Machinery Lubrication Home Page

On-Site Analysis Introduces Coolant Analyzer

2012-02-09T09:23:19-06:00

On-Site Analysis Inc. has introduced a new coolant analyzer that can perform nine diagnostic tests in less than a minute. With a touch of the screen, the OSA4 CoolCheck can determine the coolant formulation as well as detect problems within the cooling system.

This unique analyzer was designed to replace subjective test strips and expensive, time-consuming laboratory testing. It represents the latest advances in infrared spectrometry technology by instantly capturing data and comparing it to known norms, thereby alerting you to abnormal or severe coolant system conditions.

Incorporating an embedded XP Panel PC that is coupled with a dual-path multi-wave spectrometer, the high-tech analyzer not only conducts on-site tests on engine coolant but also comes with a small thermal printer that prints

Advice for Measuring Oil Filter Life

2012-02-08T10:52:49-06:00

"We have a filter that appears to have been in service for nearly two years without any indication of blocking. Is this normal?"

While contaminant ingression varies according to environmental and production/maintenance activity, some filter manufacturers specify a life of six months. It is generally a good strategy to take an upstream and downstream particle count to ascertain if the filter is still working properly. If not, replace the element.

Consider the maintenance history and try to establish an average life for previous elements, as this will give some indication if two years is abnormal.

However, there are a number of ways in which the filter may fail without tripping the indicator, and this may lead the unwary to believe the filter is a good value. Without

National Petrochemical & Refiners Association Changes Name

2012-02-07T10:46:12-06:00

The National Petrochemical & Refiners Association (NPRA) recently changed its name to the American Fuel & Petrochemical Manufacturers (AFPM). The trade association represents high-tech American manufacturers of virtually the entire U.S. supply of gasoline, diesel, jet fuel, other fuels and home heating oil, as well as the petrochemicals used for thousands of products in daily life.

"This trade association has been around for 110 years, serving our nation and the American people," said AFPM chairman James Mahoney, executive vice president of operations excellence and compliance for Koch Industries. "We believe our new name better describes who we are and what we do. Our members have been able to stay in business all these years – and will stay in business for many, many decades to come – because American consumers continue to choose our products in the free market."

"An America without domestic fu

Diagnosing Oil Problems with a Laser Pointer

2012-02-06T10:54:49-06:00

"I recently read that a laser pointer can be useful for identifying suspended solids and oil/water emulsions in sight glasses. How does this work?"

One of the things you are looking for is reflective light fragments indicating large solid particles suspended in the oil. You can observe this by experimenting with a new turbine oil or other rather clear oil in a sample bottle.

With the laser passing horizontally through the oil, sprinkle table salt into the open mouth of the bottle. You will see something of a laser light show as the salt falls through the light beam. Without the use of the laser, the salt in the oil is completely invisible to the eye.

Another practice is to observe the laser light beam on a white piece of paper after it passes through the oil. Is the

How to Evaluate Oil Filters

2012-02-02T11:51:27-06:00

This 8-minute, 22-second video explains what you need to know to evaluate oil filters. Learn important terms such as pore size, porosity, flow rate and differential pressure, as well as the different filter types and when each is used. Find out how the various rating systems are determined, why efficiency is critical, how to compare filters, what to watch out for, precautions to take when you increase filtration, and much more.

Eastman Chemical to Acquire Solutia

2012-02-02T08:11:59-06:00

Eastman Chemical Company and Solutia Inc. have entered into a definitive agreement under which Eastman will acquire Solutia, a performance materials and specialty chemicals company that offers a range of products including heat-transfer fluids and aviation hydraulic fluids.

The transaction, which was approved by the boards of directors of both companies, remains subject to approval by Solutia’s shareholders and receipt of required regulatory approvals as well as other customary closing conditions. The transaction is expected to close in mid-2012.

“The acquisition of Solutia is a significant step in our growth strategy and one that I am confident will strengthen Eastman as a top-tier specialty chemical company with strong, stable margins,” said Jim Rogers, chairman and chief executive officer of Eastman. “The addition of Solutia will broaden our geographic reach into emerging geographies, particularly Asia Pacific, establish a powerful combined pla

Why a Grease's Base Oil Viscosity is Important

2012-02-01T10:33:45-06:00

"Is it important to consider the viscosity of the oil used to make a particular grease if they both have the same NLGI 2 rating?"

