Machinery Lubrication

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10

COVER STORY

Machinery

Lube Room Challenge

Machinery Lubrication’s annual Lube Room Challenge showcases exceptional lube rooms submitted by readers who
have transformed their lubricant storage and dispensing methods to best practices.

2

CERTIFICATION NEWS

Justifying the Cost of Excluding a Gram of Dirt

Eli Lilly’s Wenzel Embodies the Spirit of ICML

AUTHOR: JIM FITCH

AUTHOR: SUZY JAMIESON

Many variables and factors influence the cost of excluding a gram of
dirt. However, there are many more costly consequences associated
with failing to exclude.

6

FROM THE FIELD

How a Band-Aid Solution Can
Fix Your Hydraulics Problems

6 Steps to Update Your Lubrication Program
AUTHOR: STEPHEN SUMERLIN

AUTHOR: BRENDAN CASEY

There’s a negative bias toward the BandAid solution in engineering, but there
are times when a convenient shortcut is
needed. The trick is being able to recognize when a Band-Aid solution
is appropriate and when it is not.

Lubricant Analysis in Steam Turbines
AUTHORS: BEATRIZ GRACA, JORGE SEABRA, PINTO SOUSA

Discover the potential of analytical ferrography
in diagnosing the early stages of sludge and
varnish problems so the root cause can be
determined and corrective action taken before
a catastrophic failure occurs.

More

By successfully completing the very first ICML exam 10 years ago,
Rendela Wenzel not only became one of the first ICML-certified professionals but also the very first ICML-certified female practitioner.

44

HYDRAULICS AT WORK

24

September - October 2011

34

AS I SEE IT

OIL ANALYSIS

Lubrication

When updating your lubrication program, it is important to think of
every aspect of lubrication. Just working on one area will not yield the
results you desire.

46
48

LUBE-TIPS
Our readers provide excellent advice on a
host of lubrication-related issues.

BACK PAGE BASICS

Comparing Gasoline and Diesel Engine Oils
AUTHOR: JEREMY WRIGHT

While gasoline and diesel engine oils generally have the same anatomy
and are formulated from the blending of base oils and additives, they
actually are quite different when examining the lubricant’s required
performance for each engine type.

Editorial Features

Departments

20 GET TO KNOW
32 NOW ON MACHINERYLUBRICATION.COM

18 PRODUCT NEWS
22 CROSSWORD PUZZLER

30 BOOKSTORE
40 PRODUCT SUPERMARKET
42 TEST YOUR KNOWLEDGE

Contamination Control

AS I SEE IT

JIM FITCH NORIA CORPORATION

JUSTIFYING the
COST of EXCLUDING
a GRAM of DIRT

For years Noria has been saying, “The cost of excluding a
gram of dirt is probably only about 10 percent of what it will
cost you once it gets into your oil.” Recently, a Noria training client
asked us to document proof of this statement.
It reminds me of a widely used quote from Benjamin Franklin: “If
you think education is expensive, try ignorance.” Or another familiar
one: “Pay me now or a whole lot more later.” Proactively investing in
reliability and machine wellness is very often challenged by the need
to justify. Management is always asking for financial analysis and to
“make the business case.”
Conversely, a financial study rarely is produced to obtain funds
to repair a failed machine, especially when plant production has
stalled. Sadly, I’ve heard maintenance folks say that they’ve quit
trying to propose proactive measures to management. They claim
it’s easier to just let the machines fail.
This is like saying it’s easier to just wait until you have a heart
attack than to proactively make the lifestyle changes needed to avoid
heart disease (diet, fitness, quit smoking, etc.). These differences are
often deeply ingrained in management and business culture. Does
your organization have the “here and now” folks or those who “plan
and prepare?”
On the bright side, an increasing number of companies are led
by managers who do “get it.” Much of this has been driven by the
growing base of documented success stories from organizations
and program leaders who have championed change and happily
reported their results. They didn’t need to be beaten over the head
but rather took the initiative and captured the benefit.

escalate the ingress. Air typically enters through vents and breathers,
past shaft seals, unsealed hatches and cleanout covers, and other
unprotected machine openings.
New oil is also a source of contamination, as are invasive inspection and repair activities. Hydraulic systems using linear actuators
receive a high percentage of their particles from ingression past worn
wiper seals and rod seals. Of course, mechanical wear, corrosion,
oil degradation and surface exfoliation are also common sources of
solid particles.
The cost of contaminant exclusion relates to both retrofitted
hardware and routine maintenance tactics for blocking contaminant
entry. These costs include such things as transfer cart filtration, proper
breathers on machines and lubricant storage vessels, improved seals
(labyrinth, for instance), tighter system closures, greater awareness
and care during internal
inspections and part
replacement (education
and better procedures/
tools), routine cleaning of

The Cost to Exclude a Gram of Dirt
For those wondering what is meant by excluding a gram of dirt,
it’s a rather simple concept. First, figure out what the contaminant
is (dirt, coal dust, fly ash, etc.) and then determine the point(s) of
entry (tank vent, worn seals, hatch, etc.). Some do this by examining
particles found in used filters and sump sediment aided by common
laboratory tools (XRF, SEM, optical microscopy, etc.).
For many machines, the inhaling of airborne contaminants into
reservoir and tank headspace is the primary source of contamination.
Forced convection of air by thermal syphoning, machine-driven air
currents (e.g., movement of gears, plunging oil return-line flow) and
cyclical changes in the tank oil level (hydraulic cylinder movement) can
2|

September - October 2011

www.MachineryLubrication.com

Machinery

Lubrication
PUBLISHER
Mike Ramsey - [email protected]

machine exteriors and many other similar methods.
Depending on the type of machine, this could
generate initial costs ranging from $100 to $1,000
per machine. There is also an annual ongoing cost
of routine maintenance relating to contaminant
exclusion (e.g., replacement breathers).

The Cost of an Unexcluded
Gram of Dirt
1. The Cost of Machine Wear Caused by
Ingressed, Unfiltered Particles
We are all aware that particles make particles. The number of new particles generated
from a single ingressed particle depends on
many factors, including the type of machine,
filtration, settling, number of frictional zones,
working clearances and operating speeds. Basically, it relates to how many surface scratches
and indentations a particle is allowed to
make before it is pulverized, settles to the tank
floor or removed by an oil change or filter. If
ingressed particles reach the filters fast, there
is less damage and few new wear particles are
produced. Conversely, if no filtration or poor
filtration is the case, this leads to longer particle
residence time in the fluid and thus more damage
and more production of wear debris.
An average ingressed dirt particle (left unremoved in the oil) will generate somewhere
between five and 20 new particles (secondary
particles). Some of these particles will make more
particles (tertiary particles). The situation is selfpropagating. Additionally, you can imagine that
a single scratch mark from a grain of dirt can
produce a corkscrew wear particle long enough
to crush into five or more particle segments.
Take a look at the data below from 17
hydraulic systems (ref. Pall Corporation). The
highly filtered five cleanest systems only had 7
percent wear particles (metallic). The destructive
dirt was removed quickly, preventing the generation of secondary and tertiary particles. On the
other hand, the five dirtiest systems generated

117,768 new particles, representing 42 percent of
all the particles in the fluid. If a better filter was
then applied, the filter would plug quickly from
the high concentration of particles, of which
nearly half were formally a part of the machine.
The Costs: The high cost of machine
repair and lost production (if no oil filter or
poor-quality filters are used) is 10 to 10,000
times the cost of contaminant exclusion.

2. The Cost to Remove Ingressed
Particles by Oil Filtration
In well-filtered, high-ingression systems such
as off-road hydraulics, more than 90 percent of
the particles found in oil filters are likely to be
terrain dust (ingested from the air). For indoor
equipment running in a relatively clean environment, the filter might be loaded with 50 to
90 percent metallic particles. By comparison,
particles in unfiltered systems such as splash-fed
gearboxes might be more than 95 percent metallic
due to self-propagating particle generation.
Filters cost less to maintain (last longer) when:
• Particle ingression is kept in check (seals,
breathers, etc.).
• High oil cleanliness targets are set and
maintained.
If you can’t keep ingression in check, you
are left with using filtration to stabilize high oil
cleanliness targets. This is best done by removing
particles quickly. Remember, the longer particles
are allowed to stay in the oil, the more secondary
and tertiary particles are generated. Then, they
too have to be filtered out (increasing the cost of
filtration). One or more of the following methods
are the best ways to remove particles quickly:
• Locate filters just downstream of ingression
sources, such as on a hydraulic return line.
• Maintain a high flow rate through filters (to
quickly carry particles to filters for removal).
• Employ multiple filters.
• Use high capture-efficiency filters.

FIVE CLEANEST

MIDDLE SEVEN

FIVE DIRTIEST

Total Particles

980

33,000

280,400 (the cause)

Total Nonmetallic

911

20,643

162,632

Total Metallic

69

12,357

117,768 (the effect)

Percent Metallic

7%

37%

42%

Relative Filtration Cost

1

2

4

GROUP PUBLISHER
Brett O’Kelley - [email protected]
EDITOR-IN-CHIEF
Jason Sowards - [email protected]
SENIOR EDITOR
Jim Fitch - jfi[email protected]
TECHNICAL WRITER
Jeremy Wright - [email protected]
CREATIVE DIRECTOR
Ryan Kiker - [email protected]
GRAPHIC ARTISTS
Steve Kolker - [email protected]
Gustavo Cervantes - [email protected]
Julia Backus - [email protected]
ADVERTISING SALES
[email protected]
Phone: 800-597-5460
MEDIA PRODUCTION MANAGER
Rhonda Johnson - [email protected]
CORRESPONDENCE
You may address articles, case studies,
special requests and other correspondence to:
Editor-in-chief
MACHINERY LUBRICATION
Noria Corporation
1328 E. 43rd Court • Tulsa, Oklahoma 74105
Phone: 918-749-1400 Fax: 918-746-0925
E-mail address: [email protected]

MACHINERY LUBRICATION Volume 11 - Issue 5 September —October
2011 (USPS 021-695) is published bimonthly by Noria Corporation,
1328 E. 43rd Court, Tulsa, OK 74105-4124. Periodicals postage paid
at Tulsa, OK and additional mailing offices. POSTMASTER: Send
address changes and form 3579 to MACHINERY LUBRICATION, P.O.
BOX 47702, Plymouth, MN 55447-0401. Canada Post International
Publications Mail Product (Canadian Distribution) Publications Mail
Agreement #40612608. Send returns (Canada) to BleuChip International, P.O. Box 25542, London, Ontario, N6C 6B2.
SUBSCRIBER SERVICES: The publisher reserves the right to accept or
reject any subscription. Send subscription orders, change of address and
all subscription related correspondence to: Noria Corporation, P.O. Box
47702, Plymouth, MN 55447. 800-869-6882 or Fax: 866-658-6156.
Copyright © 2011 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
without express written permission of Noria Corporation is prohibited.
Machinery Lubrication is an independently produced publication of
Noria Corporation. Noria Corporation reserves the right, with respect
to submissions, to revise, republish and authorize its readers to use the
tips and articles submitted for personal and commercial use. The opinions of those interviewed and those who write articles for this magazine
are not necessarily shared by Noria Corporation.
CONTENT NOTICE: The recommendations and information provided
in Machinery Lubrication and its related information properties do not
purport to address all of the safety concerns that may exist. It is the responsibility of the user to follow appropriate safety and health practices. Further,
Noria does not make any representations, warranties, express or implied,
regarding the accuracy, completeness or suitability, of the information
or recommendations provided herewith. Noria shall not be liable for any
injuries, loss of profits, business, goodwill, data, interruption of business,
nor for incidental or consequential merchantability or fitness of purpose, or
damages related to the use of information or recommendations provided.

Award Winner, 2008, 2010 and 2011

www.MachineryLubrication.com

September - October 2011

|3

AS I SEE IT

Of course, all of this costs money, plus
the hassle to maintain. In contrast, a filter
used as an air breather will hold more
particle mass (perhaps two to five times
more) than the same filter used to clean oil
(same size and micron performance).
As a final note on filtration, while many
contaminant-exclusion tactics can prevent
the entry of particles of all sizes, oil filtration, on the other hand, is selective. It
generally only removes particles above the
micron rating (say, 10 microns), leaving the
smaller particles undeterred and available
to do damage to the base oil, additives and
the machine.
The Costs: The cost to filter your
way to clean oil is perhaps 10 times
greater than the cost of exclusion.

3. Increased Oil Consumption Due to
Uncontrolled Particle Ingression
Most people don’t associate particle
contamination with lubricant service life,
oil change frequency or the overall cost of
lubricant consumption. We’ve reported
many times in Machinery Lubrication on
how oils age. For instance, one of the wellknown drivers of oil oxidation is the presence
of catalytic wear metals in the oil. Wear
particles don’t get into the oil by themselves.
One very common source of wear particles is
particle-induced wear (secondary and tertiary,
as previously discussed). Suspended dirt
particles also provide a site for oil additives
to hitch a ride. This ties up these additives,
which suppresses their ability to perform their
intended function.
So less dirt ingression means less wear
debris production, which means less antioxidant additive depletion, which means less oil

4|

September - October 2011

consumption (from additive depletion and
base oil oxidation) and less downtime from
oil changes and flushing. We’ve also reported
in the past the many hidden costs of an oil
change. One consultant (Ken Brown) has
estimated that an oil change can cost more
than 40 times the cost of the oil and labor.
An oil change is disruptive to the
machine. It not only can cause downtime
but also an internal disturbance that can
lead to collateral damage. One common
and serious disturbance is called the “fish
bowl effect,” which relates to the redistribution of sediment as a result of an oil change.
Of course, dirty oil is also a primary
cause of oil leakage. Particle contamination
abrades seals over time. Some companies
have reported more than an 80-percent
reduction in leakage as a result of maintaining higher oil cleanliness.
The Costs: Oil consumption and
associated costs (including seal repairs)
may exceed 10 times the cost of contaminant exclusion.

4. Energy Consumption Losses Due to
Particle-induced Wear
Wear not only leads to machine operational failure but also impedes performance
in the intervening period leading up to
repair or overhaul. During this period there
is usually impaired productivity due to sluggish or erratic machine function. There is
also increased energy consumption. For
instance, when hydraulic pumps and actuators wear, they lose volumetric efficiency.
This slows work (pumps and actuators move
slower) and increases the consumption of
energy (and heat distress to the lubricant).
Gears and bearings also consume more
energy as a result of wear.

Even diesel engines suffer from
decreasing combustion efficiency due to
wear in the valve train, bottom-end bearings and combustion chambers (rings,
piston, cylinder wall, etc.). A corresponding
increase in fuel consumption results. Wear
in these zones is often associated with
particles in the lubricating oil. One simple
way to exclude particles from entering the
crankcase is to enhance the quality of the
induction air filter.
The Costs: The cost of lost work and
increased energy consumption over the
life cycle of the machine may exceed 20
times the cost of contaminant exclusion.

The Tally
As you can see, many variables and
factors influence the cost of excluding a
gram of dirt. However, there are many more
costly consequences associated with failing
to exclude. The quote at the beginning of
this article claimed a 10-to-1 difference. On
closer inspection, the actual difference is
arguably more than 100-to-1 when taken
across the life of the machine.

