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JAnUARY/feBRUARY 2011 vOL 12, nO. 1 www.LMTinfo.com
contents
AchIevInG effIcIencIeS ThROUGh PRAcTIceS & PRODUcTS
Features
PROfeSSIOnAL DeveLOPmenT SeRIeS
Lubrication Certication: Types, Requirements, Benets
OneO2-FOTOLIA.COM; Aamon-FOTOLIA.COM
10
This article is the first in a year-long series on how lube pros can achieve
certification and whats in it for them when they do.
Ray Thibault, Contributing Editor
DeLIveRInG The GOODS

16
The Anatomy Of A centralized Lubrication System:

Series Progressive (Or Single Line Progressive) Systems
Which centralized, automated lube-delivery system is best for an application?

This month, we examine the most highly engineered of them all.
Ken Bannister, Contributing Editor
UTILITIeS mAnAGeR
18
n Big money Talks

William C. Livoti
n Part I: making energy Savings happen Through People

Henry Molise, P.E., HCM Energy Consulting, LLC
LAB SPOTLIGhT
24
Introduction To common Oil-Analysis Tests

(And how To Take A Successful Sample)
This regular feature will be looking at the most common oil-analysis tests
and some of the labs that conduct them.
dePartMeNts
4
6
8
26
Publishers Statement
28
30
30
Problem Solvers
my Take
from Our Perspective
Contamination
Solutions Showcase
classied
Supplier Index
Achieving efciencies
Through Practices & Products
Apply for a free, one-year subscription at
www.LMTinfo.com
JANUARY/FEBRUARY 2011
www.lmtinfo.com | 3
PUBLISHERs Statement
Bill Kiesel, Publisher
Alive & Kicking. . .

And Growing Strong
ou may have read about the recent release of Mark Twains

autobiography100 years after his death. News of this muchanticipated event reminded me of one of my favorite Twain
quotes: The reports of my death are greatly exaggerated.
He, of course, was referring to some confusion around the illness
of a cousin. Somehow, an obituary had been written, erroneously
listing the famous author as the dearly departed. Today, more than
a century later, I think this quote could easily apply to some of us
in the B2B arena who are still delivering print publications and
ancillary products to specific markets. To paraphrase Mr. Twain:
The reports of our demise have been greatly exaggerated.
At Applied Technology Publications theres still plenty of life left
and lots of growing going on! We spent much of the economic
downturn expanding our print, online, digital and other products and are excited about the future, especially since lubrication professionals are so crucial to the global economic recovery.
Were ready and eager to help you get this show on the road!
Here are just a few of the great new things weve begun rolling out in
Lubrication Management & Technology this month:
n Maintenance & Reliability Innovator Of The Year Award in
conjunction with Ken Bannisters new Maintenance Technology
column entitled Dont Procrastinate. . . Innovate! (Pg. 6)
n The Anatomy of A Centralized Automatic Lubrication System to
help you select the correct system for your application. (Pg. 16)
n Green Gadgets, Efficient Gadgets and Reliable Gadgets to help
you do your jobs better, faster, safer. (Pg. 22)
n Lab Spotlight, exploring oil-analysis tests and labs. (Pg. 24)
n Lube Starz, profiles of some of our hard-working readers. (Pg. 17)
This list reflects just some of the new growth youll find amid
our already strong lineup of offeringsincluding a bigger and better
MARTS (Maintenance & Reliability Technology Summit) that
kicks off April 26 with the 2nd Annual Reliability Gives Voice to Autism
charity gala. Our goal is to give you everything you need. Moreover, we
want to serve you better than ever. Happy New Year! LMT
Achieving EffiCIencies
THROUGH PRACTICES & PRODUCTS
January/February 2011 Volume 12, No. 1

arthur l. rice
President/CEO
arice@atpnetwork.com
bill kiesel
Executive Vice President/Publisher
bkiesel@atpnetwork.com
Jane alexander
Editor-In-Chief
jalexander@atpnetwork.com
RICK CARTER
Executive Editor
rcarter@atpnetwork.com
Kenneth E. Bannister
ray thibault, CLS, OMA I & II
RAYMOND L. ATKINS
Contributing Editors
RANDY BUTTSTADT
Director of Creative Services

rbuttstadt@atpnetwork.com
GREG PIETRAS
Editorial/Production Assistant
gpietras@atpnetwork.com
ellen sandkam
Direct Mail
esandkam@atplists.com
edward kane
Reprint Manager
800-382-0808, ext. 131
ekane@fostereprints.com
Editorial Office
1300 South Grove Ave., Suite 105
Barrington, IL 60010
847-382-8100 / FAX 847-304-8603 www.Lmtinfo.com
Subscriptions
For inquiries or changes contact Jeffrey Heine,
630-739-0900 ext. 204 / Fax 630-739-7967
Lubrication Management & Technology (ISSN 19414447) is published bi-monthly by Applied Technology
Publications, Inc., 1300 S. Grove Avenue, Suite 105,
Barrington, IL 60010. Periodical postage paid at
Barrington, IL and additional offices. Arthur L. Rice, III,
President/CEO. Circulation records are maintained at
Lubrication Management & Technology, Creative Data,
440 Quadrangle Drive, Suite E, Bolingbrook, IL 60440.
Lubrication Management & Technology copyright
2011. No part of this publication may be reproduced
or transmitted without written permission from the
publisher. Annual subscription rates for nonqualified
people: North America, $140; all others, $280 (air).
No subscription agency is authorized by us to solicit
or take orders for subscriptions. Postmaster: Please
send address changes to Lubrication Management &
Technology, Creative Data, 440 Quadrangle Drive,
Suite E, Bolingbrook, IL 60440. Please indicate
position, title, company name, company address. For
other circulation information call (630) 739-0900.
Canadian Publications Agreement No. 40886011.
Canada Post returns: IMEX, Station A, P.O. Box 54,
Windsor, ON N9A 6J5, or email: cpcreturns@wdsmail.
com. Submissions Policy: Lubrication Management &
Technology gladly welcomes submissions. By sending us
your submission, unless otherwise negotiated in writing
with our editor(s), you grant Applied Technology
Publications, Inc., permission, by an irrevocable license,
to edit, reproduce, distribute, publish and adapt your
submission in any medium, including via Internet, on
multiple occasions. You are, of course, free to publish
your submission yourself or to allow others to republish
your submission. Submissions will not be returned.
Printed in U.S.A.
4|
lubrication management & technology
MY TAKE
Jane Alexander, Editor-In-Chief
Its About Time!
appy New Year! I have some real good news for you. But first, the badThe perfect storm thats
been brewing with regard to the dwindling labor pool and the loss of so many skilled, knowledgeable, experienced craftspeople from the workforce is about to blow. This isnt just me talking.
Let me quote one of my favorite industry experts (and yours):
Statistics on the issue abound, including this: The Employment Policy Foundation (EPF)
projects that well suffer an 80% skill loss over the next 10 years as the Baby Boomer generation officially becomes eligible for retirement. We must recognize that a large percentage of
those skilled jobs will be lost foreverand that the remaining workforce will be expected to
absorb and cope with the devastating results. The clock is ticking faster and faster
These chilling words come directly from the first installment of contributing editor Ken Bannisters new column running every other month under the banner of Dont ProcrastinateInnovate!
in Maintenance Technology (MT) magazine. According to Ken, we shouldnt look to government
to legislate us out of the danger were in. Who knows what that might entail? He says its going to take
some real innovation on the part of our industriesand the individuals now working in themfor us
to survive the killer storm that is bearing down on us. We at Applied Technology Publications (ATP),
parent of both MT and Lubrication Management & Technology (LMT), and the Maintenance &
Reliability Technology Summit (MARTS) have heard the message loud and clear. Moreover, were going
to put some real money where our editorial mouth is.
Along with Kens new MT column, were launching the Maintenance & Reliability Innovator of the
Year Award programand the good news for you is that its open to those in the lubrication community!
The competition will allow you to pass on and share your successful innovative gizmos, gadgets, procedures, methods and ideas with others in the maintenance and reliability arena. Additional details will
come in future issues of both MT and LMT. In the meantime, though, you can learn more about the
topic by going online* and reading Tick-Tock: Time To Innovate!
Please note that Ken is issuing a challenge to all maintenance and reliability professionalsincluding you
on the lube side of the houseto put on your innovative-thinking caps. Theres no time to waste, he says:
Begin writing down whatever improvement ideas you have and prepare yourself for a wave of innovation
as we explore ideas to help us make it through our perfect storm. I agree. Its time to get going!
By the way, on behalf of all of us at Applied Technology Publications, let me take this space to thank
you for your past support. We look forward to serving your lubrication-information needs for many
years to come! LMT
jalexander@atpnetwork.com
* http://www.mt-online.com/component/content/article/282-january2011/1661-dont-procrastinateinnovatetick-tock-time-to-innovate.html?directory=90
6 | LUBRICATION MANAGEMENT & technology
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FROM OUR PERSPECTIVE
Ken Bannister, Contributing Editor
Chasing An Optimal State?
irtually every continuous-improvement