It is critical to consider the base oil viscosity when selecting a grease. The NLGI number relates to the consistency of the grease, not its viscosity per se. It is possible to create NLGI #2 grease using ISO VG 10 base oil or ISO VG 1000 base oil. One would never use ISO VG 10 oil in an application that demands ISO VG 1000.

We shouldn't casually consider the base oil requirement when selecting grease. As an example, open gear greases are frequently NLGI #0 or #00, but they are made using very high viscosity base oil.

Easylube System Integrates Radio Frequency Identification

2012-02-01T09:03:04-06:00

Easylube has introduced an automatic lubrication system that uses radio frequency identification (RFID) technology to track and manage lube points throughout a plant. The computerized maintenance management system is designed to provide precision bearing lubrication and condition monitoring by recording each bearing specification, working condition, lubrication and maintenance history.

Exact regreasing volumes and intervals are calculated using minimum quantity lubrication (MQL) formulation. MQL software is included with each Easylube Patrol Management Kit and can be easily installed on a PC.

The system’s automatic regreasing mechanism is an electromechanical gearset incorporated in the RFID lubricators, which keep lubrication at sufficient levels. Each lubricator also features a bi-colo

Why New Oil Color Varies

2012-01-30T14:02:44-06:00

"We notice a different color in the lubricants we get from our lubricant supplier in each shipment of the same product. Sometimes the oil is lighter colored, cloudy, darker, etc. Is this a problem?"

For Group I mineral oils, slight changes in color or darkness often occur due to differences in crude stock. Color bodies in mineral oils are generally associated with sulfur or aromatic impurities. The darker the base oil, the more of these impurities you usually find. Dark color is more pronounced in higher viscosity mineral oils.

Certain additives also contribute to color, especially those containing sulfur. For instance, detergents such as calcium sulfonate can substantially darken a finished oil. If your lubricant supplier has made a formulation change, this can lead to a cor

7 Steps to Protect Gearboxes from Moisture

2012-01-27T16:21:52-06:00

"Our gearboxes operate in a humid environment. Is there any way we can effectively protect against moisture ingress?"

Common sense is the key to success. The following seven steps should help:

1. Educate maintenance staff to avoid direct jetting of water at ingression points such as shaft seals and breathers, etc.

2. If water spray is inevitable, use passive shields and deflectors to avoid direct water spray on shafts, dipsticks, fill-caps, breathers, etc.

3. Use high-performance seals that suffer less wear and offer better protection against contaminants.

4. Regularly inspect and maintain gaskets on fill-caps, hatches, etc.

5. Replace dipsticks with level indicators.

6. Keep hatches closed tight.

7. Replace a

Honeywell Technology Selected for New Pakistan Refinery

2012-01-26T09:39:08-06:00

UOP LLC, a Honeywell company, has announced that its new process technology designed to help refiners get more high-value product from each barrel of crude oil has been selected by National Refinery Limited (NRL) to maximize diesel and lubricant production in Pakistan.

UOP's Uniflex processing technology was developed to help refiners processing the heaviest portions of a barrel of crude, also known as vacuum residue, into higher-value transportation fuels. This technology can deliver 90-percent conversion of vacuum residue to transportation fuels while minimizing byproducts. Traditional bottom-of-the-barrel upgrading process technologies have only been able to convert 60 to 70 percent of vacuum residue to transportation fuels.

"Uniflex technology offers the highest conversion rate of bottom-of-the-barrel crudes to high-value products available today," said Pete Piotrowski, vice president and general manager of Process Technology and Equipment for Honeywell

Extending Oil Service Life

2012-01-25T09:10:00-06:00

"Can I expect a synthetic engine oil to extend the service life above that of a mineral oil? Also, can the service life of oil be extended by increasing sump capacity? For example, if we double the sump capacity, can we then expect the service interval to be doubled or is there a ratio?"