About the Author
Jim Fitch has a wealth of “in the trenches”
experience 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 jfi[email protected].

www.MachineryLubrication.com

Hydraulics

HYDRAULICS
AT WORK

BRENDAN CASEY

HOW a BAND-AID
SOLUTION can FIX
your HYDRAULICS
problems

Last year there was a book on the New York Times bestseller list called Have a New Kid by Friday. It was written by
psychologist Kevin Leman and has sold more than 400,000 copies.
To capitalize on this book’s success, Leman is hurrying out another
titled Have a New Husband by Friday.
Leman’s literary success is testimony to the appeal and popularity of the quick (and effortless) fix for a problem. Don’t get me
wrong, I have no issue with the concept of a quick fix where one is
legitimately available, but as a parent I know you can’t replace a
child’s bad behavior with good in seven days. Most parents can’t
even read the book in seven days. As a husband, I also know my bad
habits won’t be eliminated in seven days. My wife may well be able
to replace me in seven days but not change me.
Any thinking person knows instant results for anything but the
simplest of problems are an illusion, but this is not to say that the
notion of a quick fix or even a Band-Aid solution doesn’t have its place.
Last week I had a conversation with a longtime client who’s been
having a long-running battle with the manufacturer of a hydraulic
machine he purchased three years ago. The machine has never

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91%

September - October 2011

of people have used a BandAid solution for a problem,
according to a recent survey at
www.machinerylubrication.com

The trick is being able to recognize
when a Band-Aid solution is appropriate and when it is not.
performed to either my client’s satisfaction or the manufacturer’s
advertised specifications.
This client is an owner/operator, which means his machine is his
livelihood. And he’s had enough. So now he’s taking the machine’s
manufacturer to court — a decision he hasn’t taken lightly.
Although he didn’t consult me directly about this issue, I was
aware of the problems he was having and the way in which the
equipment manufacturer was responding to them. The crux of the
issue, and one which will now be argued in court, is the machine
model my client bought was marketed as a “professional” version,
meaning it was designed to be used a minimum of eight hours a day,
five days a week. This is in contrast with hobbyist or weekender use
of typically a couple of hours in a stretch, a couple of days a week.
The trouble is, when the “professional” model my client purchased
was operated continuously for more than a couple of hours, its
performance dropped off dramatically. The primary reason for this,
which was blatantly obvious to me, was insufficient installed cooling
capacity, or more accurately, no cooling capacity at all.
Not only did I share this assessment with my client, but because I’d
done work for him before and didn’t want to see him lose work and
income as a result of the machine’s obvious design flaw, I presented
him with a Band-Aid solution — switch to a high-VI synthetic oil.
Now don’t get me wrong. I’m all for doing things right. The
correct solution to this issue was to install a heat exchanger of sufficient capacity to maintain an appropriate and stable operating oil
temperature and therefore viscosity. But in this case, there were two
major barriers to this happening. The first was the compact nature
of the machine, which allowed for little or no space to retrofit a
hydraulic oil cooler. The second was my client quite rightly expected
the machine’s manufacturer to do this under warranty, which meant
they first had to admit the machine had a design flaw.

81%

of people view Band-Aid solutions
negatively, based on survey results
from www.machinerylubrication.com
www.MachineryLubrication.com

HYDRAULICS AT WORK

Switching to a high-VI synthetic oil would do nothing to address the
issue of insufficient cooling capacity, but it would help the machine cope
with it. So in this respect, it definitely qualified as a Band-Aid solution.

The Best Kind of Solution
In his book, The Tipping Point, author Malcolm
Gladwell describes why Band-Aid solutions should
be viewed in a positive light.
“But that phrase (Band-Aid solution) should not
be considered a term of disparagement. The BandAid is an inexpensive, convenient and remarkably
versatile solution to an astonishing array of problems.
In their history, Band-Aids have probably allowed
millions of people to keep working or playing tennis
or cooking or walking when they would otherwise
have had to stop. The Band-Aid solution is actually the best kind of solution because it involves solving a problem with the
minimum amount of effort and cost. We have, of course, an instinctive disdain
for this kind of solution because there is something in all of us that feels that
true answers to problems have to be comprehensive, that there is virtue in the
dogged and indiscriminate application of effort, that slow and steady should
win the race. The problem, of course, is that the indiscriminate application of
effort is something that is not always possible. There are times when we need a
convenient shortcut, a way to make a lot out of a little...”

8|

September - October 2011

Unfortunately, my client didn’t act on this advice. Maybe it was
because, despite the apparent widespread popularity and seductive appeal of the quick fix, we have been conditioned to think of
Band-Aid solutions in negative terms. This negative bias toward the
Band-Aid solution in engineering is particularly strong, and in many
situations, rightly so. For example, there’s no way a Band-Aid solution is appropriate for the recent problems of the Rolls-Royce Trent
900 engines fitted to the Airbus A380. But if you have a mini-digger
with a chronic overheating problem that is not easily corrected,
being open to a Band-Aid solution can be very constructive.
As mentioned earlier, I’m all for doing things the right way, and I
consider quick-fix, silver-bullet, magic-pill, cure-all solution-seeking as
lazy and unrealistic. But as author Malcolm Gladwell says, “There are
times when we need a convenient shortcut…” The trick is being able to
recognize when a Band-Aid solution is appropriate and when it is not.
I wish this client the best of luck with his lawsuit. He deserves to
win. But more than that, having declined the Band-Aid solution,
now he has to win.

About the Author
Brendan Casey is the founder of HydraulicSupermarket.com and the
author of Insider Secrets to Hydraulics, Preventing Hydraulic Failures,
Hydraulics Made Easy and Advanced Hydraulic Control. A fluid power
specialist with an MBA, he has more than 20 years of experience in the
design, maintenance and repair of mobile and industrial hydraulic equipment. Visit his Web site: www.HydraulicSupermarket.com.

www.MachineryLubrication.com

10 |

September - October 2011

www.MachineryLubrication.com

Machinery Lubrication recently issued its annual Lube Room
Challenge for readers to submit exceptional lube rooms that
incorporate best-practice features. Several readers met the challenge with

evidence of how their lubricant storage and dispensing methods have been
transformed. The following entries showcase how designing a proper lube
room is one of the first steps to achieving lubrication excellence.

Agrium
Tim
m JJohnson at Agrium’s Conda phosphate operation in Soda Springs, Idaho, was just waiting for a chance to show the improvement that had
bbeen made to his plant’s lubrication program. The photos below illustrate just how far the company has come in a relatively short period of time.
re

fo

Be

One of the company’s previous lube rooms used typical barrel racks,
no desiccant breathers or oil filtration. Oil inventory space was
small, forcing some stock to be left outside exposed to the elements.
r

te

Af

The new oil filtration and dispensing room allows oil to be delivered directly to the inside of the room, avoiding hazards and
exposure to the elements. This room is climate-controlled and
large enough to fit all oils that are used in the plant’s equipment.
r

te

Af

re

fo

Be

The old-style lube room required all oil drum delivery from
vendors to be done outside and then moved through a narrow
doorway, exposing personnel to hazardous conditions.
r

te

Af

The view from the inside of the new oil filtration and dispensing
room shows oil filter units, dispensers, desiccant breathers and
oil inventory. Instructions for the operating filter system are
available on the bulletin board. The floor is covered with a nonslip epoxy coating, which improves the safety of personnel and is
tough enough for the heavy loads from the oil drums. Desiccant
breathers are installed on all oil barrels when put into service.
When an empty barrel is replaced, the new oil is allowed to
multi-pass in the filter system for two hours before dispensing.
This results in typical ISO-rating improvements from 20/17/14 at
the beginning of multi-pass to 15/14/13 when complete.

This is a close-up of the oil dispenser. Each type of oil has been
tagged on the on/off switch, fill piping and at each drum filter.
The dispenser tray is engineered to hold more than 55 gallons in
the event of an upset. Also, the floor is designed to contain all oil
stocked inside this room in case of accidental spills.

www.MachineryLubrication.com
www
MachineryLubrication com

September - October 2011

| 11

COVER STORY

Cargill
Cargill’s facility in Newark, Calif., follows best practices by filtering and
dispensing in designated containers. Previously, lubricant was dispensed in whatever container was available. Now color-coded containers with like-colored tags are
posted at each piece of equipment.
re

r

te

fo

Be

Af

The Cargill facility uses colorcoded containers with like-colored
tags that track when the oil and
filters were last changed.

enabling all the new oil and fluids to be filtered. Hydraulic fluids are
filtered to an ISO 4406 cleanliness standard of 17/15/13. Motor oil
and transmission fluids are kidney-looped with 10-micron filters for
a period of up to 24 hours. Fluids are then dispensed through Graco
pumps and separate 10-micron filter assemblies. Transfer carts are
also equipped with the same quick couplers, and they receive the
same filtering process before they are used.
To minimize contamination, the vents from the IFH tanks are
independently plumbed to a centralized overflow container system,
which is vented with a desiccant filter. Transferring the fluids
consists of a sequence that uses different types of pumps specific
for a type of fluid being pumped. Hydraulic and specialty fluids are
dyed to specified colors for easy identification. EWEB uses a series
of containers that are also color-coded and labeled for the same
specific fluids. Spill containment is utilized for all storage tanks and
racks. The lube room also includes spill clean-up materials, spill
dikes and absorbent wipes.
The room has been equipped with an emergency shower and
eye-wash station. The facility is certified in Oregon as an Eco-Biz
facility, meaning that it has reached the highest standards in minimizing its environmental impact. EWEB employees have taken pride
in implementing proper material-storage methods and hazardous
waste-management techniques within the lube room.

Eugene Water and Electric Board
The Eugene Water and Electric Board (EWEB), Oregon’s largest
public utility, is no stranger to promoting sustainable practices. Its
lube room is no exception. It consists of two double-walled storage
tanks that are used for synthetic-blended motor oils. It also entails
a modified IFH storage and dispensing system that handles
hydraulic and transmission fluids, as well as Rhino Tuff poly
tanks for coolant and washer fluids. The room features concrete
walls, a sealed floor, a fire sprinkler system and an automated
climate-control system that maintains the room at a consistent
temperature throughout the year.
Through lab testing of incoming oils and fluids, EWEB identified that in many cases the oil and lubricants that were purchased
were filthier than the fluids that were being removed. Because of
this, EWEB equipped all of its storage tanks with quick couplers,

EWEB’s lube room consists of two double-walled storage tanks for
synthetic-blended motor oils, a modified storage and dispensing
system that handles hydraulic and transmission fluids, as well as
tanks for coolant and washer fluids.

…in many cases the oil and lubricants
that were purchased were filthier than
the fluids that were being removed.
The EWEB lube room also has an emergency shower and an
eye-wash station.

12 |

September - October 2011

www.MachineryLubrication.com

COVER STORY

MillerCoors
MillerCoors first upgraded its lube room in Golden, Colo., several
M
years ago with some significant changes. Although the more recent upgrades
are minor in comparison, they are still important in the company’s journey
to world-class lubrication. The MillerCoors lube room now has an exhaust
ventilation system, fire-protection system and explosion-proof lighting
fixtures. A training room has been created specifically for lubrication with
a 3-hour class offered. A bi-weekly “Lube-Tips” style e-mail is sent out
to all the packaging teams on best lubrication practices and lubrication
safety issues. The e-mails provide a great way to keep people thinking about
lubrication and its importance to the reliability of the equipment.
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Oil drum transfer pumps were often left in poor environments (left)
where they could be exposed to contaminants. A storage drum for
the pumps was provided to keep them cleaner and in one place
(right). There are also separate hoses to avoid cross-contamination
of lubricants. Both the pumps and the hoses have identification tags.

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This old drum pump setup (left) had basic transfer pumps.
Although breathers were later installed on each drum, the oil was
still not being filtered, and the operators had to hook up an air
hose to the pumps. No 5-S visuals were in place. The picture on
the right shows the new pump systems with 10-micron filters and
5-S visuals on the floor with oil identification placards on the wall
behind each drum.

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These color-coded grease guns (left) help with easy identification
of grease types. They also have the health hazard tags included on
them. The guns pictured were just out of the box and had not yet
been fitted with coupler tip covers that are used for contamination control. MillerCoors also carries different sizes of disposable
funnels (right) and tries to promote their use.

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This old wooden workbench (left) was being used for filling Oil
Safe secondary containers and for cartridge replacement of grease
guns. It was replaced with a stainless-steel table (right) similar to
those used for food preparation in restaurants. It provides a cleaner
setting to do this work.

Utilizing Oil Safe secondary containers helps in the identification
of the many lubricants being used as well as contamination control.
Although a lubricant identification system was in place, MillerCoors’ Richard David came up with new identification cards that
also incorporate symbols to go along with the color coding. Between
the two systems, it is almost impossible to mix up lubricant types.
David’s lubricant identification cards also promote good visual
factory practices.

14 |

SSeptember
b -O
October
b 2011

Although this area is not
inside the MillerCoors lube
room, it is a big part of
the company’s lubrication
efforts. Realizing the importance of proper lubrication,
the
management
team
allowed for the creation of
a training room specifically
for lube training. A 3-hour
class is offered that covers
basic lubrication best practices, the importance of lubrication
and how it is instrumental to the reliability of the equipment.
The Noria DVD “Lubrication Basics for Machinery Operators” is
used to reinforce much of what is covered in the class.

www.MachineryLubrication.com
M hi
L bi i

Georgia-Pacific
Initially, the oil storage room at the Georgia-Pacific mill in
In
Muskogee, Okla., needed a lot of attention.
When the room was overhauled, an HVAC unit was installed
to maintain room temperature, the entire room was cleaned and
repainted, new lighting was installed, new cabinets for equipment
filters and oil transfer pumps were put in, press filters were added to
clean the oil before it enters storage totes, new oil containers were
purchased and proper labelling was instituted.

The plant’s next steps toward achieving lubrication excellence will be to change from a 10-micron filter to a 5-micron
filter to improve particle counts, implement monthly preventive
maintenance, train all operations and maintenance staff on the
fundamentals of lubrication, revise the sampling program and
install proper oil sampling ports on the equipment.
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Before overhauling its lube room, the Georgia-Pacific mill faced a
significant challenge to meet its cleanliness objectives.

www.MachineryLubrication.com

After the lube room was modified, the condition of the storage room and its
contents were dramatically improved.

September - October 2011

| 15

COVER STORY

Power Partners
Power Partners Inc. in Athens, Ga., never really had a lube storage room, but
company officials thought they were fine until they read a few articles in Machinery
Lubrication and attended a Reliable Plant Conference. They quickly realized they
had a big problem.
The company has come a long way over the last 14 months. While there are a
few more things they want to accomplish, they are extremely proud of their efforts.
With the new lube room and enhanced policies and procedures that go with it,
Power Partners has realized an annual cost savings of more than $28,000. Factor in
the other reliability programs they have implemented in the shop, and the annual
cost savings total more than $46,000.
Rio Tinto transfers oil from 55-gallon barrels into totes, which
are then filtered and fitted with desiccant breathers.

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The original Power Partners lube room featured metal funnels
out in the open along with buckets and barrels everywhere.
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At the new Rio Tinto lube room, all
oil is dispensed into color-coded
containers, which are cleaned
after use.

Temple-Inland

The company’s new lube storage room has dedicated storage
totes, a communications corner, clear grease guns with calibration stickers, an oil matrix that details which oil goes in which
machine, and oil transfer jugs that are tagged and color-coded.

The
Th
h Temple-Inland lube room in Cumberland City, Tenn.,
boasts drums with air-powered pumps and 5-micron filters, sample
ports and quick disconnects on the drums and Oil Safe containers.
Oil is filtered as the Oil Safe containers are filled, and the lids do not
need to be removed to fill. The pumps can also be utilized to polish
the oil before use.
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Rio Tinto
The
Th
h lube room at Rio Tinto Minerals in Boron, Calif., was built
in 2007 and has been maintained thanks to the hard work of the
lube crew and support from upper management. The company
transfers oil from 55-gallon barrels into totes using dedicated filter
carts. The totes are then filtered to achieve the desired ISO standard
and fitted with desiccant breathers. Oil samples are taken monthly
to verify continued compliance. All oil is dispensed into color-coded
containers, which are cleaned after being used.
16 |

September - October 2011

These photos show the Temple-Inland lube room before
changes were made.
www.MachineryLubrication.com

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At Temple-Inland’s new lube room, oil is filtered as the Oil
Safe containers
con
are filled.

Cerveceria Bucaramanga
The
Th
h initiative to modify the lube room of Cerveceria Bucaramanga, a SABMiller plant in Colombia, began after company personnel
read an article in Machinery Lubrication on the advances of Clopay
Plastics’ lube room. They felt encouraged to improve their lube room
and received advice from Noria Latin America as well as a lot of training,
which was important to their success. They also have included several
practices from the Oil Analysis Basics book by Noria Corporation.
With the improvements, Cerveceria Bucaramanga now has an oil
cleanliness level of ISO 4406 (14/12/8) on its oil
storage tanks. The lube tasks also are ergonomic
and easier to perform, having been optimized by
more than 15 percent. The workers feel proud of
this and take great care to maintain this goal and
even improve upon it.

After strategic improvements were made, the new lube
room at Cerveceria Bucaramanga in Colombia includes a
used oil storage area and dedicated filters for intermediate
oil containers.

