MLA I
International Paper
Colby Earthman, MLT I
Charles Michel Lili, MLT I
Kepco Philippines
Joel Girado, MLT I
Kimanis O&M
Alddyrine Gungat, MLA I
Mohd Rozairie Bin Jahir, MLA I
Kinetics Commercial Co.
Koustuv Mohanty, MLA I
Koch Industries
Kyle Thayer, MLT I
Lubrication Engineers Inc.
Michael Kidder, MLT I
Luminant
Dennis Horton, MLA II
Maersk Oil Trading
Lubricants
Sandip Jarode, MLT I
Mosaic Company
Linda Easterwood, MLT I
Motiva Enterprises
Rickey Thibodeaux, MLT I
Nestle
Justin Egner, MLT I
Michael Fannock Jr., MLT I
John Jenkins, MLT I
David Panto, MLT I
David White, MLT I
Norampac
Adam Paduano, MLT I
Nucleoelectrica Argentina
Ivan Barvarich, MLT I
Oelcheck
Uwe Baumbach, LLA II
Oklahoma Gas & Electric
James Rader, MLA I
One Stop Solutions
Samir Bhagwat, MLA I
Ontario Power Generation
Mahyar Hosseinnejad, MLA I
Pacific Drilling
Clifford Smith, MLT I
Packaging Corp. of
America
Stacey Pefley, MLT I & MLA I
Garrett Allen, MLA I
Logan Davis, MLA I
Kline Duplechin, MLA I
Jeffrey Kiser, MLA I
Robert Koths, MLA I
William Loftin, MLA I
Christoper Martin, MLA I
Jody Mitchell, MLA I
Morris Murray, MLA I
Jackie Park, MLA I
Jared Pickering, MLA I
Petron Corp.
German Crisostomo, MLT I
Raymond John Valin, MLT I
Petronet LNG
Pawan Chaturvedi, MLT I
Plant Reliability Engineering
Timothy Arlidge, MLT I
PTT Public Co.
Apiwat Iamborisuth, MLA II
Teeralak Tharawut, MLA II
PUR Oil Technologies
Alexander Shafirovich, MLT I
Rio Tinto Need to take
Craig Walker, MLT I an exam?
Rodolub Commercial ICML regularly holds exam
Lubricants sessions throughout the
Ricardo Figueira da Silva, United States and the
MLT I world. Upcoming dates
Alexandre Clemilson Chagas,
and locations for ICML
MLT I
exams can be found at
SGS www.lubecouncil.org.
Giuliana Zavaleta Teran, MLA II
SIL
Adalvan Dutra de Miranda,
MLT I
Antonio Fernando Rogerio ICML Certifications
Pelozio, MLT I
David Tavares, MLT I LLA I
Marcos Vieira de Oliveira, L ABORATORY LUBRICANT
MLT I A NALYST LEVEL I
Sinclair Wyoming Refining
Gene Goetz, MLA II MLA I
Fallon Schmidt, MLA II M ACHINE LUBRICANT
A NALYST LEVEL I
SKF Canada
Mahmoud Aliani, MLA I MLA II
Steag M ACHINE LUBRICANT
Paulo dos Santos, MLT I A NALYST LEVEL II
Subway Company of Sao MLA III
Paulo M ACHINE LUBRICANT
Cassio Murilo Adriano, MLT I A NALYST LEVEL III
Total Petrochemicals &
Refining
MLT I
Mark Reynolds, MLA II M ACHINE LUBRICATION
TECHNICIAN LEVEL I
United States Gypsum Co.
Steve Chambers, MLT I MLT II
Western Municipal Water M ACHINE LUBRICATION
District TECHNICIAN LEVEL II
Jason Baringer, MLT I
www.machinerylubrication.com | January - February 2015 49

BACK PAGE BASICS
L OREN G REEN | N ORIA C ORPORATION
ADVANTAGES of Contracting
Out Your LUBRICATION Program
A cross industry there has been a
move toward predictive and
proactive maintenance, but
unfortunately a large number of organiza-
tions are still operating in the reactive
maintenance mode. This can be a difficult
cycle to break due to the efforts required just
to keep equipment running. Frequently,
repairs only involve getting machines back up
and not actually fixing them.
50 | January - February 2015 | www.machinerylubrication.com
Many maintenance departments are
also woefully understaffed. Even teams
with sufficient personnel often spend so
much time fighting fires to keep the plant
operating that little time is left for predic-
tive or proactive maintenance. There simply
are not enough hours in the day and not
enough maintenance mechanics to repair
the equipment properly in many organiza-
tions. This creates considerable demand on
Lubrication Programs
resources in the form of parts, labor and
time. In addition, the cost of a breakdown
can be significant, with the repair of the
breakdown only a small portion of the
breakdowns total cost.
Studies have shown that most organiza-
tions spend only 5 percent of their
maintenance budget on lubricants and
lubrication, yet approximately 70 percent
of equipment failures are lubrication
related. This would include applying the
wrong lubricant, relubricating too often or
not often enough, using too much or too
little lubricant, and not controlling contam-
ination adequately. In the end, your
maintenance dollars will be spent one way
or another. It is just a matter of when and
how much. If you skimp on lubricants,
breathers, filters, etc., you will continue to
spend vast amounts of money on equip-
ment downtime and repairs.
44
P E R C E N T
of MachineryLubrication.com
visitors say their plant outsources
lubrication or maintenance tasks to
contract-based laborers

