Machinery Lubrication May - June 2010 - Ecn5.com

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Learning Sessions Essentials for Best-Practice Lubrication PMs and Inspections Jim Fitch, Noria Corporation Daily one-minute inspections can often be more effective than even the most sophisticated oil analysis program performed monthly. The key is high frequency (daily) and the revealing quality and thoroughness of the inspection. Similar to fishing, you can’t catch a fish unless your hook is in the water (inspection frequency), and you’ve got to know how to fish (quality of the inspection). Leading organizations have learned these skills. In this session, you’ll learn the techniques of these essential inspection practices. What It Takes to Build an Award-Winning Lubrication Program Staley, predictive maintenance analyst, Energizer Battery Company In this session, Rick Staley will discuss the lean journey Energizer’s lubrication program went through – from dirty oil entering the plant to its current status as an international award-winner (2009 Augustus H. Gill Award recipient). He will stress pitfalls, challenges and how to gain support from management to get buy-in. He will cover oil analysis trending, how early detection paid huge benefits and proper sampling techniques. The presentation will consist of the fundamentals, which is the foundation to a strong program. Also covered will be setting standards that must be maintained to prevent setbacks (it’s much easier to hold a standard than to slip and have to rebuild), performing audits for these set standards, and choosing the correct personnel for positions. What Makes a Good Lubrication PM? Mark Barnes and Jason Kopschinsky, Noria Corporation Lubrication preventive maintenance (PM) tasks traditionally have been vague at best. It is still not uncommon to come across a lubrication PM for a critical machine that simply states: “Lubricate the machine.” This special double session will explore what really makes a good lube PM and what format it should be presented in. You’ll learn why and how to use a variety of formal PMs, which include full reference procedures for the new lube technician, task sheets for the experienced tech and visual documents for operators. Selecting a New Lubricant Supplier – Beyond Price Jason Kopschinsky, Noria Corporation There’s more to selecting a new lubricants supplier than the price of lubricants. Price does play a role, but today, most suppliers offer a range of products and services to support your lubrication excellence initiatives. This session will help you navigate the window dressing and help you formulate a rational and systematic approach to selecting a new lubricant supplier. A Comprehensive Look at How a Temple-Inland Plant Changed its Lubrication Program Randy Hall, predictive maintenance technician, Temple-Inland In this case study session, Randy Hall will share his insights on the progress of the Temple-Inland Gypsum Wallboard plant’s lubrication program. Included in this presentation are the improvements made to the lubrication storage shed, servicing equipment and bulk oil filtration. He will highlight the modifications that were made to reservoirs and gearboxes to help prevent contamination and make servicing easier. He will share some ideas that didn’t work very well and what was done to correct them. He also will provide a list of items used and where they were purchased. Oil Analysis Gets to the Root of a Power Plant’s Gearbox Problem James D. “Pete” Peterson, senior CBM specialist, Alabama Power Company This case study session explores the action plan of Alabama Power Company when a problem was discovered on a pulverizer gearbox. This was the very first “find” that the speaker was involved in after being brought on to the plant’s condition-based maintenance team. It provides a good demonstration of the importance of having “in-house” oil testing capabilities. Routine analysis of the oil from the pulverizer gearbox showed a high ferrous index. Further investigation revealed a “wiped” thrust bearing, which was replaced. Three years earlier, before the in-house oil lab was set up, a similar problem (wiped thrust bearing) was not detected, resulting in a catastrophic failure of the gearbox, leading to a complete gearbox rebuild. Designing Your Contamination Control Strategy Jarrod Potteiger, product and educational services manager, Des-Case Corporation Studies show that fluid contamination is responsible for as much as 82% of machine wear. By eliminating these contaminants, you can eliminate the majority of machine wear and ultimately maximize equipment life. Of course, you can’t eliminate all contaminants, but you can reduce them. The aim should be to control contamination to the extent that provides the greatest benefit. This session will help you design an effective contamination control program and the topics covered include: defining