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These photos show the old Cerveceria Bucaramanga lube room before the improvement
project began.
www.MachineryLubrication.com

September - October 2011

| 17

PRODUCT NEWS

MOTOR OIL
Valvoline’s NextGen motor oil features a new formula made from
50-percent recycled oil to deliver 100-percent engine protection.
Developed through years of research, technology and innovation
from scientists coupled with improvements in the oil re-refining
process, NextGen motor oil is good for engines and the environment, exceeding industry specifications with reduced environmental
impact compared to non-recycled motor oil.
Valvoline

www.valvoline.com
800-832-6825

FILTER PACK

FOOD-GRADE LUBRICANTS
The new UltraLube food-grade lubricants not
only meet NSF standards but also offer four
times the natural lubricity of petroleum-based
oils. These bio-based oils instantly penetrate
into areas where lubrication is needed most
and create a long-lasting bond to metal and
plastic surfaces. Specifically formulated with
EP additives to provide protection under heavy
shock loads, UltraLube H1 Food Machinery
Grease is ideal for lubricating bearings, gears
and machine slides. It also offers superior
adhesion and protects all ferrous metal
components from rust and corrosion.

The new FilterPak from Y2K Fluid Power incorporates a sturdy diamond-plate aluminum frame,
a milled-aluminum grip and a 1-hp Viking pump
with a capacity of 2.5 to 5 gallons per minute. It
also sports a visual indicator with 50 psi bypass,
a 10-foot swivel discharge hose, a 7-foot swivel
suction hose, a 3-foot electrical cord and an on/
off switch.
Y2K Fluid Power
www.y2kfluidpower.com
888-925-8882

UltraLube
www.UltraLube.com
800-545-1689

FOOD-GRADE PENETRATING OIL

PORTABLE
LUBRICATION SYSTEM

The new Food Grade Penetrating Oil
from CRC is an effective and efficient
non-silicone lubricant for use on all
food-processing equipment. The
highly refined white mineral
oil is colorless, odorless
and tasteless to meet NSF
and FDA standards. The
general-purpose penetrant
can be used to loosen
rust, scale and corrosion
around fasteners and hose
fittings on food-processing
equipment.

The new mobile lubrication system from the
IFH Group provides storage and dispensing
of lubricants for industrial plants requiring
lubrication maintenance at multiple locations over a large area. The new system is
delivered on a pallet that allows it to be placed
in the bed of a truck for mobility anywhere
within the plant. It includes two 50-gallon
and two 25-gallon steel containers with PVC
sight gauges. Air-operated piston pumps
provide a 5-to-1 pumping ratio, while filters
on the side remove any dirt or small particulates. Startup is quick and easy with the
onboard gas-operated air compressor.

CRC
www.crcindustries.com
800-556-5074

18

September - October 2011

The IFH Group
www.ifhgroup.com
800-435-7003
www.MachineryLubrication.com

METAL-WORKING FLUID
Developed for use in high-pressure applications, the new Cimperial 1072-HFP fluid from Cimcool is recommended for all metals and
heavy-duty machining operations including turning, drilling, tapping,
reaming, gear cutting and broaching. It prevents, controls and reduces
foam even when fluids are used in high-pressure delivery systems.
Cimperial 1072-HFP also provides excellent lubricity, extends fluid life,
is operator and machine friendly and helps prevent corrosion on parts
and machine components.
Cimcool
www.cimcool.com
888-246-2665

PRESSURE SWITCH
SKF’s new DSB1 pressure switch for monitoring centralized lubrication systems is designed to attach directly to the lubricant line.
This position is in contrast to conventional pressure switches that
branch off to a cul-de-sac where grease is never mixed, which can
form a blockage, harden and render the pressure switch ineffective.
The new DSB1 pressure switch is installed before the last distributor,
where the grease consumed by the distributor constantly flows past
the switch, effectively preventing blockage.
SKF
www.skf.com
267-436-6000

MARINE ENGINE OIL

FOOD-GRADE
COMPRESSOR LUBRICANTS
Ultrachem has developed a new line of Omnilube food-grade rotary screw and reciprocating air-compressor lubricants with improved
wear, oxidation and lubricity. These fully
synthetic compressor oils are formulated from
high-quality polyalphaolefin (PAO) base oils
with a proprietary additive package to achieve
long life. The oils meet all of the requirements
of the USDA and FDA H-1 regulations, and
conform to NSF requirements. They are also
approved for Kosher use.

Royal Purple’s new line of multi-vis 30-weight and
40-weight four-stroke High Performance Marine
(HPM) engine oils promise to give boaters better
protection for their engines. These new oils feature
Royal Purple’s advanced additive lubricant technology, Synerlec, which creates an ionic bond
that adheres to metal parts to provide continuous protection and strengthens the oil
for better performance. It also has
high film strength that prevents
contact between metal parts and
improves sealing inside the engine
for more complete combustion
and reduced wear.
Royal Purple
www.royal-purple-industrial.com
888-382-6300

Ultrachem
www.ultracheminc.com
302-325-9880
www.MachineryLubrication.com

September - October 2011

19

ML

GET TO KNOW

Christensen
Directs Lube

Crew at
Kennecott
Utah Copper

Name: Jan Christensen
Age: 60
Title: Lubrication Technician 2
Company: Kennecott Utah Copper
Location: Magna, Utah
Years of Service: 10 years

Jan Christensen began working on heavy equipment as a mechanic in
1973. He started with Fluor Industrial Services working at Kennecott
Utah Copper’s smelter in 2002 as a mechanic. He joined the lube team in
November 2006 and has worked in several important roles for the lube team,
providing valuable input and overseeing key projects since that time.

Q What made Rio Tinto and Kennecott Utah Copper (KUC)
decide to put more emphasis on machinery lubrication?

A At the KUC smelter, we implemented changes that led toward
improving reliability, including hydrocarbon management in 2001
and 2002. This improvement was aided by Rio Tinto’s corporate
drive toward improved reliability and hydrocarbon management
during the same timeframe. The rate of improvement increased
when Rio Tinto placed additional focus on these areas in 2004.

Q How did you get your start in machinery lubrication?
A I have been working at the KUC smelter since January 2002. Prior
to working at the smelter, I worked on heavy equipment for 30 years.
I also purchased lubricants and did oil sampling. I came to this job
in the lube group in November 2006 under the direction of the reliability group and have been with the group since then.

Q What types of training have you taken or been involved
with? What about future training?

A Before working for KUC, I had several hydraulic and electrical
training classes on cranes and other heavy equipment. Since coming
to KUC, I have had oil analysis level I, II and III and machinery lubrication level I training from Noria, as well as training from suppliers.
I have also been involved in several Rio Tinto internal human capital
management (HCM) program assessments.

Q What is the range of equipment that you service through
lubrication tasks at the smelter?
A We service pumps, fans, conveyor belts, compressors, feeders,
agitators, ball-and-roller mills and other smelter-processing equipment.

Q What is a normal work day like for you?
A We have a six-man lube crew that is dedicated to grease and
oil-related issues. On any given day, you could find us doing any
of the following: oil changes, grease routes, oil routes, oil sample
routes and filter cart routes. On these routes, we check automatic
20 |

September - October 2011

lubricators, replacing faulty or empty units as needed, check and
maintain oil levels, and inspect desiccant breathers and replace
them as needed.

Q What lubrication-related items are you currently
working on?
A I am working on installing a head space-management system for
our bulk oil totes in an effort to improve our new/bulk oil cleanliness. I am also gathering data to set up electric motor grease routes
throughout the plant.

Q How does your company view machinery lubrication in
terms of importance, strategy, etc.?
A Our six-man crew works for Fluor Industrial Services, the
company KUC contracts to perform maintenance at the smelter.
The lube group reports to the reliability group. Both of these groups
are highly motivated to make sure the equipment is lubricated properly and with the correct lubricant. Rio Tinto and KUC have high
HCM standards, which we are working hard to meet.

Q What have been some of the biggest lubrication project
successes in which you have played a part?
A We have installed new poly totes with kidney-loop systems
used to store new bulk oils, as well as a lube trailer to be used
on some of our remote equipment for oil changes. We have also
installed several kidney-loop systems throughout the plant and
implemented filter cart routes. I have also been involved with peer
review/peer assist HCM assessments at the smelter and other
plants within KUC.
Q What do you see as some of the more important trends
taking place in the lubrication and oil analysis field?

A We are seeing oil companies being pushed to become more
accountable for their products, and we have been getting more
on-site oil analysis testing equipment.
www.MachineryLubrication.com

ML

CROSSWORD PUZZLER
Get a Printable Version
of This Puzzle Online at:
MachineryLubrication.com/puzzle

1

2

3

4
5

6
7

8
9
10

11

12

13

14

15

16
17

18

ACROSS
1 A process for treating raw extracted base stocks with
hydrogen to saturate them for improved stability.

7 The degree of opacity of a fluid.
8 A failure generally associated with a valve whose movements
are restricted due to small particles that have wedged in
between critical clearances.

10 The sum of atmospheric and gauge pressure.
13 The most common type of grease today.

14 Wear phenomena taking place between two surfaces having
oscillatory relative motion of small amplitude.

16 Particles added per unit of circulating fluid volume.
17 A form of wear in which seizing or tearing of the gear or
bearing surface occurs.

18 The addition of fatty oils and similar materials to
lubricants to impart special properties.

DOWN
2 A measure of the total acidity or basicity of an oil.
3 An engine design in which oil is not retained in a pan beneath
the crankshaft.

4 The brown or black viscous residue from the vacuum
distillation of crude petroleum.

5 Ability of a lubricant to resist natural degradation upon
contact with oxygen.

6 Capable of being mixed in any concentration without
separation of phases.

9 A unit of kinematic viscosity.
11 Ability of a fluid to dissolve inorganic materials and polymers,
which is a function of aromaticity.

12 The relationship of flow per unit area to differential pressure
across a filter medium.

15 A container for storage of liquid in a fluid power system.
Get the solution on Page 29.

22 |

September - October 2011

www.MachineryLubrication.com

OIL ANALYSIS
BY: BEATRIZ GRAÇA, INEGI; JORGE SEABRA, FEUP; AND PINTO SOUSA, PORTUCEL

Lubricant

Analysis
in
Steam
Turbines

T
Oil Degradation

Turbine oils are subjected to a wide range of conditions —
extreme heat, entrained air, moisture, contamination by dirt and
debris, inadvertent mixing with different oil, etc. — that degrade
the integrity of the hydrocarbon base stock and deplete the additive chemistries, causing irreversible molecular changes. There are
two primary degradation mechanisms in turbine applications —
oxidation and thermal degradation.
Oxidation is a chemical process where the oxygen reacts
with the oil molecules to form a number of different chemical
products, such as carboxylic acids. The rate at which this occurs
depends on a number of factors. Temperature is perhaps the
most critical one, since the rate of oxidation doubles for every
rise of 10 degrees C. The temperature above which this occurs is
influenced by the oxidation stability of the oil and the presence of
catalysts and pro-oxidant conditions such as water, air, certain
metals, fluid agitation and pressure.
Thermal degradation is the breakdown of the oil molecules
by heat (high temperature), forming insoluble compounds that
frequently are referred to as soft contaminants. Typically, thermal
degradation occurs as a result of micro-dieseling, electrostatic

I
up
Gro

s
Oil

The majority of phenols
have depleted
Group II & III Oils

Time

Degradation trend of different base stock oils

24

September - October 2011

spark discharge and hot spots. Micro-dieseling is the combustion
of imploding air bubbles creating adiabatic compressive heat
(often exceeding temperatures above 1,000 degrees C). Electrostatic spark discharge results from the internal molecular friction
that generates high-voltage electric charges such as where oil
passes through very tight clearances at high flow rates, producing
temperatures over 10,000 degrees C.
Over time, it has become clear that the oxidation performances
of the different base stock classes are quite different. The high
natural oxidative resistance of Group II turbine oils combined
with specific antioxidants employed (usually based in phenol and
amine compounds) provide a non-linear behavior in terms of
their molecular degradation over time. As a result, the majority of
standard oil analysis tests offer little to no warning as the lubricant starts to degrade and generate system deposits. Instead of
degradation occurring in a linear and predictable fashion, many
of the modern turbine oils fail rapidly.
Changes in the oil’s molecular structure due to additive depletion and the development of insoluble particulates are among
the first oil degradation conditions that affect equipment performance. The sequential process will be the formation of sludge
and varnish, which are common occurrences in turbo-generators.
Besides these oxidation and thermal degradation byproducts
being the main contributors for the development of varnish and
deposit problems in turbines, they interfere with other important
properties in steam turbine lubricants, such as demulsibility and
the detrainment of air. Therefore, it is vital that appropriate diagnostic analysis be performed to detect these conditions in critical
and sensitive lubrication systems.

Ferrography Analysis
Ferrography is a technique that provides valuable information
about wear evolution in machinery through analysis of a representative lubricant sample. Developed by Vernon Westcott at
www.MachineryLubrication.com

OIL ANALYSIS

the U.S. Navy in the 1970s as a conditionmonitoring technique, it has been applied
by hundreds of worldwide users to all
kinds of lubricated systems.
The potential of ferrography is not
only limited to predictive maintenance
strategies. Its important contribution to
tribology studies, by assisting in a better
understanding of the wear mechanisms
and of the lubricant effects on the contact
surfaces, turns this versatile technology
into one of the most powerful diagnostic
tools to assess machine health, providing
valuable information about the past,
present and future condition of the
machine’s lubricated components.
The test procedure is lengthy and
requires the skill of a well-trained analyst.
As such, there are significant costs in
performing analytical ferrography not
present in other oil analysis tests. However,
if time is taken to fully understand what
analytical ferrography uncovers, most
agree that the benefits significantly
outweigh the costs and elect to automatically incorporate it when abnormal wear
is encountered.

Oil Flow

Slide
Magnet
Large particles deposit at
entry point where the
magnetic pull is the weakest.

Smaller particles deposit
along the slide as the
magnetic pull strengthens.

Analytical ferrography deposited patterns

In analytical ferrography, the solid
debris suspended in a lubricant sample
is separated and thoroughly deposited
onto a glass slide while passing across a
bipolar magnetic field. When the sample
flow is completed, a solvent “wash” cycle
removes any lubricant remaining on the
substrate, resulting in a “ferrogram,”
where the particles are all arranged by
size and permanently attached to the
slide for optical analysis using a biochromatic microscope. The particles are then
examined and classified by size, shape,
26

September - October 2011

A steam turbo-generator at a cellulose industry plant

concentration and metallurgy. This information carried by the wear particles is
valuable for the identification of the wear
mode and mechanism.

Steam Turbine Monitoring
This case study is about the condition monitoring of the lubricant in a
steam turbo-generator at a local cellulose
industry plant. The turbine is a 26 MW
Siemens G 800-2. It has been in service
for 22 years, operating continuously, with
a lubricating oil reservoir holding 8,500
liters of ISO VG 46 oil to lubricate and
cool bearings, gears and oil shaft seals and
to act as a hydraulic medium for operation
of the governor and steam control valves.
Since its initial operation in 1988,
this turbine worked with solvent-refined
base stock oil (Group I). However, due
to a manufacturer upgrade, this oil was
replaced by a hydrocracked base stock
(Group II) in 2002. In the meantime,
about 6,000 liters of makeup fluid was
added, along with a few periodic oil reservoir fill-ups, making the circulating fluid a
blend of these two base stocks.
The turbo-generator was operating and
performing normally, and no occurrences
of anomalous functions of the lubricated
components had been recorded. Nevertheless, a close monitoring of the oil
condition was ensured by analyzing the
turbine oil periodically.