and change-management program is
geared toward taking a current state and
evolving it into an optimal state. This is
also true of a lubrication-management improvement program.
In the case of a lubrication program, optimal
state begins with adherence to the 4R principles:
Deliver the RIGHT lubricant, in the RIGHT place,
in the RIGHT amount, at the RIGHT time. Simple!
If a bearing could talk, it would say its optimal
state is best achieved by delivering a small amount
of the correct lubricant on a continual basis so
that it never runs dry and falls into a boundary/
dry running state (dry friction), or that its cavity
is never over-filled, forcing it into a fluid-friction
(wet-friction) state. Both of these states are less
than optimaland will result in premature bearing
failure, as well as a marked increase in energy use
to overcome the frictional retardation force.
While vacationing in the Caribbean several
years ago, I went for what was expected to be
a relaxing barefoot stroll along the beach
albeit on a very hot day. Finding it difficult to
negotiate the scorching sand without blistering
my feet, I was forced to dash into about 18 inches
of ocean water to cool off. Trying to continue
my forward momentum there was not easy, as I
needed to exert increasing amounts of energy to
overcome the resistance of the water. Through a
little trial and error, I eventually found my optimal
state: walking in about a half-inch of water.
There was almost no resistance and it was nice
and cool and easy to move through with good
traction. It didnt take long for me to realize that
this is how a bearing must feel in its optimal and
not-so-optimal states.
Running a successful lubrication program
based on a manual-system approach requires
a vigilant lubrication person who must always
ensure that: (1) the right lubricant is in the grease
gun; (2) the same grease gun is always used, in
order to guarantee the same shot size delivery
8|
LUBRICATION MANAGEMENT & TECHNOLOGY
every time; and (3) he/she lubricates to a strict

timetable and consistently/rigorously maintains
absolute cleanliness of both gun and nipple.
You probably know that this reality is difficult
to achieveand that a most likely result is a nonoptimal, feast-or-famine lubrication state.
To combat a non-optimal
lubrication state, we must convert
to the use of centralized and
automated lubrication systems.
To combat a non-optimal state, we must convert
to the use of centralized and automated lubrication systems that are set up to deliver a small
amount of lubricant on an almost continual basis.
Automated systems deliver generous benefits over
manual lubrication techniques that include up
to three times extended bearing life and elimination of all of the associated downtime costs,
reduction in lubricant use and significant energy
savings (with an associated carbon-footprint
reduction)and all at little capital cost, which, in
turn, generates fast and easy return on investment.
To assist you in choosing the correct automated delivery systems for your particular
application(s), Lubrication Management &
Technology is launching a continuing series
on The Anatomy of a Centralized Lubrication
System. Over the course of the year, well review
the pros and cons of different system types and
explain how they work. Please turn to page 16,
where our first installment in this series focuses on
Series Progressive Delivery Systems. LMT
kbannister@engtechindustries.com
PROFESSIONAL DEVELOPMENT SERIES
Thumbs up on this
Lubrication
Certification:
This article kicks off a
year-long discussion on
certification of lube pros,
the means by which you
can achieve it and whats
in it for you when you do.
Ray Thibault
CLS, OMA I, OMA II,
MLT, MLT II, MLA II, MLA III
Contributing Editor
lmost every professional group has certification