Global Training Calendar
MARCH 2015
MACHINERY LUBRICATION I
Sao Paulo, Brazil March 2-5, 2015
PRACTICAL OIL ANALYSIS
Daegu, South Korea March 2-5, 2015
FUNDAMENTALS OF MACHINERY LUBRICATION
Bogot, Colombia March 3-5, 2015
BEARING RELIABILITY
Len, Guanajuato, Mxico March 10-12, 2015
FUNDAMENTALS OF MACHINERY LUBRICATION
Koge, Denmark March 10-11, 2015
FUNDAMENTALS OF MACHINERY LUBRICATION
Mandaluyong City, Philippines March 14-16, 2015
FUNDAMENTALS OF MACHINERY LUBRICATION
Kuala Lumpur, Malaysia March 16-18, 2015
FUNDAMENTALS OF MACHINERY LUBRICATION
Jakarta, Indonesia March 17-19, 2015
PRACTICAL OIL ANALYSIS
Lima, Per March 17-19, 2015
FUNDAMENTALS OF MACHINERY LUBRICATION
Florence, Italy March 18-20, 2015
LUBRICATION SCHOOL I
Brisbane, QLD, Australia March 23-25, 2015
www.machinerylubrication.com
ML
IMPLEMENTING ASCEND
Len, Guanajuato, Mxico March 24-26, 2015
FUNDAMENTALS OF MACHINERY LUBRICATION
Antofagasta, Chile March 24-26, 2015
FUNDAMENTALS OF MACHINERY LUBRICATION
Moscow, Russia March 24-26, 2015
OIL ANALYSIS II
Bangkok, Thailand March 24-27, 2015
ICML certification testing is available after
most of the courses listed. Please visit
www.lubecouncil.org for more information
on certification and test dates.
| January - February 2015 | 51
 BACK PAGE BASICS

Now consider the cost savings an effective lubrication program

can provide in the form of increased equipment reliability, reduced PERFORMED PERFORMED BY
PROGRAM BY IN-HOUSE CONTRACTOR
lubricant consumption and fewer repair parts. Lower overtime
FEATURE/NEED TECHNICIANS PERSONNEL
costs could also pay for the programs implementation and
management. Doesnt this sound like something that would be of Lubricant Optimization X
interest to your plant manager? Lubrication PM Optimization X

Lubrication: A Skilled Trade Lubrication Program Survey X

It is important to realize that proper lubrication is a skilled Equipment Modification
trade. Lube technicians must be trained how to determine which X
Recommendations
lubricant is best for each application. They should also know how
to calculate the correct relubrication quantity and frequency. In Equipment Modification
X X
Installation
order to learn these skills, technicians must be trained and certi-
fied. Just like every other skilled trade, lubrication requires a Lubrication Program
X X
training and certification component. Management
With the average age of skilled workers approaching 60, more
Lubrication Inspections X X
and more of these individuals will be retiring in the next several
years. Sadly, few younger workers are entering into the skilled Lubrication Activities X X
trades, which will leave a huge deficit of trained workers.
Lubrication Certifications X X
If you do not have immediate access to skilled, trained and certi-
fied lubrication technicians, it may be time to look into contracting Lubrication Training X
out this function. A good contractor not only can provide trained
and certified lube techs but can also help you develop procedures and, in a very brief period of time, make significant improve-
for your lubrication-related tasks as well as implement, maintain ments to your lubrication program that will be reflected on the
and manage your lubrication program. Granted, you will spend bottom line.
more than 5 percent of your maintenance budget, but in return you
will lower your equipments breakdown frequency and the costs About the Author
associated with repair parts, overtime, downtime, etc. Loren Green is a technical consultant with Noria Corporation,
Contractors should have the training and requisite skills to focusing on machinery lubrication and maintenance in support of Norias
survey your facility and make immediate recommendations for Lubrication Program Development (LPD). He is a mechanical engineer
equipment modifications, lubricant selections and other neces- who holds a Machine Lubrication Technician (MLT) Level I certification
sary changes. They should also be able to properly install the and a Machine Lubricant Analyst (MLA) Level III certification through

modifications, implement the procedures and lube routes, and the International Council for Machinery Lubrication (ICML). Contact
monitor their completion. Loren at lgreen@noria.com to find out how Noria can help you improve
In short, a contractor is equipped to walk into your facility your lubrication program.

Most organizations spend only

5 percent of their maintenance
budget on lubricants and
lubrication, yet approximately
70 percent of equipment failures
are lubrication related.

52 | January - February 2015 | www.machinerylubrication.com

Seeing Oil Like Never Before
With The Condition Monitoring Pod

Built-in oil
sampling port

Access point for quick

syringe sampling and hand-held
instrument tests

Indicator detects
abnormal corrosion and
varnish conditions

3-D sight glass enables quick

inspection for water emulsions,
foam, sediment and bubbly oil

Nut allows for easy sight glass

rotation (to inspect magnetic rod) Cross-hairs for
or removal (for cleaning) observing oil level

Easy-to-remove and
view magnetic plug

Machine Reliability Gets a Boost

The new Condition Monitoring Pod is a multi-parameter inspection device that
modernizes and expands the power of daily one-minute inspections. An oil sampling
valve, magnetic plug, corrosion/varnish inspection indicator, and a quick lubricant access
point provide the ultimate in versatility. Most bulls-eye level gauges can confirm oil volume but
cant help identify the root causes and symptoms of machine failure. This revolutionary inspection tool bolsters
reliability through quick access to multiple field lubricant tests and displays instant feedback on the condition of
the lubricant and its operating environment.

Toll Free 1-888-742-2021 Luneta.com

Patent Pending
Go to noria.com/quicktips/ for more videos.
 GREAT IDEAS
START HERE.

Now in its 16th year, Reliable Plant serves as the leading

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FULL CONFERENCE REGISTRATION INCLUDES:
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