Turbine Oil Analysis
A lubricant analysis program was
applied quarterly, taking two samples
from the oil reservoir and sending it to
independent laboratories. The standard
methods used at one of the laboratories
to assess the condition of the turbine
oil were:
• Kinematic viscosity at 40 degrees C
(ASTM D445)
• Water by Karl Fisher (ASTM D6304)
• Insoluble particulates (ASTM D4898)
• Acid number (ASTM D664)
• Neutralization number (ASTM D974)
• Elemental spectroscopy (ASTM D5185)
• Rust (ASTM D665-A)
• Demulsibility (IP 19)
• Foam (ASTM D892)
• Flash point (ASTM D92)
• Air release (DIN 51636)
• Cleanliness code (ISO 4406)
• Linear sweep voltammetry (LSV),
(ASTM D6971)
Simultaneously, at another laboratory,
ferrography and Fourier transform infrared
(FTIR) analysis were performed along with
other techniques. These analyses allowed
a complemented diagnosis not only of the
condition of the oil but also of the turbine
wear rate conditions.
In this case study, among all the
standard test results obtained, those
that showed some indications of fluid
www.MachineryLubrication.com

ANALYTICAL RESULTS FROM STANDARD TESTS
DATE

Jan-10

Oct-09

Jul-09

May-09

Jan-09

45.9
0.14
606
3.2
400/0
242

45.8
0.08
442
4.4
50/0
238

44.3
0.12
368
4.2
300/0
229

45.9
0.1
305
8.4
190/0
232

46.6
0.06
>1200
2.4
470/0
210

<0.05
7
23/21/17

147
3.7
22/19/16

65
5.8
22/19/16

179
9.5
23/23/22

<0.05
7.5
23/21/18

95
<10

-

62.2
19.7

67
4

70
-

REFERENCE

PHYSICAL PROPERTIES
Viscosity@ 40°C [cSt]
41.4-50.6
Acid Number [mgKOH/g]
0.3
Demulsibility [s]
300
Air Release [min.]
5
Foam, seq. I [ml/ml]
450/0
Flash Point [°C]
>185
CONTAMINATION
Water Content [ppm]
100
Insolubles [mg/100ml]
10
ISO CODE
18/16/12
VARNISH POTENTIAL
Amine %
>25
RULER
Phenolic %
>25

Analytical results from standard oil tests show the oil viscosity and acid number are within
the range over the time period.

degradation were the demulsibility, air release,
particle count and LSV. As can be seen in the
table above, the oil viscosity and acid number
are within the range over the time period. Water
contamination and foam tendency are maintained low. However, the particle contamination
is high for all the evaluated period, the phenolic
content falls below critical in some samples and
the demulsibility is also affected significantly.
The sequential events in the oil degradation
produces an eventual depletion of the antioxidant additives. The aminic/phenolic antioxidant
mixtures actuate as a complex system. The aminic
inhibitor works to neutralize the free radicals that
cause oil oxidation, but it is then regenerated by
phenolic, which is a good free-radical trap. When
phenolic levels fall below a critical level, the oil is
in danger of rapid degradation, resulting in the
formation of soft contaminants and varnish. Soft
contaminants are typically less than 2 microns in
size and cannot be removed through standard
mechanical filtration. They are insoluble and polar
in nature, and are unstable in a non-polar oil environment, such as hydrocracked base oil (Group II).
The high ISO Codes obtained, mainly in terms
of small particles (less than 4 microns), can be
related with this turbine oil degradation process.
Demulsibility is also compromised by the presence of polar contaminants.
For the lubrication of turbo-generator bearings, the cleanliness level with respect to particles
in the oil is of the utmost importance. Consequently, a proactive action is taken through
periodical on-line oil purification (filtration
during 24 hours) to achieve the system cleanliness
in accordance with OEM recommendations (ISO
www.MachineryLubrication.com

18/16/12). However, a swift increase of the ISO
Codes is consistently verified during the operation
of this turbine.
The ferrography analysis completed for the
same period revealed valuable information on
the oil’s solid contamination. In all ferrograms,
the presence of soft contaminants that resulted
from oil thermal degradation and additive depletion was observed. This information is essential
to identify the reason for the persistent high ISO
Codes obtained in particle counting. Although
soft particulates are not harmful in terms of
wear, they contribute to the generation of surface
deposits, as detected through ferrography.
Figure 1 shows two photomicrographs of
these particles deposited on a ferrogram as
observed under white/green light and polarized
illumination. The polarized light allows the identification of non-metallic particles (crystalline and
amorphous materials, for instance) by the brightness of light reflected. Note the brown pattern
evidenced by some of these particles.
The particles in the ferrogram of Figure 2 are
very small in size, and due to polarity, they easily
aligned along the magnetic field of the ferrograph. These particles have the tendency to form
agglomerates, which when overstressed with the

Figure 1. These two photomicrographs show
turbine oil crystalline contaminants (1,000x
magnification).
September - October 2011

27

OIL ANALYSIS

oil, form a large
coherent structure
by a molecular
polymerization.
The
varnish
Figure 2. Particles
build-up
seems
to
aligned on the
ferrogram to the
be a consequence
magnetic field
of this physicochemical process, as can be realized by the
photomicrographs in Figure 3, obtained
in different oil samples. All these kinds
of particulates have polar affinities and
high molecular weight and tend to be
adsorbed onto dipolar metallic surfaces as
a sticking matter, which in turn captures
hard contaminants as they flow within the
system. They are capable of shutting down
a turbine or causing serious damage,
which is frequently related to bearings and
servo applications.
Another technique employed to
monitor the oil condition was FTIR, which
is used to measure organic molecular
components, monitor additive depletion (antioxidants) and identify organic
degradation byproducts (oxidation).
The monitoring of specific antioxidant
depletion in used
lubricants is still
considered a relatively new research

Figure 3. Ferrogram photomicrographs
of the turbine oil particles in different
samples (1,000x magnification)

area. However, some studies show that
the rate of antioxidant depletion is related
to lubricant degradation or affected by
the antioxidant mix or base stock type
used to produce the lubricant.
Used oil samples are complex
mixtures of different chemicals, including
compounds derived from the formulation of the base oil and its additives,
and from oil degradation products and
contaminants. As a result, a used oil
spectrum is complex and essentially the
net sum of the spectra of all the individual
compounds making up the sample. In
fact, because of this complexity, the used
oil spectrum alone is of limited value and
must be compared against the spectrum
of the unused oil to be of significant
analytical value.
Figure 4 shows transmittance spectral
snapshots of the new and used turbine
oil. The black spectrum is that of the new
oil (new base stock – Group II), while
the red spectrum is from the blend oil
in service, which still contains a small
percentage of Group I base stock oil.
Nevertheless, the spectra revealed identical functional groups.
In analyzing the spectrum overlays,
you can clearly see relative molecular
changes in the oxidation peaks, as well as
thermal degradation of the oil through
the signs of nitration. Another molecular
alteration is observed where the phenolic
antioxidants are characterized. The type
of decomposition detected in the used
oil spectrum is commonly observed in
FTIR analysis of fluids where thermal
breakdown took place.

Used Oil

phenol
inhibitors
(depletion)

New Oil
oxidation and
thermal
degradation

Figure 4. FTIR spectra in transmittance/wavenumber (cm-1)
of new and used turbine oils

28

September - October 2011

Filter Analysis
Static-generated sparks are very
common incidents in the filtering systems
of turbo-generators. This is a phenomenon of molecular friction occurring as
oil flows through small clearances, such
as the filter media. Since oil and filter
media are both dielectric, this electrical
energy builds until a limit is reached,
and then sparks are released in the
lubrication system in the direction of the
ground. These electrical arcs can have
an extremely high, localized temperature
(about 20,000 degrees C), instantly
cracking the hydrocarbon molecule.
Since spark discharges generated
on filters and other locations are a key
root cause of varnish, and some of the
previous oil analysis results confirmed
that (through additive depletion and
high particle counts), one of the duplextype filters was dismantled and analyzed
through an optical microscope.
Evidence of electric discharge can be
easily seen through microscopic inspection of the filter media, filter core, filter
meshes and from debris carried away from
the filter.
Figure 5 shows one of the plugged
filters changed in a periodic maintenance
action due to a plugged filter alarm, with a
microscopic view of the filter mesh. As can
be seen, black and brown shiny deposits
(sludge and varnish) are present in high
concentrations, clogging the filter mesh.
The solvent used for cleaning the filter
mesh was collected and used to prepare
a ferrogram where significant amounts
of ferrous spherical wear particles were
identified (Figures 6 and 7). One source of
spherical ferrous debris is the erosion wear
activated by electrical discharges. The high
temperatures attained by the sparks on
the steel surface thermally liquefy the steel
debris, which acquires a spherical shape
due to rapid cooling under the action of
surface tension.
The microscopic analysis of the filter
core surface showed several small, circular
burned holes left by the high-temperature
spark discharges on the metal surfaces.
In conclusion, turbine oils must be
well-maintained to extend their service life
www.MachineryLubrication.com

characteristics, and these small air bubbles
are adiabatically compressed, causing varnish
to appear.
In this case study, it was recognized that
only the following techniques used to monitor
the condition of the turbine oil were efficient in
predicting eminent problems related to the generation of varnish and sludge:

Figure 5. Plugged filter from the turbogenerator and filter mesh with black and
brown shiny residue (200x magnification)

and simultaneously provide the maximum turbine
performance. However, the recent upgrade in
the turbine oil formulations has caused some
controversy. The older analytical techniques are
no longer the predictive tools able to monitor the
real condition that they once were.
The generation and presence of soft contaminants are among the main consequences of the
actual turbine oil degradation process. There are
four likely reasons for this:
• Unlike old-generation base oils (Group I), the
type of base oil currently used (Group II) does
not hold varnish precursors in suspension.
These insoluble particles may form deposits.
• Group I and Group II turbine oils possess
significantly different oxidation properties
and failure mechanisms.
• The antioxidants precipitate as they are
preferential oxides generating insoluble
particulates.
• The new generation of anti-foam
additives has less
effective air-release
Figure 6. Photomicrograph showing high
concentration of ferrous spheres (1,000x
magnification)

• Particle counting (ISO Code) was effective in
monitoring particle contamination. This was
in spite of the fact that most particle counters
are not sensitive to the small size of the polar
particles (less than 2 microns). The reason for
their efficiency was that the particles have a
tendency to form agglomerates, increasing
the size of the particulates and thus allowing
particle counting to detect them.
• The demulsibility of the oil was a critical characteristic to evaluate since it is affected by
the presence of polar particles. The alteration
of this property could be a signal of extreme
particle contamination.
• The LSV technology and FTIR are both
already recognized as important techniques
to monitor the condition of modern turbine
oils. They efficiently monitor the condition of
the antioxidant package and the creation of
soft contaminants.
• Analytical ferrography was effective in the
detection of soft contaminants and in the
identification of their nature. In the hands of
a skilled analyst, analytical ferrography is a
powerful technique to identify turbine oilrelated problems, providing a root cause
based on the morphology and characteristics of the insoluble particles, as well as
monitoring the progressive mechanism of
varnish formation.
From Page 22
D
R
Y
S
U
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P

G

Figure 7. Photomicrographs of small burned
holes on the surface filter core (200x and
1,000x magnification)
www.MachineryLubrication.com

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September - October 2011

29

BOOK STORE

Welcome to Machinery Lubrication’s
Bookstore, designed to spotlight lubricationrelated books. For a complete listing of books
of interest to lubrication professionals, check
out the Bookstore at store.noria.com.

How to Select a Motor
Oil and Filter for
Your Car or Truck

Author: Jim Fitch
Publisher: Noria Corporation
Before spending any more money
on oil changes, synthetic oils,
premium filters, engine flushes
or oil treatments, learn what
leading lubrication expert Jim
Fitch recommends. With these
sound recommendations, you’ll know exactly what to do next
time you change your oil — for about the price of an oil change.
How to Grease a Motor
Bearing Training Video

Format: DVD
Fo
Publisher: Noria
Corporation
Anyone responsible
for the maintenance,
operation and reliability of electric motors
w
will benefit from this
training video. It provides
plant personnel with an overview of the best practices for lubricating electric motor bearings. You can use the video to train
operators, lubrication technicians, mechanics, electricians and
maintenance personnel for years to come.

Machinery Oil Analysis —
Methods, Automation & Benefits

Author: Larry A. Toms
This book uniquely presents the
entire practice of oil analysis as
a condition-monitoring tool for
machines. The in-depth analysis
describes the what, when, where
and how-to for machinery
lubrication, machinery failure
and maintenance concepts, oil
sampling and testing, statistical
analysis and data interpretation.
Lubrication Fundamentals
— Second Edition

Authors: D. M. Pirro
and A. A. Wessol
This newly revised and expanded
reference book emphasizes the
need for lubrication and careful
lubricant selection. Thoroughly
updated and rewritten, the
Second Edition of Lubrication
Fundamentals discusses product
basics, machine elements that
require lubrication, methods
of application, lubrication, lubricant storage and handling,
lubricant conservation and much more.

Industry Practices for Electric
Motor Bearing Lubrication

Publisher: Noria Corporation
Discover what works for motor
bearing lubrication while benchmarking your lubrication program
to 200 plants. Noria Corporation
researched electric motor bearing
lubrication at 200 North American plants and condensed the
results into this valuable research
analysis report.

Oil Sampling Procedure Posters

Publisher: Noria Corporation
This set of three posters visually displays step-bystep oil sampling procedures for in-service lubricants
and hydraulics. Each poster includes a list of required
equipment necessary to follow the procedure. The
procedures featured in the set are for high-fluid
pressure systems, low-fluid pressure systems and systems at
atmospheric pressure.

For descriptions, complete table of contents and excerpts from
these and other lubrication-related books, and to order online,
visit: store.noria.com or call 1-800-597-5460, ext. 204
30

September - October 2011

Card
www.MachineryLubrication.com

ML

NOW ON

MachineryLubrication.com

Every day, thousands of industrial professionals from around the United States
and around the world visit the Noria Corporation Web sites. See what makes these sites so
popular and informative. Visit us today and every
day at www.machinerylubrication.com.

Automated Lubrication —
Benefits and Design Options
While grease guns and manual lubrication seem
to get the job done for many maintenance operations, their benefits often cannot compare to those
provided by an automated lubrication system in
terms of productivity, environmental issues and
worker safety. An automated lubrication system
helps to prevent bearing failure by providing the
right amount of the right lubricant at the right time
to the right place. Find this article in the Bearing
Lubrication section on the ML site.

How Infrared Thermography
Predicts Failures
This video offers expert analysis of how
infrared technology can predict equipment failures. Access this 9-minute, 11-second video at
www.machinerylubrication.com.

32 |

September - October 2011

Demystifying Sludge and Varnish
You could tar your roof with it. It sticks to
everything. It spreads like cancer. You thought
you were getting rid of it with the oil change
and flush, but it is back again, lurking in your
oil and gripping the insides of your machine.
Maybe you have it now . . . sludge and varnish.
Do you know what causes it and how to stop
it from spreading? Discover the destructive
potential of sludge and varnish as well as how
to prevent it from coming back by reading this
article on the ML site.

Hydraulic Gear Motors
and How They Work
Get a detailed look at the interior of a
motor, its gears and body. Watch how oil is
pushed into the inlet port and through the
outlet, traveling between the gear teeth and the
gear housing, generating the rotation of the
shaft. Access this 2-minute, 11-second video at
www.machinerylubrication.com.

Managing the Risk of
Mixing Lubricating Oils
Today’s high-performance lubricants
are specifically formulated with a carefully
selected balance of performance additives and
base stocks to match the lubrication requirements of the equipment in which they are
used. When lubricants are mixed, this balance
is often upset. Mechanical problems leading to
shorter equipment life can occur, sometimes
catastrophically. Read this article on the ML
site to learn why mixing lubricants is fraught
with danger to your equipment, your business
and your wallet.
www.MachineryLubrication.com

www.MachineryLubrication.com

September - October 2011

| 33

ML

CERTIFICATION NEWS

ELI LILLY’S WENZEL
EMBODIES the
SPIRIT OF ICML
BY SUZY JAMIESON, ICML

Ten years ago, ICML held its very first examination session
in Biloxi, Miss., changing the course of the machinery
lubrication industry. In the small pioneering group of only six
practitioners stood Rendela Wenzel, who took it upon herself to
be part of the very first group of ICML candidates. By successfully completing that first ICML exam, she not only became one of
the first ICML-certified professionals but also the very first ICMLcertified female practitioner.
In celebration of ICML’s 10th anniversary, we wanted to tell
Wenzel’s remarkable story.
Wenzel remains one of a still few female reliability engineers and
machinery lubrication practitioners. Although part of an ICMLaward-winning team, she was one of the people ICML recognized
at the 2011 Reliable Plant Conference in Columbus, Ohio, as
embodying the spirit of ICML in the area of certification.
Wenzel is currently the corporate lubrication technical team
leader for Eli Lilly. She has 14 years of experience in maintenance
and operations, troubleshooting maintenance issues, implementing

Rendela Wenzel (center) and her team from Eli Lilly were the recipients of the 2008
John R. Battle Award.