programs to recognize achievement above and beyond
whats normally required just to do a job. Doctors
and lawyers aspire to be Board Certified in their
respective specialties. An engineer can obtain a Professional
Engineer (P.E.) license that demonstrates a high level of
expertise. In the accounting world, its desirable to be listed
as a Certified Public Accountant (CPA). The manufacturing
industry also has several certifications. For example:
The Vibration Institute has four levels of certification for analysts. There
also are certification programs in Thermography and Ultrasonics.
The Certified Maintenance & Reliability Professional (CMRP) certification is offered by the Society for Maintenance & Reliability Professionals.
Introduced in 2001, this certification program has become very popular
among those in the maintenance and reliability field, including many in
the lubrication community.
Obtaining such certifications demonstrates a competence and a desire to
exceed normal job requirements. This, of course, doesnt mean that all certified
individuals in a profession are more competent than those who are not certified. However, when it comes to selecting employees and/or service providers,
the fact that a candidate holds certification from a credible, recognized body
can make a big difference in the selection process.
10 | LUBRICATION MANAGEMENT & TECHNOLOGY
Table I. Certifications Offered by the International Council of Machinery Lubrication (ICML)
Certification
Machinery Lubrication Technician Level I
Machinery Lubrication Technician Level II
Machinery Lubrication Analyst Level I
Machinery Lubrication Analyst Level II
Machinery Lubrication Analyst Level III
Laboratory Lubrication Analyst Level I
# Certified
Year Introduced
3435
207
184
2194
161
58
2001
2007
2010
2001
2002
2002
What about lubrication specifically? Are there any certifications available? What are they? Who should have them? What
are the benefits? What are the requirements for obtaining
these certifications?
Presently, there are two major certifying organizations for
lubrication-related activities: the International Council of
Machinery Lubrication (www.lubecouncil.org) and the Society
of Tribologists and Lubrication Engineers (www.stle.org).
International Council of Machinery Lubrication (ICML)
ICML was formed in 2000 to promote competence in the
field of lubrication through the development of certification
standards. All of its certifications are in compliance with ISO
18436-4 or ISO 18436-5. Table I lists the certifications available
through ICML.
The two most popular certifications from ICML are the
MLT I and the MLA II. The MLA II and III were originally
named MLA I and MLA II. When ICMLs work was pioneered
into the first international standard on qualification and assessment of oil-analysis personnel (ISO 18436-4), the then-MLA I
was deemed too high a standard for an entry level of an international standard and became equivalent to the ISO category
II. The then-MLA II became equivalent to the category III
of the ISO. To denote such equivalence, ICML renamed its
MLA I and II as MLA II and MLA III, respectively.
The Category I of the standard was inspired by the ICML
MLT I, with some very basic oil-analysis elements added
as it was being used for a standard targeting oil analysts.
The new MLA I, with the subject areas of the MLT I plus the
basic oil-analysis elements, was introduced by ICML in 2010.
Therefore, if the formal training in the MLT I class includes
basic oil analysis information in oil sampling, lubricant-health
monitoring and very basic wear debris monitoring and analysis,
both MLT I and MLA I certifications can be obtained from the
same class by taking two separate exams.
The MLT I is designed for individuals involved with dayto-day lubrication of machinery. Many of those certified
are lubricant end-users, as evidenced by the large number
of manufacturing companies that have associates with this
certification. MLT II is directed at advanced understanding
of lubrication concepts. One lubricant company, Lubrication

Engineers, is strongly encouraging its sales representatives to
become certified as MLTsand through a structured training
program, the company now has 65 of them certified as such. This
type of program benefits both the company and the personnel
involved. In addition to the resulting certification, the knowledge gained in preparing for the exam helps generate better
solutions for customer problems.
The concepts in which proficiency is required to pass the
MLT I exam are as follows:
Maintenance Strategy (5%)
Lubrication Theory (10%)
Lubricants (15%)
Lubricant Selection (15%)
Lubricant Applications (25%)
Preventive and Predictive Maintenance (10%)
Lube Condition Control (10%)
Lube Storage and Management (10%)
MLA I-III involves demonstration of the skills that are necessary for performing lubricant analysis for machine condition
monitoring. The most common certification in this category
is the MLA II. The following are the concepts necessary to pass
this exam:
Lubricant Roles and Functions (4%)
Oil-Analysis Maintenance Strategies (4%)
Oil Sampling (29%)
Lubricant Health Monitoring (21%)
www.LMTinfo.com | 11
Table II. Requirements & Pass Rate for Various ICML Certifications
Certification
Experience
Training Requirements
Exam
Pass Rate
Two years post-secondary education

or on-the-job training in maintenance
or lubrication.
16 hours of documented training

in machinery lubrication.
Achieve a 70% score on 100question multiple-choice exam.
62%
MLT I
MLT II
Three years post-secondary

education or on-the-job training.
32 hours of documented formal

training in machinery lubrication.
49%
MLA I
12 months experience in
lubrication-analysis-based
machinery condition monitoring*.

training as outlined in the Body
of Knowledge of the MLA I.
64%

training in lubrication analysis
as outlined in the Body of
Knowledge of the MLA II.
61%
MLA II
24 months experience in lubricationanalysis-based machinery condition

monitoring*, plus have the MLA I
certification or 960 hours experience
in oil analysis.

training in lubrication analysis
as outlined in the Body of
Knowledge of the MLA III.
48%
MLA III
36 months experience in lubricationanalysis-based machinery condition

monitoring* and have MLA II
certification.

training in oil analysis for
machine condition monitoring.
68%
LLA I
Two years post-secondary education

or on-the-job training in lubrication, lubricant analysis, chemistry,
maintenance or reliability.
* Months of experience are based on 16 hours minimum per month of sampling and analysis experience.
Lubricant Contamination Measurement and Control (25%)

Wear Debris Monitoring and Analysis (17%)
Its worth mentioning that the large number of MLA II-certified individuals come primarily from oil-analysis end-user
companies and international laboratoriesnot from domestic
oil-analysis labs. Over its short history, ICML has done an
outstanding job promoting lubrication certification. Today, there
are nearly 1250 companies that have at least one ICML-certified
person on staff. A total of over 6200 certifications are now in the
ICML system. Table II lists the requirements for various ICML
certifications, along with the pass rate.
Table III. Certifications By The Society of
Tribologists and Lubrication Engineers (STLE)
Certification
# Certified Year Introduced
Language(s), cost, renewal and recertification particulars. . .

ICML exams are offered in English, Spanish, Portuguese,
Italian, French, Korean, Japanese and Mandarin (and, upon
request, can be offered in other languages). The exam cost
in most countries is $200USD. Recertification is required
every three years, at a cost of $100, along with achieving
15 points related to lubrication activities or retaking a
50-question, multiple-choice exam.
Society of Tribologists and Lubrication Engineers (STLE)
Founded in 1944, STLE was originally known as the American
Society of Lubrication Engineers. It offers the certifications
listed in Table III.
Originally designed for lubrication engineers, the CLS is the
oldestand considered the highest-levellubrication certification. The very rigorous CLS exam (which had a 60% pass rate in
2010) covers the following 16 areas of lubrication:
Certified Lubrication Specialist (CLS)
913
1993
Lubrication Fundamentals
Oil Monitoring Analyst Level I (OMA I)
315
1999
Fluid Conditioning
Oil Monitoring Analyst Level II (OMA II)
17
2001
Certified Metalworking Fluids Specialist