Synthetics can have extended drain intervals. However, the factor at which the extended drain would be assumed depends on many factors, including contamination control and exclusion, typical operating conditions of the vehicle, temperature, etc.

A larger sump equates to more additives and detergents for the same engine. Therefore, a larger sump will extend the service life. Assuming all conditions are the same, twice the oil in the sump should provide twice the service life.

Controlling Degradation in Biodegradable Greases

2012-01-23T09:11:24-06:00

During lubricant operation, temperature, pressure and load are the main factors influencing degradation. To monitor this degradation process in lubricating oils, industry has defined specific test methods involving correct sampling and analytical techniques to provide efficient information on the correct oil change interval. Applying these condition monitoring practices to lubricating greases is much more complex, especially when they are ester-based biodegradable greases. This explains why industry relies on time-based intervals (preventive maintenance) for grease-lubricated system procedures.

In order to establish a correct maintenance protocol, it is important to understand how the degradation process occurs in biodegradable and mineral greases, and to identify adequate control parameters, limits and sampling frequency (or regreasing frequency).

Oxidation Process

To evaluate the different techniques, a mineral grease and a biodegradable grease were oxidiz

Consequences of Using the Wrong Oil

2012-01-20T08:25:48-06:00

"What are the consequences of using an oil with anti-wear additives (ZDDP) in a steam turbine where it is recommended to use turbine oil?"

1. The polar nature of ZDDP will affect the air release, foaming and demulsibility characteristics of the oil. In other words, it is more likely to foam and retain air and water in suspension. This increases the risk of a wipe.

2. ZDDP hydrolyzes into hydrogen sulfide and sulfuric acid. Because water is always a risk in steam turbines, this is a concern.

3. While much less so than EP oil, ZDDP-based anti-wear oil can corrode babbitted surfaces.

4. ZDDP also might interfere with rust and corrosion inhibition.

Can Filters Remove Additives?

2012-01-18T08:54:27-06:00

"Is there a risk of altering a lubricating or hydraulic oil with 1-micron or submicron filters? For instance, could they reduce the EP additives?"

There are several ways to strip additives from lubricants. Polar aggregate separators (for example, activated alumina), vacuum or thermal dehydration, centrifugation and absorbent depth filtration all present some risk. However, with careful planning, the risk can be minimized and the benefit of contamination control maximized.

There are some classes of additives that certainly can be removed with fine depth media filtration. Many types of lubricants have defoamant additives. These are semisolid suspensions in the 5- to 10-micron range and are filterable.

Efficient 1-micron filters can potentially remove EP (sulfur and

Condition Monitoring of Tactical Vehicle Engines

2012-01-16T09:22:20-06:00

In 2004, a field trial was initiated over a four-year period with tactical and combat vehicles. The spectrum included armored reconnaissance vehicles (ARV) as well as main battle tanks (MBT). Oil samples removed from the monitoring well were taken every 90 days with an oil sampling kit normally used for aviation components. To avoid cross-contamination with other functional fluids taken from the vehicle, every sample was taken with a new sampling kit.

Among the monitored vehicles were 40 main battle tanks (Figure 1), 25 armored infantry fighting vehicles (AIFV), 16 armored howitzers, 25 armored reconnaissance vehicles (ARV) and 10 mechanized infantry combat vehicles (MICV).

Keeping Stored Gearboxes Healthy

2012-01-13T08:37:50-06:00

"How long will oil in stored gearboxes last?"

If stored properly, the oil could last several years. Consider these points when storing gearboxes:

One concern is the unit’s headspace. The gearbox should either be filled to the top with oil or stored with a preservative oil that incorporates a vapor phase corrosion inhibitor (VPCI).

Be sure to use caution when filling the unit, as filling it entirely could cause leakage around shaft seals.

If there is no VPCI, the components above the oil bath level will likely become dry and susceptible to corrosion. Even if the shaft is periodically rotated (as it should be), some components (splash-lubricated bearings) may not be lubricated.

Additionally, the breather fitting should be removed and rep

Sources of Silicon in Oil

2011-12-19T16:16:39-06:00

"What are the possible sources of silicon in oil?"