34 |

September - October 2011

solutions to these problems and supervising skilled trades. Wenzel
has a level II certification in both lubrication and vibration analysis,
and a level I certification in both infrared thermography and ultrasonic analysis. A Six Sigma Green Belt and a certified maintenance
and reliability professional (CMRP), she has a bachelor’s degree in
mechanical engineering and a master’s degree in business administration. Wenzel is also a member of ICML and the Society of
Maintenance and Reliability Professionals (SMRP).
She began her career at the Chrysler Foundry in 1997 as a process
engineering intern in the core delivery area. After a few months,
Wenzel became the team leader for operations and maintenance for
the cleaning area.
“All engineers at Chrysler start out on the floor to gain experience working with the people and equipment that they support
and redesign,” Wenzel says. “This was an excellent opportunity for
me to be able to see the struggles that workers have with equipment and learn how to design those issues out with mechanical
solutions. I also learned to work with people of various backgrounds in a union environment and still be able to be effective at
implementing those solutions.”
Wenzel then moved to International Truck and Engine (Navistar)
in 1999 as a maintenance engineer over the crankshaft line for the
steel business unit at the Indianapolis engine plant.
“I was tasked with developing a job description for a maintenance engineer and a predictive maintenance program for the entire
site,” she recalls. “Navistar knew that this was a new role in industry,
and they needed individuals to go out and get trained on how to
implement it in their facilities. This is where I learned about Noria
and the ICML.”
Wenzel’s task was to develop a lubrication program and implement it in a union environment.
“I went to Oil Analysis I and II training from Noria and became
MLA I certified through ICML in January 2001,” she says.
Wenzel took the information she learned back to her facility
and developed a robust and highly successful lubrication program,
www.MachineryLubrication.com

www.MachineryLubrication.com

September - October 2011

| 35

CERTIFICATION NEWS

Along with Kurt Bittner of PSEG Nuclear and Scotty Lippert of Clopay
Plastics, Wenzel was honored at the 2011 Reliable Plant Conference in
Columbus, Ohio, as representing the spirit of ICML.

which was later replicated at Melrose Park and also the Huntsville,
Ala., facility. She was able to transform the culture of reactive maintenance into a proactive environment that valued reliability activities
and wanted them integrated into their PMs and daily operator tasks.
“I took the structure of the existing vibration program as a
model and integrated an oil and thermography program into the
PM tasks and jobs of the craftsmen,” Wenzel notes. “This was a
daunting task in a union environment. Oil analysis was an extra
task for the machine repairmen, and thermography was an extra
task for the electricians.”
Oil analysis became something that Wenzel and her team did
routinely over the next three years to diagnose many potential failures, which resulted in greater uptime.
“I implemented the changes in very small increments, including
oil leak-detection devices such as a UV light and dye that could
find oil leaks,” she says. “One leak in our facility equated to more
than $42,000 per year in savings. I decreased oil consumption by
25 percent and eliminated time-based oil changes. I added proper
sampling ports, revamped our lube room and instituted an operator machine-cleaning program. The production on our bottleneck
step increased by 10 percent, which eliminated one shift per week
of overtime.”

36 |

September - October 2011

Wenzel then had the opportunity to obtain her master’s degree
in 2003 and wanted to broaden her experience base by switching
industries. She started with Eli Lilly in 2003 as a reliability engineer
in the insulin side of the business. Her role was to be the reliability
engineer over the Humalog product line in B130.
“I took the knowledge from my Noria training and replicated
my efforts in B130 to establish a robust and successful oil analysis
program,” she says. “My building was certified by the corporate
lubrication technical team as world class in the fall of 2003 and
was the first manufacturing facility to be certified by the corporate
team. This was a great achievement only being with the company
five months.”
For a minimal investment of $5,000, Wenzel took the shell of a
lubrication program and turned it into the pilot plant for the rest
of the company to follow. After replicating this program for the
remaining manufacturing facilities at Eli Lilly, the corporate team
applied for the ICML John R. Battle Award.
“Our team decided to use my area for the application, and we
were the 2008 John R. Battle Award recipients,” Wenzel says. “I
took over the reins of the corporate lubrication technical team from
Wayne Ferguson in 2009. Since then, we have maintained the 12
areas of the company that are world-class certified, established two
lubrication courses (basic and advanced lubrication fundamentals)
at Lilly for all engineers, supervisors and crafts, and are in the process
of replicating all these policies and procedures to all our sites.”
To date, more than 900 Eli Lilly and contract employees who
come into direct contact with critical machinery have been trained
in lubrication fundamentals.
When asked to think back to Jan. 26, 2001, the day she took that
first ICML exam, and about her journey until now, Wenzel offered
a gracious response that demonstrates why she is one of the best
examples of the spirit of ICML.
“The last 10 years have been a very rewarding journey for me
through three different types of industries, learning the cultures,
designing and implementing lubrication programs, and developing
policies and procedures to ensure the longevity of the programs,”
she adds. “I feel very blessed to have been put in the situation to be
able to make a difference by helping make equipment safer, more
reliable and easier to maintain.”

www.MachineryLubrication.com

www.MachineryLubrication.com

September - October 2011

| 37

CERTIFICATION NEWS

RECENT RECIPIENTS OF ICML CERTIFICATION
The International Council for Machinery Lubrication (lCML) would like to congratulate professionals worldwide
who have recently achieved certified status through ICML’s 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).
Azman BinBadron, MLT I
Eduardo Bruschi, MLT I
Claudio Marcos Madureira Martins,
MLT I
Humberto Mozer Carvalho, MLT I
Brittany J. Russo, MLA I
Acerias Paz del Rio S.A.
Jaime Augusto Rodriguez Orozco,
MLT I
Aerospace Testing Alliance
Joo D. Reynolds, MLA II
Al Bedaya Consultancy &
Marine Survey LLC
Khaled Aly Matar, MLA I
Alcoa
Cheyene Robert Buse, MLT I
Jennifer Lynn Cheaney, MLA I & MLT I
Joseph F. Clayton, MLA I & MLT I
Jonathan A. Fulton, MLA I & MLT I
David T. Gainer, MLA I & MLT I
Allen Hohl, MLA I
Nathan Jones, MLA I & MLT I
Neil Kennedy, MLA I
Robert Koehler, MLA I & MLT I
Shawn L. Mayo, MLA I & MLT I
David Michael Patterson, MLT I
Ben Robak, MLT I
Robert C. Rockhill, MLA I & MLT I
Dave A. Swindell, MLA I & MLT I
Yi-Hsien (Tim) Yang, MLA I & MLT I
Allegheny Technologies
Brandon Gaskey, MLA I & MLA II
Dale L. Jones, MLA I, MLA II & MLT II
Allied Reliability
John M. Trulli, MLT I
Apache Corporation
Keith Madsen, MLT I
Arauco
Jaime Bohme Fuentealba, MLT I
Alfredo Boettcher Schell, MLT I
ATI Wah Chang
Boyd Koehler, MLA I
Jim Scofield, MLT I
Jon Walberg, MLA I
AV Technology Ltd.
Carl Dawson, MLA I
Tim Wilkinson, MLA I
Birmingham Water Works Board
Jonathan Malloy, MLA I
Cargill Inc.
Jessie Barlow, MLT I
Steve Brantley, MLT I
Terry Wayne Brewer Jr., MLT I
Rodolfo Cabrera, MLT I
Daniel M. Dicke, MLT I
Jimmy Goff, MLT I
Kevin Gorski, MLT I
Dave Horn, MLT I
Thomas Edward Jackson, MLT I
Harrison W. Joyce, MLT I
Joe Lemer, MLA II & MLT I
Chris M. Lindgren, MLT I
Michael S. Moore, MLT I

38 |

September - October 2011

David J. Peraza, MLT I
Mark Resendez, MLT I
John Reyes, MLT I
Troy Rooney, MLA II
Jeremie D. Walker, MLA II
Cariboo Pulp & Paper Company
Don Edwards, MLT I
Brent Janischewski, MLT I
Steve Logan, MLT I
York Malner, MLT I
Cameron McPhedran, MLT I
James R. Porter, MLT I
Scott E. Richardson, MLT I
Rob Rolfe, MLT I
Jason Phillips-Watts, MLT I

Energy Northwest
Jeff Scott, MLA II
Entergy, Inc.
James R. Fraser, MLA II
Exelon Corporation
Steven Wood, MLA I
Filtramax
Francois Lepine, MLA I
First Energy Corp.
James E. Black Jr., MLA II
Scott K. Graton, MLA II
Florida Power & Light
David LaGuardia, MLA II

Chevron
Hilary A. Fernando, MLT II
Aimee Hawkins, MLT II
Sorasak Saengwanit, MLT II
Alexander William Stephenson, MLT II

Flow Dynamics and Automation
Phillip Scrimpshire, MLT I

Cia. Vale do Rio Doce
Luis Orlando Pino Delgado, MLA II

Georgia-Pacific
Greg Van Camp, MLT I
Shawn M. Day, MLT I
Dennis R. Leach, MLT I
Alex Moses, MLT I
William R. Nichols, MLT I
Wayne Noakes, MLT I
William Paul Terrell, MLT II
Jason Vance, MLA I & MLT II

Cliffs Natural Resources
John Freiberg, MLT I
Cloud Peak Energy
Jeffrey Biegel, MLA III
Compañia Teck Minera
Quebrada Blanca S.A.
Rodrigo Gonzalez C., MLT I
Cristian Jesus Parra Rios, MLT I
Roberto Joaquin Ramos Hernandez,
MLT I
Conauto
Jorge Fernando Calero Mejia, MLT I
Del Monte Phils., Inc.
Cirilo Amoy, MLT I
Eleazar S. Orina Jr., MLT I
Diavik Diamond Mines
George M. Fancy, MLA II
Dave Frederick Forster, MLA I &
MLA II
J. David Monchuk, MLA I & MLA II
Alexander Shank, MLA I
Anand Sharma, MLA II
Jim Simmons, MLA II
Jim A. Strickland, MLA I
Dubai Aluminium Co. Ltd.
Shajeev Puthalath, MLA I

GenOn Energy
Ryan Bailey, MLT I

Greenlub Lubrificantes Ltda.
Rogerio Zadra, MLT I
Hedcor Inc.
Niel Cabang, MLT I
Dennis Miranda, MLT I
Holcim Inc.
Jason Frankiewicz, MLT I
Charles E. Gibbs, MLT I
Alvin Chester C. Oreiro, MLT I
Pete Oviedo Jr., MLT I
David “Coop” Towle, MLT I
The Hurt Company, Inc.
Newton Hopkins, MLT I
Roy M. Christoffel, MLT I
Industrial Oils Unlimited
Danny “Mike” Toney, MLT I
Insight Services
Eric Ambrose, MLA II
Monika Malcolm, MLA I
Dwon Ruffin, MLA I

DuPont
Erica R. Cross, MLT I
Larry E. Kunze, MLA II
Richard Lipscomb, MLT I
Aaron P. Moore, MLT I
John Edward Nesselroad, MLT I
Brian Thompson, MLT I

IPM
David Williams, MLT I

Eastman Chemical
Earl F. Edens, MLA III

Japan Atomic Power Co.
Atsuya Tsuruzono, MLA III

EMA Lubricants Co.
Syed Sadath Hussain, MLT I

Jimah O&M Sdn Bhd
Sofian Bin Sahat, MLT I
Mohd Fauzi Bin Hamin, MLT I

Emirantes Aluminium
Mohammed Yousef Abusheikha,
MLA I

ITW Polymex
Ricardo Joel Duarte Loperena, MLT I
Aldo Guatemala, MLT II
Edgar Guzman Lopez, MLT I

JM Huber
Dana Rowan, MLT I

The JM Smucker Co.
Patrick Lalor, MLT I
James Robert Pant, MLT I
Kanden Plant Corp.
Kazuyoshi Hagane, MLA II
Yoshitaka Nakano, MLA II
Tomohiro Sanda, MLA II
Kennecott Copper
Kirk Dittmar, MLT I
Lubrication Engineers Inc.
Patrick R. Bilberry, LLA I
Larry Boyle, MLT I
Bruce A. Bruner, MLA II
James Cowles, MLA II & MLT II
Jacob Bryant Davisson, LLA I & MLA II
Mike Hall, MLT I
Sarah Hall, MLT I
Berle Hartman, MLT I
Caleb D. Hayes, MLT I
Eric Ndegwa, LLA I
Brian L. Nelson, MLT II
Stan Nelson, MLT I
Sam R. Quakenbush, MLT I
Daniel Roberts, MLT I
Birju Shah, MLT I
Chris Shelly, MLT I
Bob Sodergren, MLT I
Gregory Spiers, MLA I & MLT I
Derek Taylor, MLT I
Bernie A. Thomsen, MLT I
Matthew Valentine, MLA I & MLT I

David William Niebergall, MLA II
Derek Rice, MLA II
Kelly Therrien, MLA II
Reid Foley Williams, MLA II
Shaun K. Wright, MLA II
Greg A. Zimmer, MLA II
MRG Labs
Richard N. Wurzbach, LLA I
Newmont Mining Corp.
Brett Eugene Morton, MLA I
NextEra Energy
Jerry Lee Barske Jr., MLA II
Nissan
Chad Crane, MLT I
David Gross, MLT I
Noria Latin America
Francisco J. Paez Alfonzo, MLA III
Norske Skog Tasman
Grant Carncross, MLT I
Eric Horwood, MLT I
Rhys Drayson, MLT I
NRG Energy Inc.
Joshua Shewan, MLA I
OCI Wyoming L.P.
Dean Kendall, MLT I

Lubrication Systems Company
Osmari Chacon, MLA III

Oil-Dri
Donald K. Everett, MLT I
Kim Robert Jaynes, MLT I
Mitchell Jon Schalk, MLT I
Jim Warden, MLT I

Luminant Power
Jeremy Layne Swanson, MLA III

Overlake Oil
Paul Hawkes, MLT I

Machine Evaluation
Michael E. Thornton, MLT I

Owens Corning
Andrisa Jefferson, MLT I

Matzan Reliability Engineering
Matt Arndt, MLA II

Pemex Gas & Petroquimica
Basica
Alejandro Castillo Lazaro, MLT I
Carlos Alberto Dominguez Osuna,
MLT I
Ramiro Fernandez Martinez, MLT I
Javier Garcia De Leon, MLT I
Juan Enrique Germanos Otero, MLT I
Francisco Javier Gonzalez Juarez,
MLT I & MLT II
Octavio J. Guerrero Hernandez,
MLT I
Wilberth Guillermo Herrera Osorio,
MLT I
Jorge Higa Arvizu, MLT I
Roberto Martinez Bustos, MLT II
Miguel Martinez Luria, MLT I
Erick Martinez Ramirez, MLT I
Medardo Melo Sanchez, MLT I &
MLT II
Gabriel Olan Gonzalez, MLT I
Jose Manuel Perez Sosa, MLT I
Raymundo Rodriguez Romero, MLT I
Omar Valdivia Maza, MLT I & MLT II
Edgar Genaro Vega De Leon, MLT I
Gabriel Zavala Gomez, MLT I

Mecoil Diagnosi Meccaniche Srl
Giacomo Mariani, MLT I
Michelin Tires Corporation
Jerry Gibson, MLT I
Micron Technologies
David A. Peck, MLT I
Mighty River Power Ltd.
Allan Heath, MLT I
Peter Martin, MLT I
Mike Ranger, MLT I
Andre Richards, MLT I
Peter Smith, MLT I
Jeremy Wilson, MLT I
MillerCoors Brewing Company
Thomas Lloyd Davis, MLT I
MinePro Chile S.A.
Marcos Castro, MLA II
Carlos Tomas Mondaca Lopez, MLA II
Mosaic Company
Rodney E. Bernath, MLA II
Kelly M. Chalus, MLA II
Brad L. Gabrielli, MLA II
Garrett Matthew Kuntz, MLA II