(CMFS)
61
2005
Storage, Handling and Application of Lubricants

Monitoring and Reducing Consumption of Lubricants
Gears
Bearings
Seals
Fluid Power
Lubricant Manufacturing
Pneumatics
Metalworking
Solvents and Cleaners
Problem Solving
Lubricant Analysis
Lubrication Programs
Many lubricant companies have stressed the importance of
achieving the CLS to demonstrate the competence of their sales
representatives and technical personnel. Increasing numbers of
lubricant end-users are working to achieve the CLS, and major
North American oil-analysis labs have focused on having their
analysts obtain both the CLS and OMA certifications to demonstrate their competence. (INTERESTING NOTE: The four oilanalysis laboratories having the most CLS-certified analysts are
ALS, Analysts, Inc., Polaris and Herguth. They account for most of
the individuals that are CLS-certified oil analysts.)
Some of the major lubricant companies are promoting/
encouraging their distributor/marketer representatives to obtain
the CLS certification. Chevron is the leader in this area, with the
largest number of CLS-certified personnel, as well as the largest
network of CLS-certified marketers. Developed nearly 10
years ago, Chevrons program stressing the importance of CLS
certification has been very successful. Still, you dont have to
be a major lubricant company to promote certification.
Schaeffer Manufacturing, for example, initiated a formal

training program in 2004 to help its representatives achieve
CLS certification. This has led to over 50 people becoming
CLS-certified
edthats more than many of the large lubricant
companies. Schaeffers management believes the certification not only has helped build a sales force that is highly
competent in solving lubrication problems, it has opened
doors with many new accounts. (INTERESTING NOTE:
As a demonstration of Schaeffers commitment to the certification of its sales/technical personnel, even the company president has obtained his CLS.)
The latest certification introduced by the STLE is the
CMFS (Certified Metalworking Fluids Specialist). This is the
most specialized certification that the organization offers
and has the most stringent requirements. In 2010, this exam
had only a 50% pass rate.
Another certification, Oil Monitoring Analyst Level II
(OMA II), is also rather specialized. Only 17 individuals
have achieved this certification. This select group has 50%
of its members from Canada. (INTERESTING NOTE: The
company Analysts, Inc., has four OMA II-certified associates,
the most for any oil-analysis lab.)
Table IV lists requirement for various STLE certifications.
All STLE exams are based on multiple choices, with OMA I
having 160 questions and the CLS having 155. The pass rates
listed in Table IV are for 2010. Only two individuals took the
OMA II exam in 2010, thus the pass rate is not listed.
STLE exam language(s), cost,
renewal and recertification details
STLE exams are currently offered only in English. To promote
these certifications internationally, the exams will be offered
in other languages in the future. The exam cost is $440 for
non-STLE members, and $330 for members. The certification
must be renewed every three years. The renewal fee is $250
for non-STLE members and $130 for members. Four requirements out of a list of 11 must be met for recertification or
the exam must be retaken. The renewal requirements are not
difficult to obtain, and demonstrate learning and continued
involvement in the lubrication field.
Table IV. Requirements for Various STLE Certifications
Certification
Experience
Training Requirements
Exam
CLS
Three years minimum experience in the

field of lubrication.
None
Achieve 70% score in 155-question

multiple-choice exam.
OMA I
One year active employment utilizing oil

analysis in the field of lubrication.
16 hours in oil-analysis-related
courses, including company classes.
Achieve a 70% score on 160-question

OMA II
One year active employment utilizing oil

analysis in the field of lubrication.
16 hours in oil-analysis-related
courses, including company classes.

CMFS
Minimum of a two-year degree in science

None
or engineering. Three years minimum
experience working in a manufacturing
environment as a fluid specialist or five years
in a laboratory environment as a chemist.

Certification Benefits
A common question from lubricant sales and technical representatives, along with plant personnel, is What does a certification do for me, and which ones should I get? The answer
to the first part is greater compensation and possibly greater
opportunity. Consider the following:
The November 2006 issue of LubesnGreases documented
the monetary value of a CLS through a survey of salaries of
lubricant sales reps. The survey revealed that those with
a CLS were better-compensated than their peers without
the CLS. This was quite evident in the area of distributor
sales, where CLS-certified reps earned $30,000 p/yr more on
average. Having the CLS shows you have passed a difficult, allencompassing exam in the lubrication field. (INTERESTING
NOTE: Some lube companies put such value on certain certifications that they make them prerequisites to future promotions.
Companies even have been known to pay a bonus for passing a certification examfrom $500-$5000, in some cases.)
The more time and effort

you put into self-study,
the greater your chances
of passing an exam.
There are lubricant- and oil-analysis-bid situations where
having a certain number of Certified Lubrication Specialists is
part of the requirements to submit a bid. The MLT certification is very popular with plant-equipment lubricators and
supervisors. For too many years, oilers were not recognized as
vital to plant operation. This has changed, and the requirement
for more knowledgeable lubricators is emerging. Certification
programs have helped in this process. A very important benefit
of obtaining a certification is the knowledge gained in preparing
for the exam through structured training classes and self-study.
A certified person who is purchasing a lubricant or service
is more prone to deal with someone who has demonstrated
his/her own competence by also obtaining a certification
I know of actual situations where lubricant sales reps were
unable to arrange appointments with potential customers until
they achieved a particular certification. This has become even
more prevalent in our current economic environment.
End-users must cut into already precious time to see sales
reps. An unknown, uncertified rep will have more difficulty
arranging a face-to-face meeting with purchasers than an
unknown, yet certified individual.
A certified rep, at least on the surface, appears to signal
greater competency. Thus, he/she stands a better chance of
getting an appointment with someone who IS familiar with

lubricant certification programs.
One of the requirements for both STLE and ICML certifications is that lubricant-related activities, such as attending
conferences and training classes, need to be documented every
three years for purposes of recertification. This requirement, in
turn, results in certified individuals having more of a tendency to
continue learning than uncertified personnel. (INTERESTING
NOTE: Certified individuals often exude more confidence in the
work environment than those who are uncertified.)
Conclusion
For those who attain lubrication certification, there are many
benefitsboth monetary and personal. The avenues to certification are available through two major certifying bodies: the
International Council of Machinery Lubrication (ICML) and
the Society of Tribologists and Lubrication Engineers (STLE).
To date, ICML has granted 6000 certifications through six
programs. STLE has granted over 1200 certifications involving
four different programs.
What certification is best for you? Presently, the MLT I and
MLA II are the most popular (with a large number of manufacturing-plant personnel holding these certifications). The CLS
is especially popular with lubricant companies and their sales
representatives and lubricant personnelits still considered the
premier certification for the total field of lubrication, as it involves
demonstrating knowledge in 16 separate areas. Interest in the CLS,
though, is also increasing in manufacturing plants, primarily
with individuals heavily involved in lubrication decisions. As
noted previously, the major oil-analysis laboratories consider
the CLS important for their analysts. Other certifications, such
as the MLT II, MLA III, CMWFS and the OMA II, are more
specialized, as evidenced by the small number certified.
How do you achieve a certification? First, having experience
in the lubrication field is very important. Next, you will need
to do some self-study. (The more time and effort you put into
self-study, the greater your chances of passing an exam.) Finally,
attending a certification preparation class is very helpfuland
is mandatory for any ISO-compliant certification. Your chances
for success improve by taking certification exams soon after
taking the associated training program. For more information
on certification classes and to see who is certified, go to www.
lubecouncil.org and www.stle.org.
Whats next?
This series continues through 2011 with discussions of topics
found on the MLT, MLA, OMA and CLS exams. In the next issue,
well cover Basic Principles of Lubrication. LMT
Contributing Editor Ray Thibault is based in Cypress (Houston),
TX. An STLE-Certified Lubrication Specialist and Oil Monitoring
Analyst, he conducts extensive training in a number of industries.
Telephone: (281) 257-1526; e-mail: rlthibault@msn.com.
BOOSTING YOUR BOTTOM LINE
Is It Time For An
Energy Assessment?
ow long has it been since your