optimum fluid cleanliness levels, identifying the most costeffective measures to achieve those targets, and finally how to effectively measure contaminant levels. You’ll learn the most common lubricant contaminants, how they affect machinery and how to stop them. Plus, you’ll leave with some simple-yet-effective methods for analyzing the cost and benefits of contamination control to ensure that available resources are deployed in the most effective way possible. Strategic Greasing for Rolling Element Bearings Stephen Sumerlin, Noria Corporation When it comes to greasing, there are many ways to get it right and get it wrong. There are a lot of misperceptions that greasing is a simple task and doesn’t require any skill or dedication. Greasing element bearings is more of an exact science than not, stemming from weighing a shot of grease from “your” grease gun to calculating re-grease volumes and frequencies. When compared to other lubrication tasks, greasing is one of the more simple tasks in execution, but it can prove to be a difficult task to execute without flaw. This session will explore the strategies for proper greasing techniques for element bearings, and will expand your perception of the dedication and precision that is required to get the most from each stoke of the grease gun. One Hydraulic Filter for Your Entire Factory – Is it Possible? Garret Hendrix, owner, Hendrix Engineering Purchasing, tracking and stocking dozens of different hydraulic filter elements burdens many companies and has a negative impact on hydraulic reliability when replacement elements aren’t available. This session will introduce you to hydraulic filter standardization based on SAE Standard J6022, with the ultimate goal of using only one filter element type for the entire factory. A case study of a standardization project implemented for a Tier 1 automotive supplier having more than 160 hydraulic power units, and approximately 80 different filter types and sizes will be presented. Filter standardization lowers inventory expenses, increases hydraulic reliability, reduces machine downtime, increases asset life and leads to a lower overall cost of production. In these times of lean manufacturing and heightened competitiveness which surely will not subside going forward, filter standardization is yet another method to achieve a reliable plant and a lower cost of operation. Oil Sampling Fundamentals: A Step-by-Step Guide to Doing it Right Jeremy Wright, Noria Corporation Proper oil sampling is critical to an effective oil analysis program. Without a representative sample, further oil analysis endeavors are futile. There are two primary goals in obtaining a representative oil sample. The first goal is to maximize data density. The sample should be taken in a way that ensures there is as much information per milliliter of oil as possible. This information relates to such criteria as cleanliness and dryness of the oil, depletion of additives, and the presence of wear particles being generated by the machine. The second goal is to minimize data disturbance. The sample should be extracted so that the concentration of information is uniform, consistent and representative. It is also important not to contaminate the sample during the sampling process. In this session you’ll learn the sampling procedures, sampling hardware and sampling locations for getting the best possible, consistent oil samples. For complete conference and expo information 6 and updates, visit conference.reliableplant.com
Your full-conference badge gets you into sessions from all three co-located conferences. Real Strategies. Measurable Results. Specifying Filter Carts Correctly for Maximum ROI Preventing Ingress Contamination through Bearing Cavity Pressurization Expert Advice on Creating a World-Class Lube Room Jeremy Wright, Noria Corporation Filter carts are an ideal way to periodically decontaminate lubricated systems. Every filter cart should be compatible with the lubricant and the intended application. When considering the addition of a filter cart to your contamination control program, there are many things to consider. This presentation will cover all of the variables that need to be accounted for to help determine exactly what details you need to provide your supplier. The leading suppliers will be able to design the filter cart to meet your exact needs, giving you the most for your investment. The 100 Failure Modes of Lubrication from RCM Analysis Terry Harris, president, Reliable Process Solutions Understanding failures modes of your equipment, processes and individual components is an important function. Every manufacturing or processing plant has rotating equipment that is performing plant functions. When this equipment stops working, your processes cease to perform their designed expectations. The negative impacts are operations downtime, reduced capacity, lower quality and EH&S