Silicon is measured by oil analysis labs to determine dirt ingression. More often than not, high silicon readings indicate dirt. However, there are several other possible sources. The four most common are:

1. Defoamant Additive — Many oils contain defoamants based on polymeric methyl silicone. Because silicone contains the element silicon, the presence of this kind of additive will show a positive silicon reading in spectrometric analysis. The typical levels of silicon seen under these conditions are around 1 to 10 ppm.

2. Silicone-based Sealant — Many sealants used for industrial and mobile applications are silicone-based. The level of silicon observed wil

The Basics of Synthetic Oil Technology

2011-12-19T09:53:25-06:00

In the 1930s, Dr. Hermann Zorn of Germany was searching for a lubricant with the properties of natural oils derived from crude oil but without the undesirable properties (high pour points, tendency to gum or gel in combustion engines, low oxidation resistance at higher temperatures, etc.). Germany was also in need of a product that was not derived from crude oil, as the nation’s access to crude oil was becoming increasingly scarce. By the mid-1940s, the fruit of Dr. Zorn’s labor included more than 3,500 different blends of esters, including diesters and polyolesters.

The first real-world trial for these lubricants came during World War II when both Germany and U.S. forces began using synthetic base oil in aircraft engines. They noticed the synthetics made engine starts much easier in colder climates (due to the high viscosity index) and significantly decreased soot deposits that would build up in oil radiators when using conventional (crude oil-derived) lubricants.

Clopay’s Lippert Reaps the Benefits of ICML Certification

2011-12-19T08:18:17-06:00

Scotty Lippert is often referred to as “ICML’s poster boy.” For 26 years, Lippert has been with his current employer, Clopay Plastics of Augusta, Ky. He was originally hired as an extrusion operator, promoted to team leader and then to supervisor before finally landing in his current position as planned maintenance specialist/lubrication systems leader, which he has occupied for the past 14 years.

Lippert truly personifies the spirit of ICML for a number of reasons, including his mentoring, his giving nature and his passion for volunteering, which are demonstrated by his involvement in his community, where he sits on several boards and committees and serves as county magistrate and county deputy judge executive.

In 2004, Scotty Lippert and Clopay received ICML’s John R. Battle Award for excellence in machinery l

How to Develop an Effective Oil Analysis Strategy

2011-12-19T08:04:20-06:00

Joining my sister at the emergency room for an issue with her son was an enlightening moment. The ER doctor walked in, reviewed some historical records on my nephew and began asking questions. As any mother would do, my sister gave the doctor a wealth of information, both relevant and not so relevant, to the current situation. It was the doctor’s job to filter the information and determine what was truly important and helpful. He kept pressing for more information and grilling my sister for clarification on even the smallest comment, which to her may have seemed inconsequential, but to him was significant.

I couldn’t help but realize that this scenario is repeated quite often in our world of oil analysis, with a few changes in characters. In oil analysis, the patient is a machine. More specifically, it is a component of something larger. The end user has the vested interest in the health of the component, and the person evaluating the oil sample data is the doctor.

DuPont’s Nesselroad Paves the Way at Washington Works Plant

2011-12-19T07:30:31-06:00

Name: John Nesselroad

Age: 61

Title: Lubrication Technician

Company: DuPont

Location: Washington, W.Va.

Years of Service: 24 years

John Nesselroad got his start in machinery lubrication in 1989, serving as a production operator, training coordinator and lubrication technician for DuPont’s Washington Works plant in Washington, W.Va. He has also worked as an equipment operator for Universal Glass, as an operator for Shell Chemical and as a production machinist for Gould. Since 2008, he has served as a lubrication technician, helping his team improve the company lubrication program and develop a proactive approach to lubrication practices.

Invest in Proactive Maintenance for Your Hydraulic Equipment

2011-12-19T07:13:36-06:00

I recently purchased a used SUV with the plan to do some traveling with the family. It’s a big trip, starting with a journey across the Nullarbor Plain from the west to east coast of Australia. If you spend 12 hours a day in the car driving, you can cover the distance in four days.