Petrobras
Julio Cesar L. Alves, MLT I
Solange Virilo Borbily, MLT I

www.MachineryLubrication.com

Mario Roberto Leao Burle, MLT I
Cesar Figueiredo, MLT I
Sergio Peixoto Augusto Junior, MLT I
Marcos Thadeu Giacomin Lobo,
MLA I
Vinicius Moia Monte Alegre, MLT I
Rosana Villela Santos, MLT I
Petronas Gas Berhad
Gladwyn Bacena, MLT I
Muhammad Effirdaus Bin Abdul Hakim, MLA II
Pilipinas Shell Petroleum Corp.
Kerchieval G. Balingit, MLT I
Donna Christine Enriquez, MLT I
PQ Corporation
Stuart Hensley, MLT I
William M. Ledbetter, MLT I
Praxair, Inc.
Matthew Thomas, MLA I
Progress Energy
Larry E. Barnett, MLA II
PT Newmont Nusa Tengarra
Neka Damartha, MLA I
Queensland Nickel Pty. Ltd.
Andrew Camp, MLT I
James Leslie Filmer, MLT I
Anthony Philip Greinke, MLT I
Tak Sam Lee, MLT I
Russell Vernon McIntosh, MLT I
Angelo Nobile, MLT I
Matthew Joseph Paulger, MLT I
Craig Pegg, MLT I
Risto Reissenberger, MLT I
Cameron Smith, MLT I
Dane Tappenden, MLT I
Jason Bradley Townsend, MLT I
Daniel Vogler, MLT I
Bill Weston, MLT I

Charles Arthur Lewis, MLA I
Heidi A. Marshall, MLA I
Charles James Pence, MLT I
Matthew T. Platek, MLA I
Craig Alan Schrowang, MLA I
Richard D. Segovich, MLA I
Gordon L. Seymour, MLA I
Carol Jean Straub, MLT I
David S. Thompson, MLT I
Jimmy L. Uhde, MLA I
Craig William Walker, MLT I
Reggie R. Wulff, MLT I
Samsung Everland
Dae Keun Kang, MLA II
Sungil Park, MLA II
Hyun Gyu Yang, MLA II
San Roque Power Corp.
Leo V. Tibayan, MLT I
Sarawak Shell Berhad
Chow Kim Vui, MLA II
SaskPower
Mark Crooks, MLA I
Saudi Aramco
Rabi M. Hakeem, MLA I
SeaTec UK Limited
Ajay Arora, MLA II
Stanly George, MLA II
Shell Markets Middle East
Sandeep Banerji, MLA I
Shikoku Electric Power Co.
Yuji Yano, MLA III
Siemens Power Operation Inc.
Edmund M. Castro, MLT I
Elena Kristine A. Javal, MLT I
Sandy L. Uson, MLT I

R.J. Reynolds Tobacco Co.
Michael D. Cornett, MLT I
Joseph Scott Poindexter, MLT I

SKF del Peru
Roy Felix Cabezas Jara, MLA I
Ronald Vidal Ravelo, MLA II

Right Flow Reliable Solutions Inc.
Dawn April Lumbas, MLT I

SKF Maintenance Products
Gustavo Yesid Sabogal Rozo, MLT I

Rio Tinto
Morgan Hall, MLA I
Brendan Moffat, MLA I
Brian Wagstaff, MLA I

Solvay Advanced Polymers
Michael D. Dye, MLA II & MLT II
Southcoast Petroleum Ltd.
Oleksandr Bodnya, MLT I

Robinson Nevada Mining
Michael Sean Farrell, MLT I
Justin Shalako Pope, MLT I

Southern Company
Neal Mac Namara, MLA II

Roquette America, Inc.
David Chandler, MLT I
MarceyMarcey Lonning, MLT I

Sterling Steel LLC
Michael Kyarsgaard, MLA II & MLT I
Jeff Trancoso, MLA II & MLT I

Sabic Innovative Plastics
Adam E. Ball, MLA I
Norman Bulloch, MLA I
Christopher M. Corbitt, MLA I
Joseph Lee Dean, MLT I
Dennis R. Dick, MLT I
Lance Foreman, MLA I
Gerald Goebel, MLA I
Jeff C. Hutcheson, MLT I

Taylor Enterprises
Thomas J. Loar, MLA II
Teck Highland Valley Copper
Mark Baker, MLA II
Shane Kozoriz, MLA II
Mark Mulroy, MLA II
Temple-Inland Forest Products
William Scott Davis, MLA II

ICML Certifications
LLA I = Laboratory Lubricant Analyst Level I
MLA I = Machine Lubricant Analyst Level I
MLA II = Machine Lubricant Analyst Level II
MLA III = Machine Lubricant Analyst Level III
MLT I = Machine Lubrication Technician Level I
MLT II = Machine Lubrication Technician Level II
www.MachineryLubrication.com

Tenaga Nasional Berhad
Venoth Kumar Govindasamy, MLA II
Thomas Petroleum
Ricky Edward Cantrell, MLT I
James Grant Clark, MLT I
Dee Harold Draper, MLT I
Brandon S. Ford, MLT I
Rodolfo J. Gonzalez Jr., MLT I
Kimbery A. Gregory, MLT I
Chris Dewain Harris, MLT I
Mark Wesley Hudson, MLT I
James C. LaBeff, MLT I
Dennis G. Maietta, MLT I
Nicole Martin, MLT I
Ronnie Wayne Pewitt, MLT I
Ricky Roden, MLT I
David L. Sanchez, MLT I
Frank Eidin Slaugh, MLT I
Garrick Ashley Thomas, MLT I
Thunder Bay Coal Co.
Michael Siegert, MLA II
Tohoku Electric Power Co.
Takuya Saito, MLA II
Masayuki Shimada, MLA II
Nobuhiko Umeki, MLA II
TSNZ Pulp & Paper Maintenance Ltd.
Selwyn Pryor, MLT I
Unicco
Aaron Chad Abbott, MLT I
James R. Anderson, MLT I
Charles Mettler, MLT I
Brian Keith Miles, MLT I
Valero Energy Corporation
Allan R. Thibodeaux, MLA II
Jimmy Thomson, MLA II & MLT I
Verso Paper
Edwin W. Ames, MLT I
Caleb Bell, MLA I
Stephen P. Blair, MLT I
Reginald A. Cloutier, MLT I
Robert Allden Downes, MLT I
Scott Dyar, MLT I
Thomas Henry Heywood, MLT I
James H. McClure, MLT I
Michael D. Michaud, MLA I
Terry Arlene Ring, MLT I
Travis C. Veilleux, MLT I
We Energies
Mark J. Smith, MLA II
WesTrac Pty. Ltd.
Philip De Wet, MLA II
Xstrata
Luis Angel Romero Carlos, MLA II & MLT I
Yonden Engineering Co.
Keiichi Shimomoto, MLT I

Need to take
an exam?
ICML regularly holds
exam sessions throughout
the United States and the
world. Upcoming dates
and locations for ICML
exams can be found at
www.lubecouncil.org
September - October 2011

| 39

PRODUCT SUPERMARKET

Ensure protection from live parts and
arc flash - Safety Plugs allow technicians to quickly connect/disconnect
electrical equipment. Exclusive features protect from electrical hazards
and simplify NFPA 70E compliance.
FREE samples available.

Escalator Chain Lube is a synthetic
lubricant; it excels in lubricating the
chains of escalators, moving sidewalks
& elevator doors. Its high-film strength
improves equipment reliability while
reducing lubricant consumption.

Meltric Corporation

www.royal-purple-industrial.com
888-382-6300
[email protected]

www.meltric.com 800-433-7642
[email protected]

Maximize productivity and reduce
costs with the power of Castrol High
Performance Lubricants. • Gear Oils
• Greases • Hydraulic Oils • Way
Lubricants • Compressor Oils •
Chain Oils. Only Castrol Industrial
has the technology inside. Contact us
[email protected]

The SureSample utilizes a patented
vacuum technology that eliminates
the need for sample pumps. Simply affix the length of tubing to the
SureSample bottle, insert into a
reservoir or sample port, and let the
bottle do the rest.

Cannon Instrument Company

www.cannoninstrument.com
800-676-6232
[email protected]

Krytox® Fluorinated Greases and Oils
are chemically inert, insoluble in common solvents. Temperatures range
from -103° to 800°F. Compatible with
plastics, rubber, ceramics and metals.
Nonflammable, oxygen compatible,
no silicones or hydrocarbons. H-1/H-2
Food Grades available.

Analysts, Inc.

Miller-Stephenson Chemical
Company, Inc.

www.analystsinc.com 800-655-4473
[email protected]

www.miller-stephenson.com
203-743-4447

Isn’t it time you streamlined your
fluid handling?

UE Systems, Inc.

Summit Varnasolv will alleviate problems from varnish and carbon in your
rotary screw or rotary vane compressor. Clean your compressor while it
is running, no need to disassemble.
Use Varnasolv to clean heat transfer
systems, high temperature chains
and gearboxes.

www.uesystems.com
800-223-1325
[email protected]

www.klsummit.com/varnasolv.pdf
800-749-5823 [email protected]

Castrol Industrial
North America Inc.

877-641-1600

Know when to lubricate with UE
Systems Ultraprobe® 201 Grease
Caddy. Sensing ultrasound, Grease
Caddy isolates bearing sounds making it easier to listen in noisy plant
environments. Wear on a holster or
attach to grease gun.

40

Royal Purple, Inc.

Because viscosity measurement should
be simple, CANNON is excited to
introduce the SimpleVIS™ portable
viscometer. Everything is included to
get you started, minus your sample
and solvent. Contact us for more
information.

September - October 2011

Summit Industrial Products

The IFH Group, Inc.

www.ifhgroup.com
800-435-7003
[email protected]
www.MachineryLubrication.com

PAID A DVERTISING SECTION

BELL ULTRA’s formulation substantially reduces friction in hydraulic
systems by resurfacing metal surfaces,
resulting in LOWER OPERATING
TEMPERATURES AND POWER INPUT
and LONGER COMPONENT LIFE.
Cornerstone Controls

Valve reduces sampling time by 80%
Plus - Unique 360° rotating spout
allows easy one hand sampling. Stainless steel chain and clip. NEW higher
flow for low pressure applications.
NEW rugged spout design with easy
to grip knurled cap.

www.ccisupply.com/BellUltra
352-291-2300
flpwr@cfl.rr.com

Checkfluid, Inc.

Hornche Corporation

www.checkfluid.com 866-652-8728
info@checkfluid.com

www.easylube.com
[email protected]

One Eye Industries for all your magnetic and industrial filtration needs.
Our filtration solutions have applications in all industries. We manufacture
an extensive product line utilizing new
magnet technology.

MEMOLUB® Lubrication Systems –
Precise, Reliable. Lube up to 12 points
with the reusable MEMOLUB®. Available in 3 sizes and 4 power options,
MEMOLUB® uses low-cost replaceable lube cartridges with customerspecified grease or oil.

Harvard’s filter systems are designed and
built with quality materials and craftsmanship to provide years of trouble-free
service. Filter elements for viscosity ranges
from fuels to gear oils (ISO 1000). Customers report clean fluids to ISO 13/12/8
in operation. Contaminant capacity
per element is about four pounds. The
product has demonstrated the ability to
remove one gallon of water from oil.

One Eye Industries, Inc.

PLI LLC

www.oneeyeindustries.com
877-888-8727
[email protected]

www.memolub.com
800-635-8170
[email protected]

Maintain your fluid cleanliness
from storage to point of use
with the PROFILL portable fluid
transport container. PROFILL provides sealed, reliable, and efficient,
transport and accurate dispensing
of your critical fluids.

Inolex Chemical Company synthesizes
premium ester base oils for high-performance lubricant applications such
as chain formulations for oven temperatures up to 550°C. HX-1 food grade
oils for baking chains are available.

FLUIDALL Solutions

Inolex Chemical Company

www.FLUIDALL.com
800-849-0591
[email protected]

www.inolex.com
800-521-9891
[email protected]

www.MachineryLubrication.com

The Easylube RFID Patrol Management Automatic Lubrication System
provides precision bearing lubrication and condition monitoring in one
system. Easily calculate and manage
greasing quantities and intervals
using our software.

Harvard Corporation

www.harvardcorp.com 800-523-1327

Fundamentals of Machinery Lubrication provides more than 24 hours of
foundational training on best practices for machinery lubrication and oil
sampling. It lays the groundwork for
establishing a world-class lubrication
program and is a Level I certification
prep course.This online training format
allows 24/7, anywhere accessibility.
Noria Corporation

store.noria.com 800-597-5460
September - October 2011

41

PRODUCT SUPERMARKET

ML

TEST YOUR KNOWLEDGE

This month, Machinery Lubrication continues its “Test Your Knowledge” section in which we
focus on a group of questions from Noria’s Practice Exam for Level I Machine Lubrication Technician and Machine Lubricant Analyst. The answers are located at the bottom of this page.

1. Benefits generally associated with the use of synthetics include:
GARZO Model 108B controllers maintain oil levels in engines and compressor
crankcases to prevent equipment damage and save oil. The standard valve
assembly works with atmospheric tanks
or up to 15 psig oil supply pressures.

A)
B)
C)
D)
E)

Better oxidation resistance
Better compatibility with elastomers (seals)
Less toxicity
Higher cost
Better paint compatibility

GARZO, Inc.

www.garzoproducts.com/108.html
713-466-8679
[email protected]

2. The concentration of wear debris:
A)
B)
C)
D)
E)

Always increases throughout the oil circulating system
Varies throughout the oil circulating system
Always decreases throughout the oil circulating system
Is constant throughout the oil system
Varies with the pressure in the oil system

3. Which maintenance strategy is based strictly on
tasks performed at specific time intervals?

Equip your Lube Room of the future with
FLUIDALL Lubrication Storage Solutions. Reliable, Clean, Cost Effective,
and Space Efficient fluid storage systems
available in bulk and portable gravity fed
and pump/filtered configurations.

A)
B)
C)
D)
E)

Proactive
Predictive
Preventive
Percussive
Reactive

4. A critical issue when greasing a rolling bearing is to:

FLUIDALL Solutions

A) Use only the exact calculated regreasing frequency
B) Use only a pump-action grease gun
C) Allow the grease to ooze out past the seals
D) Wipe the excess grease from the zerk fitting when finished
E) Allow excess grease to get out of the roller path and exit the
housing through the drain port

www.FLUIDALL.com 800-849-0591
[email protected]

5. Which component generally requires the cleanest oil?

This DVD includes instructive videos
and animations to give viewers a
better understanding of electric
motor bearings and how to lubricate
them properly.

A)
B)
C)
D)
E)

High-pressure hydraulics
Gears
Engines
Turbines
Journal bearings

Noria Corporation

store.noria.com
800-597-5460
Answers: 1-A; 2-B; 3-C; 4-E; 5-A

42

September - October 2011

www.MachineryLubrication.com

Lubrication Programs

FROM THE
FIELD

STEPHEN SUMERLIN

6 STEPS
to UPDATE your
LUBRICATION
program

In today’s culture of looking for high returns on investments,
there are not many that can compare to a comprehensive
lubrication program. Tremendous financial savings can be enjoyed
by eliminating poor lubrication practices from an organization.
Numerous financial losses are attributable to poor and inadequate
lubrication programs and techniques, and most of the losses are
not going to jump out at you. This is why it is important to think of
every aspect of lubrication. Just working on one area will not yield
the financial results you desire. It is all or nothing. This article will
offer valuable guidance as to why and how to look at the big picture
when updating your lubrication program.

1

Benchmarking

To understand where your lubrication program needs
to be, you must first find out where it currently stands.
In order to accomplish this, an in-depth benchmarking
process must be performed to compare your current
program to industry best practices in key areas of lubrication.
Without having a metric to compare your program to, it becomes
the blind leading the blind. All successful programs start with a clear
picture of how much work they need to do to become world class and
what they need to do to get there. Transitioning a lubrication program
is not like turning on a light. It takes understanding, clear vision, dedication, champions, time and financial resources to make it happen.

2

Design and Engineering

During the design and engineering phase, look at
every lubrication point and determine what actions
need to be put into place. These actions can range
from equipment modifications and routine inspections
to one-off inspections, etc. They are usually dependent upon the
equipment type, criticality, reliability needs, financial benefit, safety
consequences and other factors that affect the bottom line. Based
on these factors, you should create clear, concise and specialized
procedures for each lubrication point. These procedures will be used
to modify equipment for contamination control, provide standards
for oil analysis and coach the lubrication technician on proper lubrication techniques (i.e., top-ups, drains, filtration and oil sampling).
During this phase, you also should make sure the correct lubricant is being used in each lubrication point. This process involves
checking the OEM recommendations for a baseline and then
performing certain calculations for proper viscosity selection,
44 |

September - October 2011

lubricant type, performance properties, re-lubrication volumes,
re-lubrication frequencies, etc. Re-lubrication volumes and frequencies often are left out of procedures, and a “shoot-from-the-hip”
method is used. Not understanding how much and how frequently
the lubricant should be supplied to an application, especially greaselubricated bearings, can cause frequent lubrication-related failures.