incidents. Reliability-Centered Maintenance can be used to define these failure modes. Lubricants and lubrication programs have more than 100 failure modes that can be defined and controlled. Understanding each failure mode can help your plant decide how to prevent and eliminate each of them. Henry Dombroski, president, Air-Tight LLC In this session, you’ll learn about prevention of ingress contamination by means of: 1) hermetically sealing the bearing cavity; 2) pressurizing the bearing cavity with low air or nitrogen pressure; 3) controlling the pressure in the bearing cavity 24/7; 4) giving a visual indication of the amount of pressure; and, 5) indicating bearing cavity integrity 24/7. If you have current bearing contamination issues, and have tried everything, attend and learn about these alternative methods for preventing ingress contamination. Lubrication’s Role in Equipment Energy Consumption John Sander, vice president of technology, Lubrication Engineers Inc. Today more than ever before, plant managers are driven to reduce operating costs. Yet due to government regulations, they are now being asked to do things that are in direct contradiction to reducing costs, such as increased safety measures and reducing plant emissions. Surprisingly, one of the major ways to achieve these goals is through their lubrication program. It may seem far-fetched that something as seemingly minimal as lubricants can provide hidden returns. This session will describe exactly how a plant’s energy consumption and emissions can be decreased while reducing and operating expenses through a plant’s lubrication program. Rick Staley, predictive maintenance analyst, Energizer Battery Company Rick Staley was instrumental in transforming the lubrication storage room at Energizer’s factory in Maryville, Mo., into a world-class example of organization, cleanliness and functionality. In this session, he will share the lessons learned from the transformation at Energizer and will outline what’s required for creating a world-class lubrication storage room at your facility. Topics and tips will range from storage and filtration to breathers and spill containment systems to identification and safety measures. Attend this session and gain the knowledge to make over your lube room. Best Practices for the Use of Off-line Filtration Units Christopher Eger, product manager for oil services, Schroeder Industries To have the best off-line filtration requires that you understand three basic areas: What are particulate, water and gas contamination? What does contamination cost you? Where are you in regards to contamination and where do you need to be? After understanding the basics of contamination, what products are available in the market to provide you with a solution? Off-line filtration systems include filtration carts and skids, contamination monitors, dehydration systems and diagnostic equipment. Cyber Café - FREE E-Mail Bookstore Looking for more information on a session topic? Excited about learning more from an expert speaker? Review and purchase a wide range of helpful titles in the bookstore. Sponsored by: Stay connected with the office and home while you’re in Nashville. Take advantage of free e-mail access in the exhibit hall. Available during show hours. Sponsored by: “Conference was great! I will be applying many of the products and processes in my plant immediately.” Save $200 on conference fees when you register before July 30, 2010 7
Page 3 and 4: CONTENTS May - June 2010 Features m
Page 6 and 7: AS I SEE IT What’s Hot? Current T
Page 8: AS I SEE IT include the use of nami
Page 12: VIEWPOINT flushing to help prevent
Page 15 and 16: essence of why Jim Collins in his s
Page 17 and 18: BY PAUL V. ARNOLD T his isn’t Met
Page 20: COVER STORY At right, Mighty Might
Page 23 and 24: “With the air seals, we add 3 cub
Page 26 and 27: PRODUCT NEWS Hose Reel Bend Restric
Page 28 and 29: HYDRAULICS AT WORK BRENDAN CASEY Ba
Page 30 and 31: FROM THE FIELD Don’t Miss Your Op
Page 32: FROM THE FIELD lubricants are at an
Page 35 and 36: stress. Some of the factors that de
Page 37 and 38: eproducibility of the RPVOT test ha
Page 40 and 41: PRODUCT SUPERMARKET PAID ADVERTISIN
Page 42 and 43: LUBRICANT SELECTION Synthetic Lubes
Page 44 and 45: BOOKSTORE Welcome to Machinery Lubr
Page 46 and 47: Welcome to Reliable Plant 2010 3 Co
Page 48 and 49: Need a Reason to Attend Reliable Pl
Page 52 and 53: Learning Sessions How to Use a Lubr
Page 54 and 55: Learning Sessions Equipment Failure
Page 56 and 57: Learning Sessions The 3 Critical St
Page 58 and 59: Exhibitor List (as of May 14, 2010)
Page 60 and 61: Registration Nashville, TN - August
Page 62: GET TO KNOW… Talking Turkey and L
Page 66 and 67: CERTIFICATION NEWS Free MLA I Upgra
Page 68 and 69: PERSPECTIVE JASON KOPSCHINSKY NORIA
Page 70: BACK PAGE BASICS JEREMY WRIGHT NORI

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