However, the Nullarbor is a desolate place. There’s not much out there. You’re lucky if you see a kangaroo or emu between gas stations, and they’re hundreds of miles apart. It’s certainly not somewhere you want to break down. This would be even more unacceptable for me, being a preventive maintenance guy and knowing if something goes wrong with the vehicle that I’m really going to hear about it from my wife.

To minimize the possibility of any nasty (and embarrassing) surprises in the middle of the desert, I took my newly acquired but pre-loved SUV down to the automobile association for a thorough workshop inspection. I dropped it off in the morning, and when

Pre-Flush for Better Oil Samples

2011-12-19T06:58:26-06:00

It is important to recognize that the amount of tubing, the size of the sample port and the volume of static oil in relation to the location of the sample port can all disturb the overall quality of the sample. For an effective, data-rich sample, appropriate pre-sample flushing volumes should be included in sampling procedures and should be specific for each individual sample port. The industry rule of thumb is to pre-flush six to 10 times the total volume of static oil in a sample tube, port, port adapter and any dead legs of pipe in the systems upstream of the sample port location.

Upgrade to a High-efficiency Filter

One of the biggest culprits for letting dirt into hydraulic and oil reservoirs is the air breather. Many systems come with a st

The Dangers of Overgreasing

2011-12-16T11:16:30-06:00

When it comes to regreasing bearings, more is not always the better option and actually can be a costly mistake. Instead, greasing should be set on a frequency with proper calculations used to determine the amount of grease needed at each relubrication. The determining factor for the amount required is based on the dimensions of the bearing or the bearing housing.

Overgreasing can lead to high operating temperatures, collapsed seals and in the case of greased electric motors, energy loss and failures. The best ways to avoid these problems are to establish a maintenance program, use calculations to determine the correct lubricant amount and frequency of relubrication, and utilize feedback instruments.

Too much grease volume (overgreasing) in a bearing cavity will cause the rotating bearing elements to begin churning

ASTM Develops New Standard Practice for Grease Sampling

2011-12-16T11:00:48-06:00

The American Society for Testing and Materials (ASTM) recently issued Method D7718-11, providing an approved standard practice for sampling critical grease-lubricated equipment.

The new standard uses the methodology of the Grease Thief, which enables users to get a representative in-service grease sample from motor bearings, gearboxes, motor-operated valves and other critical machinery, then trend the analysis results for condition monitoring.

This analysis of in-service lubricating grease not only can aid in predicting the life and condition of the grease-lubricated component, but it also can be combined with other technologies such as infrared imaging, vibration analysis and ultrasonic vibration analysis to predict when a machine may fail.

The information obtained through thes

2011 Salary Survey: What Lubrication Professionals Earn

2011-12-16T09:11:04-06:00

Machinery Lubrication recently conducted an online survey of lubrication professionals in the United States to discover what they earn based on their experience, education level, geographic location, age and other relevant factors. In addition to earning power, the survey included questions regarding company size, job security, job satisfaction and future potential.

Responses poured in from nearly every state, with Texas, California and Pennsylvania registering the most results, while Vermont, Rhode Island and Delaware were the only states not represented.

Employees from some of the industry’s largest and most well-known companies participated in the survey, including Alcoa, Cargill, Caterpillar, Dow Chemical, Holcim, Kimberly-Clark, Temple-Inland, Fluor and Entergy. We wish to extend ou

The Optimum Reference State

2011-12-16T07:38:59-06:00

These days an increasing number of companies are trying to achieve a state of lubrication called “lubrication excellence.” Others might call this “world-class” lubrication. Most understand the reliability benefit gained when excellence in lubrication is attained, yet even those who are professionals in reliability and maintenance too often have vague ideas of what defines lubrication excellence.

We all know that machines used in plant production processes are designed and built to engineering specifications intended to achieve a desired level of performance, efficiency and productivity. Using this same concept, it is reasonable to write an engineering specification for machine reliability and lubrication excellence. In the specification would be an itemized list of critical attributes needed to achieve the desired state of reliability. It should be noted that only part of the specification relates to the design and modification of the machine.