3

Lubricant Consolidation

Many times, as a byproduct of the design and engineering phase, lubricant consolidation occurs. This is
important on many levels, as it allows for a clearer picture
of what products need to be purchased, which reduces
purchasing costs, eliminates unnecessary or unused products from
inventory, decreases the likelihood of lubricant cross-contamination
and helps the lubrication team understand which products they
need and why. As the specialized procedures are created during the
design and engineering phase, each lubrication activity should have
the correct lubricant specified. This will help ensure that the technician is using the right product in the right place.

4

Storage and Handling

Once all of the necessary lubricants are identified, it is
time to think about your storage and handling practices.
Proper storage and handling techniques are essential
in developing a successful lubrication program. You
can perform all of the equipment modifications for contamination
control, but if you can’t get the lubricant from the storage room to the
application without introducing contamination, all of those modification efforts were in vain. This is why it is so critical to have a proper
lube room with dedicated receiving filtration, storage systems, filter
carts, stored filtration, dispensing equipment and a safe and clean
environment for the lubricants to be stored.
Lubricant labeling is another frequently missed opportunity.
Labeling should be a high priority when thinking of execution.
Lubricant-specific labels should be created and placed on stored
lubricants, top-up containers, grease guns, filter carts and the equipment. This makes lubrication tasks much more efficient and reduces
the likelihood of the wrong lubricant being used in the wrong application. If technicians can clearly see the label on the equipment, go back
to the lube room and find the matching label on the filter cart, top-up
container or grease gun, their jobs become much easier and safer.
www.MachineryLubrication.com

5

Implementation

After designing and engineering
a lubrication program, the next
step is to implement what you have
developed. Many times this is where
organizations fail to execute and never see the
value of all their previous efforts. Implementation is not a one- or two-day exercise but a
multi-month commitment based on available
resources. Complex types of equipment such as
hydraulic systems will necessitate multiple modifications in order to be considered best practice,
requiring a substantial financial commitment.
The modifications can include breathers, sight
glasses, dedicated sampling ports, quickconnects for periodic decontamination, filters,
etc. This is where all the time spent developing
the specialized procedures from the design and
engineering phase pays off.
Every modification activity for each piece
of equipment should have its own dedicated
specialized procedure to instruct the labor force
on how to perform the modification correctly.
Other less complex types of equipment such as
grease-lubricated bearings may not have any
modification procedures but only routine lubrication procedures. These applications do not
require as much of a financial or labor commitment to implement, and once the specialized
procedure is written, the technician can start
with the needed tasks immediately.

6

Re-benchmarking and
Continuous Improvement

After your newly revamped lubrication program has been up and
running for a while, it is time to re-benchmark
your program with industry best practices to see
where your program is now compared to where
it was during the initial benchmarking. This is
where all of the hard work in the previous steps
will show the financial rewards and re-enforce
that the decision to develop a real lubrication
program was worth the financial commitment.
As with any change of culture, management
and workforce, a lubrication program needs
constant refinement and continuous improvement. It is easy to slide back to the old ways of
doing things if not careful, especially if the organization has a high turnover rate in the labor
force. This is why it is so important to have
developed the specialized procedures during the
design and engineering phase, as they make it
easier to train new members of the lubrication
team and define how to do things correctly and
accurately the first time, which promotes a
sustainable culture change.
www.MachineryLubrication.com

September - October 2011

| 45

ML

LUBE TIPS

Readers
Supply Super Solutions
and Sound Suggestions
The “Lube Tips” section of Machinery Lubrication magazine
features innovative ideas submitted by our readers. Additional tips can be found in our Lube-Tips e-mail newsletter. If you
have a tip to share, e-mail it to us at [email protected]. To sign up
for the Lube-Tips newsletter, visit www.machinerylubrication.com
and click on the “Newsletters” link at the top.

Use Crackle Test to Detect
Water Contamination
If an oil is looking cloudy, the problem could
be water contamination. The crackle test can
generally be relied upon to confirm the presence
of water.

same time degrade another. When specified concentrations of additives become unbalanced, overall oil quality can be affected.

Oil Reclaiming vs. Oil Re-refining
Although definitions vary, the general difference between oil
reclaiming and oil re-refining is:
• Reclaiming removes solids, water, gas and other impurities
extractable by vacuum dehydration and filtration.
• Re-refining removes both soluble and insoluble impurities and
most additives, effectively bringing the used oil back to a pure
base stock. It would then need to be readditized.

Check Your Records to Control Oil Losses
If you decide to implement a program to control oil losses, one
of the first steps you can take is to check historical records of the
amount purchased compared with the amount sent for disposal.
Try to account for the difference by looking for leaks, products
consumed in the process, evaporative losses and products wasted
due to contamination or misapplication.

Know the Pour Point
The pour point is the lowest temperature at which an oil will flow. This property
is crucial for oils that must flow at low
temperatures. A commonly used rule of
thumb when selecting oils is to ensure that
the pour point is at least 10 degrees C (20
degrees F) below the lowest anticipated
ambient temperature.

What You Should Know
When Using Additives
Regarding the use of aftermarket additives and supplemental
oil conditioners, keep in mind that some base oils respond well to
additives while others may not. Also, increasing the percentage of
a certain additive may improve one property of an oil while at the
46 |

September - October 2011

Avoid Additive Leaching
Particle contamination in a lubricating or hydraulic system is
widely known as one of the most devastating contaminants. One
effect of particle contamination that is rarely discussed is additive
leaching. Many additives attach to particles and are removed along
with the particle by filtration.

Oil Sampling Strategies
When sampling new oil deliveries for testing, one strategy is to
pull the sample from just above the drum or tanker compartment
bottom — where contamination is most concentrated. Dispensing
lines from bulk transports may also be a good choice (the first and
last fluid out).
www.MachineryLubrication.com

Automotive Lubrication

BACK PAGE
BASICS

JEREMY WRIGHT | NORIA CORPORATION

Comparing GASOLINE
and DIESEL
ENGINE Oils

I’ve been instructing the Fundamentals of Machinery Lubrication course for a few years now, and many times the
course has been the birthplace of the articles I’ve written. The questions and discussions in the course are very representative of what
the average maintenance professional is curious about. Most tend
to like the discussions about passenger car and truck oils because
they not only affect them at work but also at home. In fact, I use
this curiosity to my advantage. If I ever notice a subject is starting to
bore an audience, I’ll find a way to incorporate an automotive twist
to it. Soon all the ears seem to perk up. This article is no different. I
plan to explore the similarities and differences between gasoline and
diesel engine oils to appease your curiosity.

Getting the right viscosity is
of the utmost importance.
In the broadest sense, gas and diesel engine oils have the same
anatomy or makeup. They are formulated from the blending of
base oils and additives to achieve a set of desired performance
characteristics. From this simple definition, we start to diverge
when examining the lubricant’s required performance for each
engine type.

Emissions and the Catalytic Converter
A catalytic converter is a housing that contains porous metal
filler located between the engine and muffler in the exhaust system.
Its role is to convert toxic emissions coming from the engine to stable
byproducts before they enter the atmosphere. Some of the byproducts of combustion (lead, zinc and phosphorus) can severely cripple
the converter’s ability to perform this job. Therein lies the first major
difference between the oils. Diesel engine oils have a higher anti-wear
(AW) load in the form of zinc dialkyldithiophosphate (ZDDP). The
catalytic converters in diesel systems are designed to be able to deal
with this problem, while the gasoline systems are not. This is one of
the main reasons you don’t want to use a diesel engine oil in your
gasoline engine. If your automobile was built prior to 1975, there is
a good chance it does not have a catalytic converter, and thus the
above statements do not apply.
48 |

September - October 2011

Viscosity
Viscosity is the single most important property of a lubricant. When
I am working as a consultant and designing a lubrication program,
one of the first steps I take is to calculate required viscosities. Getting
the right viscosity is of the utmost importance. The selected viscosity
needs to be pumpable at the lowest start-up temperature while still
protecting the components at in-service temperatures.
Typically, diesel engine oil will have a higher viscosity. If we were
to put this higher viscosity in a gasoline engine, several problems
might arise. The first is heat generation from internal fluid friction.
I’ve covered before how this heat affects the life of an oil. A good rule
of thumb is that for every 10 degrees C you increase the temperature,
you cut the life in half. The second problem is the low-temperature
pumpability of this higher viscosity. During cold starts, the oil may
be very thick and difficult for the oil pump to deliver to the vital
engine components in the lifter valley. This most certainly will lead to
premature wear, as the components will be interacting without the
benefit of lubrication.

Additive Levels
Diesel engine oil has more additives per volume. The most prevalent are overbase detergent additives. This additive has several jobs,
but the main ones are to neutralize acids and clean. Diesel engines
create a great deal more soot and combustion byproducts. Through
blow-by, these find their way into the crankcase, forcing the oil to
deal with them. When you put this extra additive load in a gasoline
engine, the effects can be devastating to performance. The detergent
will work as it is designed and try to clean the cylinder walls. This
can have an adverse effect on the seal between the rings and liner,
resulting in lost compression and efficiency.
So how do you know if an oil has been designed for gasoline or
diesel engines? When reading a label, look for the API (American
Petroleum Institute) doughnut. In the top
section of this doughnut will be a service
designation. This designation will either
start with an “S” (service or spark ignition) for gasoline engines or a “C”
(commercial or compression ignition)
for diesel engines.
www.MachineryLubrication.com

Level 1 Certification Preparation

“The information from this course
could save my company as much
as $20,000 in monthly oil costs.”
Jeff Smith, Maintenance Planner,
Mueller Copper Tubes

Noria Skills Training

Fundamentals of

MACHINERY
LUBRICATION
Learn Precision Lubrication Skills
For Maximizing Machine Reliability
Here’s a Sample
of What You’ll Learn:
How to build a safe and effective
lubricant storage and handling program
How to rate filters and select the right
filtration for the job
Lubricant labeling and coding systems -what works and what doesn’t
Industry’s best procedures for greasing
electric motor bearings
How to get the right lubricant in the
right place at the right time and in
the right amount

Presented by

Enroll Today! Visit Noria.com or call 800-597-5460

Noria Corporation

Apply What You Learn
And Reap The Benefits
Who Should Attend?













All Maintenance Professionals
Lubrication Technicians
Craftsmen or Millwrights
Equipment Operators
Laboratory Analysts
Lubrication Engineers
Maintenance Managers
Maintenance Supervisors
Manufacturing and Industrial Engineers
Operations Managers
Predictive Maintenance Technicians
Reliability Engineers

An Organized And Safe
Lubricant Storage Room
Solve Water-In-Oil
Problems
Reduce Electric Motor
Failures and Replacement
Costs

What Industries
Will Benefit?

Stop Pesky Oil And
Hydraulic Fluid Leaks


















Leakage is a festering sore to a machine
maintenance program. It is often the
symptom of a host of other problems. If left
unchecked, reduced machine performance
is imminent. Eliminating leakage involves
the lubrication and oil analysis programs
and should be a principal goal.

Aerospace
Automotive Manufacturing
Earthmoving
Food and Beverage
General Manufacturing
Lumber and Wood
Municipal Utilities
Petrochemical
Pharmaceuticals
Power Generation
Primary Metals
Process Manufacturing
Pulp and Paper
Rubber and Plastic
Textile
Transportation

If You Use Any Of These
Machines, This Training
Is A Must:














2

Electric Motors
Compressors
Diesel Engines
Final Drives
Gas Turbines
Gearboxes
Hydraulic Systems
Hydrostatic Transmissions
Paper Machines
Process Pumps
Rolling Mills
Steam Turbines
Blowers/Fans

Extend
Machine Life
By Up To

10X

Squeeze Maximum Life
From Lubricants
Lubricants and hydraulic fluids can have
infinite life when specific operating conditions
are stabilized. The rising costs of new
lubricants and the disposal costs of used
fluids are directives for change. Learn a
proven action plan for extending fluid life.

Improve Health
And Workplace
Safety

A More Effective
Oil Analysis Program
Effectively Troubleshoot
Lubricant-related Machine
Failures
Stop Costly
Bearing
Failures
Compare And Select The
Best Lubricants For The Job

When the goals of a lubrication program
are in sync with the oil analysis program
objectives, oil analysis becomes far more
effective. Learn how to align the programs
for maximum results.

Reduce Energy
And Fuel Costs
Create More Effective
Lubrication PMs

With hundreds of lubricant types, base
stocks, additive packages and viscosity
grades to choose from, how can a person
decide which lubricant is right for a machine?
The options are endless… synthetic or
hydrocracked?… EP or AW?… naphthenic
or paraffinic?… ISO VG 32 or 68?

Solve
Annoying
Hydraulic System Problems

Improve Equipment
Meantime Between Failures

Spend Less On Lubricants
And Filters – Not More

Enroll Today! Visit Noria.com or call 800-597-5460

Take The Guesswork Out Of
Machinery Lubrication
If you aren’t using the correct lubricant at the right time in the right quantity and in the
right place, you could be doing your equipment more harm than good. Modern
lubrication programs have changed considerably from “old school” methods that
have been passed down through generations.
This course contains a strategic collection of the very best practices for applying
and managing lubrication that you can take home and begin using right away.

Satisfied Customers Say
It Best…
“Packed with powerful information that can be
applied with measureable results, this course
provides the right training to influence a
cultural change in maintenance and operation
organizations.”
Brian Baldwin, Reliability Engineering Manager, Dynergy

You’ll Gain Practical New Skills That You
Can Use Right Away:
The Secrets Of Lubricant Selection.
This course will empower you with the knowledge to understand
important lubricant properties and strategies to select the correct
lubricant for each machine application.

The Best Practices For Lubricant Storage,
Handling And Dispensing.
Learn how award-winning maintenance programs design lube storage
areas, dispensing stations and transfer carts.

“ABSOLUTELY AWESOME! Should reduce
downtime 25 to 50 percent.”
Scott Gilreath, Lube Tech, UNICCO

“Until I attended this training, I had no idea how
poor our best practices were. Improvements
will be easy. Justifications will be easy.
Recouping the cost of this class will take
about a week!”
Tim Pendley, Mechanical Engineer, Westlake Chemical

The Four Rs Of Lubrication.
Right lubricant, right time, right quantity and right place. If these four
basic elements aren’t properly addressed, you could be doing your
equipment more harm than good. Learn the newest methods for
implementing the best lubrication practices.

“Implementing the basic principles taught
during this training would prevent premature
failure of most all of our rotating machinery!”
Brittany Russo, Reliability Engineer, Braskem

Grease Gun Or Lethal Weapon?
In the hands of an untrained operator, a grease gun can deliver pressure
up to 15,000 psi. That’s 30 times what a typical bearing seal can
handle. Once the bearing seal is broken, the bearing is on its way to
early failure. This course will teach you proper grease gun practices.

“I think the information I learned can improve
our hydraulic systems by 40 percent.”

Effective Oil Analysis With Precision
Oil Sampling.

“This training set a good foundation of
knowledge to make a measurable difference
in our lubrication program.”

Learn how to get data-rich oil samples, exactly where to install oil
sampling ports, and what sampling
equipment should and shouldn’t
be used.

What You Get
When You Attend
• Case Studies
• How To’s
• Worksheets

• Checklists
• Look-up Charts

When you leave this course, you’ll consider
your course manual an indispensable on-thejob reference for years to come.

Vernon Player, PDM Tech, International Paper

David Hull, Reliability Supervisor, Holcim, Inc.