operations had an energy assessment
by an actual energy professional:
one year two yearsnever? Taking
a step back, just what is an energy assessment
and is it really worth the trouble?
An energy assessment (sometimes called an
energy audit) provides a better understanding
of how energy is used throughout your facility and
identifies opportunities for energy savings. It may
take the form of a walk-through of your operations
to identify specific opportunities, or it may involve
detailed measurement and analysis of specific
processes and systems.
There are often many energy-saving opportunities at a facility, from quick wins, repairs and tuneups that involve minimal disruptions to equipment
and processes, to more significant upgrades and
process improvements. In the case of motor-driven
systems, an energy audit may reveal inefficient or
improperly sized motors, variable frequency drive
(VFD) retrofit opportunities, process changes that
reduce motor speed or duty and other repair and
optimization opportunities.
Is an energy assessment worth the time and
money? If improving plant efficiency and reducing
operating costs is a core strategy at your facility, then
investing in an energy audit is well worth the effort.
A skilled professional can help identify numerous
and, sometimes, hard-to-spot opportunities, as
well as help quantify potential energy savings and
payback period for identified changes. Energy
audits may also lead to intangible benefitssuch
as increasing your teams awareness of how energy
impacts the bottom line.
Getting started
To get started, collect your most recent motor
inventory data, system schematic, motor test
results and (if applicable) previous audit results. If
these resources are not readily available, begin by
taking a basic motor inventory, including motor
nameplate data, estimated operating hours and
the electric costs to operate your facility.
Next, contact a qualified energy assessor.

Your local utility may offer an assessment program or provide a list of licensed
energy service providers in your area. The
U.S. Department of Energy Industrial Technologies Program (ITP) offers audit assistance
to qualified plants.[1] The MDM Website [2] has
links to system optimization, resources from local
utilities and plant energy-management resources.
Before committing to an audit, know up front
what the approximate time and cost will be
and the typical improvements and evaluation
criteria that are recommended for your type
of facility. Review case studies and references. Be
prepared to put together an implementation plan
and take action based on the assessment results.
Regularly monitoring motor energy consumption, making motor-system efficiency improvements and tracking improvement over time are
key components to sound motor management.
Performing an energy assessment is a big step
toward identifying savings opportunities, establishing savings goals andvery important
achieving results! LMT
References
1. ITP Best Practices Plant Assessments, www.
eere.energy.gov/industry/bestpractices/plant_
assessments.html
2. www.motorsmatter.org/resources/index.asp
The Motor Decisions Matter

(MDM) campaign is managed
by the Consortium for Energy
Efficiency (CEE), a North
American nonprofit organization that promotes energysaving products, equipment
and technologies. For further
information, contact MDM
staff at mdminfo@cee1.org
or (617) 589-3949.
DELIVERING THE GOODS
The Anatomy Of A
Centralized Lubrication System
Series
Progressive
(Or Single Line
Progressive)
Systems
Ken Bannister
Contributing Editor
With some basic TLC, the Series Progressive (or Single Line Progressive) type of centralized lubrication system will deliver many years of
trouble-free service, thanks to its engineering and tamper-proof design.
(Photo courtesy of Engtech Industries Inc.)
rguably the best engineered of all lubrication systems, the Series Progressive (or Single Line
Progressive) system pumps oil or grease in either a cyclical (total loss) or continuous (recirculative) manner. Engineered to positively deliver an exact displaced amount of lubricant to every
single bearing point, the divider block design is capable of operating in severe environments and
accommodating upwards of 200 delivery points in a single pump system.
Today, most lubrication OEMs offer a version of this

popular system type. The original modeldesigned and
developed in the U.S. by the Lubriquip organization in the
early part of the 20th century and marketed under the Trabon
namecontinues to be sold today.
How This System Works
A lubricant pump is connected to an engineered network
of series progressive divider blocks, and via a controller is
allowed to pump lubricant in a continuous or controlled
cyclical systematic manner to each divider block.
Divider blocks, which are built in a modular style,

contain a series of lapped, hydraulically actuated spool
valves sized for varying displacements. The ability to
cross-port a valve results in doubling the delivery of
lubricant on one side of the valve only. The valves are
progressively linked together in series, causing them to
shuttle over to one side of the block in a progressive
pattern, then to shuttle back to their original positions
as the lubricant continues to be pumped through the
block. Because of its hydraulic nature, as a valve is shuttled
back and forth, it displaces a lubricant charge on one end
Its Time To Shine!
e
b
u
z
r
LSta
of the valve to the bearing point, while simultaneously

filling the void on the other side of the valve in preparation for displacement once the valve shuttles back.
The Pros & Cons

With some basic TLC, the Series Progressive system type
will deliver trouble-free service for many years, thanks to
its engineering and tamper-proof design. With the blocks
modularity, replacement parts are relatively inexpensive to
purchase, stock and replace. As the accompanying dividervalve photo shows, the system can even be used with a
manual grease gun to deliver an engineered amount of
lubricant to each bearing point, and be automated later.
(NOTE: The photo on page 16 clearly shows the block cycle
pin and four overpressure indicators in run position.)
The downside of the Series Progressive system is the
difficulty in adding points once the initial system is
installedalthough this can still be achieved. Moreover,
in comparison to other single line systems, the Series
Progressive type demands more system engineering. The
plus side to this, however, is that every system is engineered by the vendor specifically for your application,
and provided with schematics and a Bill of Material to
include in your CMMS and/or maintenance files.
Coming Up
In the next issue, well discuss Single Line Resistance (SLR)
centralized lubrication delivery systems. LMT
For more details on centralized lubrication systems, see
Ken Bannisters book, Lubrication For Industry, published
by Industrial Press, or contact him directly. Telephone:
(519) 469-9173; e-mail: kbannister@engtechindustries.com.
Were Looking For

Lube Starz !
LASSE KRISTENSEN - FOTOLIA.COM
Monitoring The System

To ensure every point has delivered a charge of lubricant,
the first valve in the divider block can be attached to a
cycle pin indicator that visually indicates the block has
completed one full cycle by moving in and out one time.
Attaching a counter/timer control to the cycle pin will
indicate if no delivery has taken place within a given time
period and signify a broken main delivery line.
Blocked and crimped lines can be visually detected via
simple mechanical overpressure indicators connected
at the secondary delivery-line block outlet. Whenever a
restriction-caused hydraulic backpressure is sensed, a
visual indicator pin pops up to indicate the exact line/
bearing point requiring maintenance. If no electronic alarm
sensors are used, operations and/or maintenance must
perform regular visual checks for alarm indications.
Where Are You?