In

Don't Delay After Oil Sampling

2011-12-14T09:53:43-06:00

"After pulling a sample from a piece of equipment, will the oil sample change within the sample bottle? If so, what is the longest amount of time we should allow the sample to sit?"

The moment an oil sample is taken from a machine, the sample and the oil in the reservoir begin to experience different environments. As you might imagine, at that point the properties of the two bodies begin to deviate from one another.

The greater the period between sampling and testing, the greater this deviation will be. Yes, the properties of the sample can change over time. However, the in-service oil is more likely to experience significant change.

Once taken, samples should be tested as soon as reasonably possible. To determine a time limit for shipping samples, consider the s

How to Determine if Wrong Oil Has Been Added

2011-11-30T11:52:48-06:00

"We suspect that a small amount of an electrohydraulic control (EHC) phosphate ester fluid was added to a reservoir containing a polyalphaolefin (PAO) synthetic. What is the best way to figure out if this has in fact happened?"

For oils that have wildly different base stock chemistry, the simplest method is usually Fourier transform infrared spectroscopy (FTIR). FTIR looks for functional groups in the oil sample. These functional groups act as molecular fingerprints to identify different components in the oil, as well as common contaminants such as water, fuel and glycol.

In the case of phosphate ester contamination of a PAO, you would be looking for a peak in the FTIR spectrum around the 1,700 to 1,800 wave number corresponding to the phosphate functional group. Because this

How to Fill a Grease Gun from Bulk Containers

2011-11-21T11:53:51-06:00

This video explains how to modify your grease gun so you can fill it from bulk containers. Two different procedures for filling a grease gun from a bulk container are shown.

Questions to Ask When Sourcing an Automatic Greaser

2011-11-21T11:41:34-06:00

This video details some of the questions you should be asking whenever you source an automatic greasing system. Questions include what type of operating system best suits your needs, does the lube system include a pressure gauge on the main line, does the system have high-pressure grease fittings on each individual point, does the reservoir have a revolving paddle or a follower plate on top of the grease, does the system include guarding and steel tubing, etc.

Imperial Bearing Installation, Removal and Lubrication

2011-11-09T15:05:01-06:00

This video shows how to install, remove and lubricate an imperial bearing. Segments include preparing for bearing installation, tools required to mount a bearing, shaft tolerances, different types of bearings, dismounting a bearing, relubrication intervals and ways to achieve long bearing life.

Pre-lubrication Procedure for EMD Locomotives

2011-11-09T14:40:30-06:00

This video shows the type of pre-lubrication that is required if an EMD locomotive has been shut down for more than 48 hours. Step-by-step instructions detail how to open the engine sump cover, insert the pre-lubrication pump inlet pipe into the engine sump, open the main lube oil pump discharge pipe dummy, connect the pre-lube pump outlet pipe to the main lube pump discharge pipe dummy hole, etc.

Prevent Engine Wear with Air Filtration

2011-11-04T11:06:14-05:00

"I run a fleet of heavy-duty trucks and have learned much about the importance of keeping engine oil clean. My question is how relevant is intake air cleanliness."

On a volume basis, diesel engines can use more than 20,000 times more air than fuel. Airborne dirt is abrasive to engine components, and therefore efficient air filtration is vital in avoiding premature engine wear.

In particular, turbocharger compressor blades are eroded by airborne dirt. This results in reduced efficiency causing engine power loss, increased fuel consumption and higher exhaust emissions.

Quality air-filtration systems are designed to trap most harmful dirt, but regular attention is required to assure efficient filtration without causing air restriction and intake system leaks.

Controlling Lubricant Degradation with Nanoporous Materials

2011-11-01T13:08:12-05:00

Lubricant antioxidants traditionally have attempted to halt the chain-reaction mechanism of oxidation by targeting two key points — radical scavenging and peroxide decomposition. With increasing requirements for performance, lower costs and strict environmental demands, there is an increasing interest in environment-friendly oil formulations. While using traditional antioxidant additives in lubricants leads to an improved overall performance, it comes at the expense of higher costs and environmental concerns.