“This course has provided me with an in-depth
view on how to create a world-class lubrication
program.”
Dennis Hill, Facility Engineer, Alcoa

“Vendor-neutral
Makes A Difference!”
Alfredo Romaro,
Maintenance Technician,
Kawneer Company

Enroll Today! Visit Noria.com or call 800-597-5460

3

Fundamentals Of Machinery Lubrication

Course Outline
Join This List Of World-class
Companies That Have
Benefited From Noria Training
3M
Alabama Power
Alcoa
Alumax
Ameren
American Electric Power
ArcelorMittal
Archer Daniels Midland
Barrick Goldstrike
BHP
Boeing
Boise Cascade
BP
Cargill
Castrol
Caterpillar
Centralia Mining
Chevron
Citgo
Clopay
ConAgra Foods
ConocoPhillips
Constellation Energy
Dow Chemical
Dow Corning
DTE Energy
DuPont
Dynegy
Eli Lilly
Entergy
ExxonMobil
First Energy
Florida Power
Ford Motor Co.
Formosa Plastics
General Electric
General Motors
Geneva Steel
Georgia Pacific
Georgia Power
Goodyear
Great Lakes Chemical
Harley-Davidson
Holcim
Honeywell
Intel

4

Heinz
Houston Metro Transit
International Paper
Invista
John Deere
Kinder Morgan
Koch Industries
Lockheed Martin
Lukens Steel
M&M Mars
MillerCoors
Michelin
Mosaic
Noranda Aluminum
Nova Chemicals
Owens Corning
OxyChem
Pacific Gas & Electric
Peabody Energy
Pfizer
Powder River Coal
PPG Industries
Procter & Gamble
Progress Energy
Reliant Energy
Rio Tinto
Seattle Times
Seminole Electric
Shell Oil
Southern Company
Temple-Inland
Texaco
Texas Instruments
Toyota
TXU Energy
Unilever
U.S. Army
U.S. Navy
U.S. Postal Service
USG Corporation
Verso Paper
Via Rail Canada
Westinghouse
Weyerhaeuser
Whirlpool
Willamette Industries

How Lubrication Affects Machine
Reliability
• Financial benefits from achieving lubrication
excellence
• Four equipment maintenance strategies and
when each applies
• Important implementation steps to lubrication
excellence
Lubrication Fundamentals
• Six important functions of lubricating oils
• How oils and greases are formulated and why it
is important
• How friction is generated in lubricated machinery
• The importance of oil film thickness and critical
clearances

Lubricating Grease Application Methods
• How to protect against incompatible grease
mixtures
• Advantages and disadvantages of centralized
lubrication systems
• Best practices for greasing motor bearings
• How to control pressure when greasing bearings
• The unique problems caused by over-greasing
– specific steps to eliminate
• 3 critical instructions to give your electric motor
rebuild shop
• Comparing single- and multi-point lubrication
options
• How to calculate greasing intervals and quantity
• Best practices for ultrasonic/sonic-based greasing

Understanding Additives, Base Oils
And Grease Thickeners
• How lubricant properties irreparably change
• Seven important physical properties of a base oil
• The importance of API’s five base oil categories
• What causes grease to dry out and 18 ways to
prevent it
• How to detect the root causes of lubricant oxidation
• When to select one of the six most commonly
used synthetic base oils
• How to use temperature to determine the right
base oil for your machine
• How to select grease thickeners for your application

Lubricating Oil Application Methods

Lubricant Performance Properties
• Key additives that enhance lubricant performance
• Viscosity grades, measurement and reporting
• Why Viscosity Index is important
• What causes oil viscosity to change and how to
set monitoring limits
• Lubricant performance tests and reporting
– what you need to know
• How water contamination generates other
contaminants
• How to control and eliminate aeration problems

• How to select journal bearing viscosity based on
speed

Food-grade And Environment-friendly
Lubricants
• Important USDA requirements and government
regulations for food-grade lubricants
• What you need to know about food-grade
additives, base oils and grease thickeners
• Guidelines for food-grade lubricants

• Best practice guidelines for storing spare gearboxes – lubrication matters!

Enroll Today! Visit Noria.com or call 800-597-5460

• Overview of oil lubrication methods and devices
• How to use oil mist and other automatic
lubrication methods
• Using pressure spray methods for gearboxes
• Best practices for the maintenance of grease
guns and fittings
• How to protect against problems caused by
constant-level oilers
• Overview of single-point direct lubrication systems
Journal Bearing Lubricants
• The 8 most common journal bearing lubrication
problems

Rolling-element Bearing Lubricants
• The nine critical factors affecting rolling-element
bearing lubricant selection
• How to convert required operating temperature
viscosity to ISO viscosity grades
Gear Lubricants
• 5 key requirements for gear oil
• How to select the best viscosity for a gear lubricant

• 10 conditions that may require synthetic gear
lubricants
• Lubrication best practices for enclosed gears
– a 12-point checklist
• Mastering the challenges of open gear lubrication

Fundamentals Of Machinery Lubrication

Automotive And Mobile Equipment
Drive-line Lubricants
• How to read a motor oil label – what really matters
• The six critical objectives a motor oil must accomplish
• Understanding API service classifications for
engine and gear oils
• The No.1 reason automatic transmission fluids fail
and how to protect against it
• Service classifications for automotive greases – how
to select
• Extending engine life – surprising engine oil filter
study results
Compressor Lubricants
• Steps you can take right now to combat compressor
lubricant failure
• The most common compressor lubricant stressors
• When to use synthetic compressor lubricants
and why
Steam And Gas Turbine Lubricants
• Why turbine/generator lubricants are the No.1
contributor to forced outages
• Comparing steam and gas turbine oils – how
they differ
• Checklist for best practice steam turbine lubrication
Hydraulic Fluids
• How to select the ideal hydraulic fluid viscosity for
gear, vane and piston pumps
• Nine key hydraulic fluid requirements and why
they matter
• Specific conditions that may require a synthetic
hydraulic fluid
• Fire-resistant hydraulic fluids – what you need
to know
• Hydraulic system maintenance best practices
– 21-point checklist
Contamination Control
• Strategies for building reliability through
contamination control
• The seven most destructive contaminants and how
to control them
• Specific steps for managing a proactive lubricant
management program
• The ISO Solid Contaminant Code – understand it,
track it
• 10 ways to get more mileage out of portable
filter carts
• How dirt, metal particles and soot mechanically
destroy machine surfaces

• Guidelines for controlling machine surface fatigue
and extending machine life
• The No.1 cause of machine wear and how to manage it
• How to set realistic cleanliness levels for lubricants
• Effective lubricant contamination control strategies
for extending machine life
• 4 ways water contamination attacks lubricant
additives
• How to set limits for water-in-oil contamination
• Managing the root causes of foam and aeration
• Best practices for excluding and removing
contaminants
• The right way to control contamination in tanks and
sumps
• How oil filters are rated
• Calculating the clean-up rate for portable filters
• Best practices for removing water contamination
from oil
• The unique problems created by varnish – how to
remove and stop it

• Portable oil transfer and filter cart selection advice
• How and where to store oil transfer and filter carts
• Understanding and managing lubricant storage life
• Keeping grease fresh – best practices for storage
Design And Inspect for Lube Excellence
• World-class strategies for accessorizing equipment
for lubrication excellence
• Seven critical accessories for lubricant inspection
and sampling
• The right machine accessories for effective
contamination control

Used Oil Sampling And Analysis
Fundamentals
• What oil analysis can tell you
• Types and categories of oil analysis
Oil Drains, Flushing And Reservoir
• Applications for oil analysis
Management
• Overview of oil analysis tests
• How to optimize and extend oil change intervals
• Elements of a successful oil analysis program
• Interval vs. condition-based oil changes
• How clean should oil sample bottles be?
– pros and cons
• How to find the best sampling locations
• Metrics for monitoring lubricant consumption
• Oil sampling valve and hardware recommendations
• Best practices for oil changes
• A quick method for optimizing sampling intervals
• Know how and when to perform a flush
• An oil sampling technique that ruins trending
• The best procedures for oil draining and refilling
• The importance of primary and secondary
• How and when to use the bleed-and-feed strategy
sampling points
for extending oil drains
• Advice for sampling hard-to-reach machines
• Selecting the right cleaning and flushing procedures
• How to properly sample circulating systems
Storing, Handling And Managing Lubricants • Safe, effective high-pressure sampling from
hydraulic systems
• How to set up a world-class lube room
• How to know when to reject a new oil delivery

Essential Field Inspections
• 12 questions your oil filter will answer about your
machine
• How to implement a lubricant consolidation
• Visual inspections you can get big results from
program and select suppliers
right now
• Used lubricant storage, handling and disposal best • Quick tips for using scent, sound and touch to
practices
inspect lubricants
• Bulk lubricant storage do’s and don’ts
• How to optimize your lubricant selection and
procurement process

• Guidelines for storing and handling drums
• Lubricant dispensing options and what you must
avoid
• Lubricant coding and identification systems
– what works and what doesn’t

Take This
Course Online!
Get Started Now
Visit LubeIQ.com

Enroll Today! Visit Noria.com or call 800-597-5460

5

Trainers
Get Certified!
Level I certification
testing will be held on
the Friday following the
training by the International
Council for Machinery Lubrication.

How To Certify
There are two ways to register for a
certification exam.
Online:www.LubeCouncil.org
Phone: 918-259-2950
Which Certifications?
This course is designed to help you
prepare for the following ICML certification
exams:
• Level I Machine Lubricant Analyst
(MLA)
• Level I Machine Lubrication
Technician (MLT)
Find out more about these ICML
certification exams at the ICML web site:
www.LubeCouncil.org
What Is ICML?
The International Council for Machinery
Lubrication (ICML) 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 analysis.

Jim Fitch
Jim Fitch, a founder and president of Noria Corporation, is a highly
sought-after consultant and trainer described by his clients as “insightful,
dynamic and thorough.” He has advised hundreds of companies on
developing their lubrication and oil analysis programs and has taught
more than 400 training courses in more than 20 countries.

Jeremy Wright
Jeremy Wright, a Noria senior instructor, provides a lively interactive
forum for learning at his courses. As a consultant, Jeremy has helped
numerous Fortune 500 companies develop lubrication procedures,
benchmark to best practices and implement world-class lubrication
programs.

Bob Scott
Bob Scott brings to his courses a wealth of “in the trenches” experience.
His practical “how to” advice and engaging teaching style consistently
receive top scores from audiences. You’ll reap the benefits from his
25+ years of experience with lubricants, lubrication and oil analysis
and come away from the training with solid, practical skills.

From Our Resource Center...
The Level 1 Study Packet
The Level 1 MLT / Level 1 MLA Study Packet Includes:
Flash Card Pack 385 flash cards to help you prepare for both
ICML Level I MLT and Level I MLA certification.
125-Question Practice Exam This multiple-choice practice
test is a great self-assessment tool and helps you prepare for both
ICML Level I MLT and MLA certification. Licensed for use by
one person.

Preparation Tools For
ICML Level 1 MLT
And Level 1 MLA

How To Take A Multiple-Choice Exam Includes advice from professionals who have
passed ICML certification exams as well as helpful hints for the night prior to the exam, steps to take
before entering the exam room, techniques to manage your time during the exam and advice for
handling different types of questions.

On-Site Training

Lubrication Fundamentals Discusses lubricant basics, machine elements that require lubrication,
methods of application, lubrication, lubricant storage and handling, and lubricant conservation.

We can customize
Fundamentals of Machinery
Lubrication – or any of our other courses
– to meet your unique needs. We’ll
provide expert instruction at a time and
place most convenient for your group.
Want to know more? Call 800-597-5460.
Whether you have 5 or 500 people to
train, Noria is the answer.

Oil Analysis Basics Presents the fundamentals of oil analysis for machinery condition monitoring
in an easy-to-understand format. You’ll learn everything from how to take a proper oil sample to
how to select a test slate for your applications.

6

The Practical Handbook Of Machinery Lubrication Once you start reading this book,
you probably won’t stop until you finish it. It is that easy to read. You’ll find understandable
explanations of how lubricants work, what they’re made of and how they break down.
Topics ranging from engine lubricants to industrial oils and hydraulic fluids are covered.

Enroll Today! Visit Noria.com or call 800-597-5460

Retail Price: $410.95

Your Price: $355

Plus $14 for shipping in the U.S.

Fundamentals Of Machinery Lubrication Registration Form
❑ YES! Please register me for the three-day Fundamentals of

2011 Locations And Dates

Machinery Lubrication training course for only $1,195 per person.

4 Ways To Register

@

Online
www.noria.com

Call toll-free!
800-597-5460 Or 918-749-1400

Mail the
registration form!

Fax your registration!
918-746-0925

Training Course

The phone numbers below are for booking hotel reservations only.
To register for the course call 800-597-5460 ext. 143.

Seattle, WA

Branson, MO

July 26-28, 2011
Red Lion Hotel
18220 International Blvd
Seattle, WA 98188
800-733-5466

October 4-6, 2011
Hilton Promenade at
Branson Landing
3 Branson Landing
Branson, MO 65616
417-336-5500

Nashville, TN

Course City: __________________________________________________________
Course Date: __________________________________________________________

Who Will Be Attending
Mr./Ms.: _____________________________________________________________
Job Title:_____________________________________________________________
E-mail: ______________________________________________________________
(Please list additional registrations on a separate sheet and attach)

August 16-18, 2011
Sheraton Nashville Downtown
623 Union Street
Nashville, TN 37219
800-325-3535

November 8-10, 2011
Chateau Bourbon
800 Iberville Street
New Orleans, LA 70112
888-404-6875

Las Vegas, NV
September 20-22, 2011
Rio All-Suites Hotel & Casino
3700 West Flamingo Road
Las Vegas, NV 89103
888-746-6955

Company Information
Organization: __________________________________________________________

New Orleans, LA

San Diego, CA
December 6-8, 2011
Courtyard by Marriott
595 Hotel Circle South
San Diego, CA 92018
619-481-5720

Check Noria.com for more dates and locations

Address: ______________________________________________________________
Mail Stop: ____________________________________________________________
City:________________________________ State/Province: ____________________

Registration Information

Country: ____________________________ Zip/Postal Code: ____________________

Check-in: Tuesday, 7:30 a.m. – 8:00 a.m.
Program: Tuesday – Thursday, 8:00 a.m. – 4:00 p.m.
The fee for Fundamentals of Machinery Lubrication is $1,195 per
person. For fast registration, call 800-597-5460 ext. 143 toll-free
between 8 a.m. and 5 p.m. central time Monday through Friday.
Or, fax your registration form to 918-746-0925 at any time. The fax
line is open 24 hours a day, seven days a week. We will send a
confirmation of your registration via e-mail. If your confirmation
does not arrive within 48 hours, please contact us to process your
registration immediately. In lieu of cash, check and credit cards are
preferred when paying at the training site.

Phone: ______________________________ Fax: _____________________________
E-mail:

_________________________________________________

Industry Information
❑ Agricultural
❑ Automotive Manufacturing
❑ Aviation, Rail, Maritime, Trucking
❑ Chemicals & Allied Products
❑ Construction & Allied Products
❑ Consulting/Services/Training
❑ Food Process Manufacturing

❑ General Manufacturing or Other
❑ Government/Military
❑ Laboratory
❑ Mining/Metals
❑ Petroleum Products & Refining
❑ Pharmaceutical
❑ Plastics & Allied Products

❑ Pulp & Paper, Lumber
❑ Textiles & Apparel
❑ Tire/Rubber
❑ Tobacco
❑ Utilities (Electric, Water,
Gas, Waste)

❑ Other

What’s Included

Certification Study Packet

Quantity

The Level I MLT/MLA Certification Study Packet - $355

______

$14 for shipping will be added to all study packet orders.

Cancellations And Substitutions

Method Of Payment
Payment is due before
the course

❑ Check enclosed payable to:
Noria Corporation
Mail to:

Noria Corporation
ATTN: Training
1328 East 43rd Court
Tulsa, OK 74105

❑ Charge to:


Your fee provides you the best training around, a comprehensive
manual, a free package of training materials, continental breakfast,
lunch each day and refreshments. Certification exam fees are not
included.







You may cancel your registration prior to the course date or send a
substitute. If you cancel prior to the course date, we will refund
your entire payment, cancel your invoice or, if you prefer, apply
your payment to another Noria program of your choice scheduled
within 12 months of your original event. Please note that if you do
not cancel and do not attend, you are still responsible for payment.

Card Number: __________________________________
Expiration Date: ________________________________
Name on Card: __________________________________
Signature:______________________________________

❑ Our Purchase Order is attached.
P.O.# ______________________________

Note: If you’ve already registered by phone, fax or online, please do not return this form.

Certification Exams
Certification testing is offered by the ICML the morning following
this training course at the same hotel. Please contact the ICML to
register for the certification exam or register online at their web site:
International Council for Machinery Lubrication
Phone: 918-259-2950 • Fax: 918-259-0177
E-mail: [email protected] • Online: lubecouncil.org

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