Our new Lube Starz Section is all about our readers,
the hardest-working lube pros in the universe!
Are you game? If so, please identify yourself.
We want to learn who you are, where you work,
how long youve been in your current position, what
brought you to the lubrication field and what you like
most about your job. If youre chosen as the subject
of a short, published profile, youll soon be reading
about yourself in an upcoming Lube Starz Section in
LUBRICATION MANAGEMENT & TECHNOLOGY and on our Website.
On top of that, each person profiled in this section will
receive a baseball cap designating him/her as one of
our honest-to-goodness Lube Starz.
Go to www.LMTinfo.com/LubeStarz and download the
profile form. Fill it out and follow the instructions for
submitting it with your photo. Thats all there is to it.
Start Shining!
Let Us Hear From You Soon!
www.LMTinfo.com/LubeStarz

UM BIG MONEY TALKS

William C. Livoti
Whats New in 2011:

Pending Regulation
s we enter a new year, lets first reflect on

the past. What actions (changes) have we
as a country undertaken to improve our
environment, economy and overall quality
of life? If that sounds like a trick question, it is. Its
also intended to be thought-provoking.
Legislation to address environmental issues has
the potential to significantly impact our economy
andconsequentlythe quality of our lives. Unfortunately, some proposed legislation could play a
role in stalling what most of us would characterize
as a painfully slow economic recovery.
A number of power companies say new rules
wont stop them from expanding over the next few
years. Others are replacing coal-fired plants with
cleaner natural-gas plants to avoid pending legislation that could force coal plants to install Carbon
Capture and Sequestration technology at significant
cost. Lets understand whats on the table.
As noted by Power-Gen Worldwide (www.power
genworldwide.com), the North American Electric
Reliability Corp. (NERC) has analyzed the potential
impact of four rules under development by the EPA.
They are the Clean Water Act Section 316 (b),
involving cooling-water intake structures; Title I of
the Clean Air Act National Emission Standards
for Hazardous Air Pollutants (NESHAP) for the
electric power industry, also known as the Maximum
Achievable Control Technology Standard; the Clean
Air Transport Rule; and Coal Combustion Residuals
(CCR) Disposal Regulations. The proposed regs
specifically involve:
Sulfur dioxide and nitrogen oxide caps
Reconsideration of the ambient ozone standard
Limitation of power-plant mercury emissions
A rule to tighten controls on power-plant coolingwater intakes
Another rule for managing coal ash
NERCs analysis* points to a number of possible

repercussions, should these new rules take effect:
We could lose up to 19% of our fossil-fired
steam capacity by 2018.
Planning of reserve margins could be affected.
Reserves could fall below reserve margins in
about half of NERC regions (U.S., Canada and
part of Mexico) by 2015.
Plant retirements could exceed 50GW on a fleet
capacity of 340GW (15%).
100GW (existing plants) would require large
investment to meet emission rules.
Retirements could cut demand for steam coal by
15-31%.
Natural-gas demand could grow 8-16% as some
coal plants are replaced.
Coal plants could close due to economics. (Coal
prices are a premium to natural gas by themselves.
Now add the cost of environmental controls.)
I believe in protecting our environment, cutting
energy consumption and reducing greenhouse
gaseswho doesnt? That said, we need to approach
these issues with a great deal of common sense.
Pending regulations could be tantamount to cutting
off our collective noses to spite our faces. LMT
*To read the referenced 2010 NERC analysis Potential Resource Adequacy Impacts of U.S. Environmental
Regulations, go to http://www.nerc.com/files/EPA_
Scenario_Final.pdf
Bill Livoti is a fluid power and power industry

engineer with Baldor Electric Company. Telephone:
(864) 281-2118; e-mail: wclivoti@baldor.com.
18 | UTILITIES MANAGER
VOLUME 6 / NO. 1
UM UTILITIES MANAGER
Part I of II
Making Energy Savings

Happen Through
People
DMITRIY MEINIKOV - FOTOLIA.COM
Energy-efciency isnt just about technology. If your organization hasnt

adjusted its culture to help raise and sustain the energy consciousness
of your human assets, nows the time to do it.
Henry Molise, P.E.
HCM Energy Consulting, LLC
requently, even successful world-class organizations have difculty conserving

energy and cutting the cost of utilities. This is despite the availability of more costeffective energy-management technologies than ever before. Some may be satised
with implementing a few immediate, nite savingsproverbial low-hanging fruit.
Such a strategy often captures only part of the potential savings for existing facilities,
without ensuring that future operations will be energy-efcient. For those who wish to
achieve energy savings over the long haul, modest adjustments in the culture of an organization can motivate people toward continuous improvement.
The most successfulsustainedenergy-management system is developed as a business process within

the organization. Most employees really want to help cut costs and reduce energy-related emissions; theyll
do just that if provided with the needed direction, training, resources, incentives, recognition and rewards.
It may take a few years for energy-management to fully gain momentum in an organization, but its worth
the effort for both the bottom line and the environment.
In this first installment of a two-part series, the focus is on a framework of business principles for initiating and administering an organizational energy-management system. The second installment (coming
in a special UTILITIES MANAGER follow-up in a later issue of LMT) will discuss actual energy-saving
implementation strategies.
Volume 6 / no. 1
utilities manager | 19
Understanding the energy perspective of the site manager

To understand the challenge of achieving energy savings,
consider the priorities of a site managerwhich often can be
summed up as follows:
n Get the product or service out the door.
n Have the work performed safely.
n Comply with laws and regulations.
n Keep facilities maintained for reliability and longevity.
n Minimize costs.
In the above list, energy-management would fall into the fifth
priority. A further challenge is that energy costs are often a
small percentage of the total expense budget. Yet most site
managers and their bosses would welcome a reduction in
energy costs and a reduction in environmental impact
as long as these reductions are consistent with financial and
other organizational objectives.
Energy policy: Support from the top
The most successful approach to an energy-management
culture is to begin from the top downin the form of a
commitment from the top. Thus, the first action to develop
the needed organizational culture is development of an
energy policy that is endorsed by senior management.
The energy policy needs to be only a short, simple statement of what is to be achieved from a broad perspective,
and it can be drafted at almost any level of the organization. A few paragraphs can be written to express that the
organization, with respect to energy-efficiency, will have a
policy to:
n Reduce the life-cycle costs of energy and utilities.
n Reduce energy-related emissions, on-site and off-site.
Senior management will also have a follow-up role in