Materials based on molecular sieves are envisioned as effective, environmentally safe, economical and reusable alternatives to traditional antioxidant additives. These nanoporous materials can be engineered to capture oxidized byproducts and residual water produced during the early and late stages of lubricant degradation.These materials possess tailored porosity along with a variable morphology. Therefore, they can be considered as a trapping s

How Filter Quality Affects Oil Analysis

2011-10-27T16:46:06-05:00

"How does the quality of a filter impact oil analysis results (contamination and ferrous wear)? Is it correct to say that using filters with different beta ratios in the same equipment will result in different analysis results? Is there any correlation in setting alarm levels and filter beta ratios?"

The quality of the filter is directly proportional to the cleanliness and wear rate of the system. The higher the beta for the same micron pore size will result in a faster cleanup rate. Thus, it is better able to control ingression of solids in the system. The main system ingression sources typically are seals, breathers and oil top-ups, and wear debris. When catalytic wear metals are removed from the oil, the lubricant will experience longer oxidative life.

Therefore, expect

How Much Cash Is Your Poor Lube Practices Costing You?

2010-02-19T09:17:01-06:00

An important part of lubrication excellence is being able to identify the fiscal opportunity that a well-designed and properly executed lubrication program will provide.

Valero Energy's Lubrication Transformation

2010-02-19T09:10:01-06:00

Valero Energy’s 950-acre refinery in Paulsboro, N.J., was preoccupied, busy, absorbed with its primary task of converting more than 175,000 barrels of sour crude oil every day into polished lubricant base-stocks, liquefied petroleum gases, gasolines, jet fuels, mid-distillate products, asphalt, petroleum coke and molten sulfur. The management mantra “nothing is wasted from a barrel of crude” was established to underscore the business goals of efficiency, productivity and profitability. Valero paid great attention to the oil products being refined and then sold by the company. However, opportunities existed to upgrade the refinery’s system for purchasing, storing and dispensing oil products for use in production equipment at the site.

A Q&A Guideline For Purchasing Lubricants

2010-01-01T00:00:00-06:00

Achieving optimum benefit from lubrication and maximizing equipment uptime is more than just the correct lube application and monitoring. While these are essential components, getting the correct lubricant is the first step. This is not always as simple as it sounds because of multiple vendors, sole sourcing or variable and/or qualitative purchasing decisions. It can also be exacerbated by a lack of understanding of the application and/or the significance of any changes to a lubricant. Even lubricants by the same name and from the same supplier can undergo formulation changes or changes in the place they're manufactured. Normally, this goes unnoticed with the recent proliferation of mergers, acquisitions and product dropping.

Improvement Appraisal Lubric

In Search of the Perfect Hydraulic Fluid

2010-01-01T00:00:00-06:00

Achieving Effective Machinery Lubrication

2010-01-01T00:00:00-06:00

To be effective, a lubrication maintenance program must to reduce unscheduled downtime as cost-effectively as possible. Other objectives of such efforts include:

Maximize uptime

Reduce mistakes

Use new technology where applicable

Utilize condition-monitoring tools

Use energy-saving products where justified

Reduce waste and hazardous materials

Use "greener", environmentally friendly products where possible

Foster a learning and improving work environment
Background
For electrical power stations and other industrial facilities, meeting production targets in a cost-effective manner requires the equipment involved in the generation and delivery to perform effectively and reliably.

Operating equipment wears and is either in the process of wea

Practical Lubrication of Open Gearing

2010-01-01T00:00:00-06:00

Lube System Modifications Boost Reliability

2010-01-01T00:00:00-06:00

During early 2001, a lubrication oil supply system failure on unit No. 3 of the San Onofre Nuclear Generating Station (SONGS) resulted in substantial bearing, journal and steam path damage. Figures 1, 2 and 3 illustrate the bearing and journal damage. The failure occurred when the primary and secondary AC-powered lube oil pumps failed due to a breaker failure in the switchgear, and the DC-powered emergency bearing lube oil pump failed due to a breaker trip. The SONGS units lack the shaft-driven lube oil pumps common to some designs, so the turbine generator system coasted to a stop without any lube oil. Engineers at SONGS analyzed the event and have taken actions to avoid its recurrence.