recognizing and praising energy-related achievements.
Without the up-front commitment of senior management,
progress in energy reduction and the associated cost savings
is likely to be limited and slow.
Steering the effort
Once an energy policy is in place, the use of a steering team
is the best way to develop a strategy for implementation of
the policy. Ideally, the team should represent a cross-section
of the organization in terms of: 1) function and/or division;
2) geography; 3) specialists in engineering, operations and
maintenance; and 4) ad-hoc representatives of procurement,
finance, environmental affairs and communications. The
team can be led best by a person designated as the organizations energy champion or energy manager.
The steering team should make use of the ideas of others
wherever possible, such as:
n The U.S. Environmental Protection Agency (EPA)/Dept. of
Energy (DOE) Energy Star and state energy programs
n Trade organizations
n Your local utility suppliers Websites
n Sister facilities within the same organization
n Competitors or comparable outside organizations
n Consultants
Even in businesses where competitors would never share
production technology, research technology or other trade
secrets, they often are very willing to share information on
how to conserve energy and utilities.
Goal development
Measurable goals need to be developed by the steering team.
The improvements can be expressed in terms of:
n Be a good citizen in conserving resources.

n Enhance public image.
n Percentage reductions or absolute reductionsThese

include units of energy usage, costs and related emissions.
After internal reviews, endorsement and internal publication of

the energy policy need to come from as high in the organization as possible (preferably from the chief executive officer).
n Public-relations image and community relationsThese

include favorable news coverage and public recognition by
community leaders.
REMEMBER: The greatest chance of success will

occur when the regular performance reviews of all
levels of management include demonstrated progress toward the energy policy.
20 | utilities manager
n Local, regional or national awards

In the setting of goals, the steering team needs to address
this question: What counts besides energy? Other potential
measurable savings from energy-management include:
Volume 6 / no. 1
UTILITIES MANAGER UM
n Savings in utilities-system equipment procurement.

Examples include:
Potential capital-spending avoidance or postponement
for an additional air compressor, pump, chiller, boiler,

electric substation, air handler, piping or duct system
Capital savings from bulk-purchasing of energy-efficient
equipment
n Total energy usage, all expressed in a single unit (e.g., BTUs,

Joules, kilocalories). (Note that the energy represented
by electricity can be expressed in two waysas delivered
[3413 BTU/kWhr], or as produced [often about 10,000 BTU/
kWhr]. The off-site impact is expressed as the latter of
the two.)
n Water- and sewer-use savings
n On-site utilities production (e.g., steam, compressed air,

chilled water)
n Energy-related maintenance and safety improvements
Demand-side information to keep includes:
n Increased equipment production capacity and reliability
n Sub-meter data
n Improved human productivity due to increased levels of

comfort
n Energy usage per unit (e.g., BTU/square ft., BTU per unit
of product, energy input per unit of output)
Counting these additional related savings will substantially

increase peoples interest in managing energy.
n Results of energy and cost-saving actions taken (metered

or calculated), to identify progress toward the goals
(including savings per unit of time [e.g., monthly and
annually] expressed as energy units, cost and emission
reductions [tons of carbon dioxide])
Goal-related measurements
The two basic types of energy-saving-initiative measurements are: 1) metered; and 2) calculated. In a perfect world,
all energy savings would be metered. In reality, the cost of
metering the exact savings is most often not justified by the
accuracy gained. Therefore, engineering calculations must
often be accepted to determine savings in lieu of metering.
In calculating annual savingsor attempting to meter
savingstheres often difficulty in making adjustments for
effects of year-to-year production activity, weather-related
energy usage and/or other variables. The simplest goal
is, perhaps, expressed as an annual percentage reduction,
whereby the numerator is the metered or calculated savings
for all initiatives implemented in the present year, and the
denominator is the total energy usage or cost from the
previous year.
Reporting the results
Whatever measurement system is developed, it must reflect
the organizations energy policy and goals. For operations with
multiple sites or units, a uniform reporting system is necessary.
Results need to be kept in a spreadsheet format that is
capable of statistical analysis. Assistance of specialists may
be neededfor example, in calculating emission reductions
related to energy conservation. If at all possible, the results
should be available for viewing by anyone in the organization, such as on an Intranet Website.
Supply-side information that needs to be kept by time
period includes:
n Purchased utility usage and cost (e.g., electricity, natural
gas, water, sewage-treatment services)
Volume 6 / no. 1
Benchmarking performance
Where possible, comparison of a sites energy performance
should be made against similar facilities. Seek indices that
compare unit values, such as BTU/square foot, BTU per unit of
production or input versus output. In addition, perform benchmarking of unit energy and utility costs if available. Weatherrelated adjustments may be made using local degree-day data. A
sites performance can be compared with other facilities within
the same organizationor from outside the organization. The
most confidence in the results of benchmarking comes when
more than one benchmark measurement is used. Use the findings from benchmarking to prioritize future efforts.
Financial criteria
The financial specialist is a key ally in energy management:
He/she must define the approved hurdle rate for capital
investments in energy reductions. The hurdle rate may
be expressed in terms of payback period or rate of return.
Energy investments can typically use the organizations
normal process for capital and expense appropriations, for
which the financial specialist is an advisor.
REMEMBER: More energy-saving initiatives will be
implemented where projects with returns not quite
meeting the hurdle rate can be packaged with projects
that surpass the hurdle rate. This results in the largest
possible package of savings, while still meeting the
required hurdle rate.
utilities manager | 21
Furthermore, an understanding is needed as to whether

non-monetary factors can be used to help justify energyimprovement projects, such as associated improved reliability, safety or public image.
Energy-improvement projects tend to have lower risk
than most other investments, and therefore may justify a less
stringent hurdle rate than some other projects. For example,
compare the risk of return on an energy-savings project
with the risk of investing in the research and development
of a new product, building facilities to manufacture it and
then hoping that customers will buy it.
Too many times, systems that use large amounts of energy
are specified and selected based on capital cost only. Design
and selection decisions for such facilities need to be made
based on life-cycle cost (LCC), rather than first cost. Consider
the total cost of ownership (TCO) of a boiler, chiller, air
compressor, pump or HVAC systemor, perhaps, even an
entire building or production process. Frequently, less than 10
to 20% of the TCO is represented by the capital cost, while
more than 80 to 90% of cost is for energy expenses. The
lowest LCC alternative is not always the one with the lowest
capital cost. The most common reason for making decisions
GreenEcientReliable
Theyll be showcased
regularly in our pages
over the course of the
year. Watch for them.
These sections are
designed to put a big
spotlight on all types
of products to help
you do your jobs better.
Lots better.
Next Issue:
S - FOTOLIA.COM
Efficient Gadgets
NOTE TO ADVERTISERS:
Got a Gadget to Spotlight?

Call Your Sales Rep Today, Or Contact Kathy Jaros
847.382.8100 x 117 kjaros@atpnetwork.com
Henry Molise is president of HCM Energy Consulting, LLC. A

registered professional engineer in Michigan, he has 30 years
of experience as a corporate energy manager and environmental engineer in the pharmaceutical industry. Molise is past
chairman of the Energy Committee of the Michigan Manufacturers Association. E-mail: hcmolise@juno.com.
Green
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Air Amplifier For
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XAIRs new High Temperature Air Amplifier offers a simple, low-cost

way to move high volumes of hot air to surfaces requiring uniform
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that typically remain cool. With no impellers or moving parts to wear
out, its rated for environments (even corrosive ones) up to 700 F (374 C).
The units surface is protected by a mil-spec coating process (developed
for the aircraft industry) that allows for easy disassembly or cleaning. Efficiency
is high; the sound level is low (at only 72 dba). Applications include directing hot
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A framework for success

In summary, the framework described here in Part I of
this series, is for initiating and administering energy
management as a good business practice. This can usually
be accomplished consistent with the long-standing objectives of the organization, beginning with an energy policy.
Look for the concluding installment, Part II, when we
will discuss implementation and follow-up strategies for
success. LMT
Gadgets
Weve Got
Gadgets
Galore!
based only on capital cost(s) is that it takes more effort and

understanding to calculate LCC than it does to identify
capital costs. The financial specialist can assist engineers and
managers with LCC calculation methods. The extra effort is
well worth itand can literally help pay dividends.
22 | utilities manager
Volume 6 / no. 1
Easy On. Easy Off.
BaldorDodge hydraulically-assisted ISAF bearings

are so easy to install and remove you wont believe it
until you see it. Simply slip the bearing on the shaft,
apply hydraulic pressure to position the bearing on
the adapter sleeve and youre ready to go. To remove,
apply hydraulic pressure to the dismount piston and
the bearing is pushed off the adapter sleeve. No feeler
gauges or special tools needed. Plus, once its installed,
the full shaft contact eliminates fretting corrosion.
Each bearing arrives fully assembled, sealed and
lubricated for even easier installation than ever before.
No wonder a prestigious trade publication recognized
BaldorDodge ISAF hydraulically-assisted bearings as a
product of the year winner. Easy on and off bearings
only from Baldor.
dodge-pt.com
baldor.com
479-646-4711
Unmatched Quality
Superior Reliability
Easy Installation and Removal
Quickest Delivery Available
2010 Baldor Electric Company
LAB SPOTLIGHT
Introduction To
Common Oil-Analysis Tests
(And How To Take A Successful Sample)
il analysis is one of the most valuable condition-monitoring tools available to reliability-focused operations.
Why? It can save countless dollars by preventing equipment failures and helping maximize the life of lubricants.
Oil analysis tells us the condition of a lubricant, which,
in turn, lets us be proactive about replacing it before equipment damage occurs. Wear debris analysisa specific type of
oil analysisalso can tell the condition of equipment, which
allows us to respond to potential failures at an early stage.
In short, the proper use of oil analysis can help:
Improve asset reliability
OLIVIER - FOTOLIA.COM
Acid Number measures acid buildup, which denotes oxidation.

FTIR measures chemistry changes in a lubricant, which are
good indicators of oxidation and nitration.
Base Number is for engine oils. It measures the depletion of the
detergent, which neutralizes acids.
Flash Point is a measure of light components, which lower the
viscosity of lubricants.
Particle Counts, by size and amount, are determined with the
use of a laser counter.
Identify and eliminate repetitive equipment problems

Voltammetry measures depletion of antioxidants in lubricants.
Reduce unscheduled maintenance
Maximize use of lubricants in service
Reduce maintenance and lubrication costs
Tests for equipment condition through the measurement of

wear debris include:
Atomic Emission Spectroscopy measures metals in parts per
million (limited to particles under 10 microns in size).
Extend equipment component life

Tests for oil condition include:
Viscosity measures the resistance of a fluid to flow, is the most
important property of a lubricant.
Karl Fischer measures all forms of water at low levels and
is recommended for industrial equipment. (The Qualitative
Crackle test is used for engine oils.)
Ferrous Density, both direct-read ferrogram and particle

quantifier, measures ferrous particles without the size limitation of
emission spectroscopy.
Analytical Ferrography looks at size, shape and color (the
three most important physical characteristics of a particle)
to determine the wear mechanism and severity in machinery.
This is the only common oil-analysis test that can justify equipment shutdown.
LAB SPOTLIGHT
Sampling Guidelines
Any successful oil-analysis program begins with sampling. Remember, though,
that bad data is worse than no data. Thus, if youre collecting samples incorrectly,
an oil-analysis program is a waste of time and money. Key guidelines include:
Take warmed-up machine samples while equipment is running. If thats not
possible, sample no later than 30 minutes after shutdown
Use clean, sealed bottles and flush the system properly (at least 5-10 times the
sample-line volume). This is critical when running particle counts.
Integrity
Collect samples from the right location:

Sample from live fluid zones. Fluid is moving through the system. The
best spot is the return line back to the reservoir.
Sample, if possible, from a turbulent region (such as an elbow) to get
better particle distribution.
ice
Customer Serv
Sample downstream from components such as bearings, gears, etc. Never

sample after a filter, unless youre trying to determine filter efficiency.
Sample from the same location each time. This is difficult with static
sampling, especially with the use of a plastic tube and vacuum gun. Use
permanent pitot tubes, where possible, when conducting static sampling.
Never do drain samples from the bottom of a reservoir.
Dedication
Properly document samples on the sample bottle. Its not uncommon for incorrect information to end up on a sample bottle, which leads to erroneous results.
Send samples immediately to the laboratory. An unsent sample may contain information on potential problems that cant be identified until the sample is analyzed.
Systems
Properly establish sample intervals based on the following criteria:

Criticality is the most important factor. The typical interval for critical
equipment is monthly.
OEM recommendations are important. Some OEMs provide samplinginterval guidelines.
Environmental conditions can dictate frequency. Severe environments
necessitate more frequent sampling.
Current PMs and lube- and filter-changing schedules can also dictate
sampling frequency.
Technical A
b
ility
Why would you need to use

any other lab?
Contact Herguth Laboratories, Inc.
today to find out what sets us apart.
Historical problems with the equipment (or similar equipment) may call for
more frequent sampling.
Whats Next?
During 2011, this column will explore some of the most important oil-analysis
tests. In the next issue, the focus will be on Particle Count Testing. LMT
1-800-OIL-LABS www.herguth.com

CONTAMINATION SOLUTIONS SHOWCASE
Selecting The Right

Breathers For
Bath-Lubricated
Systems
A one-size-fits-all approach to
contamination solutions wont take
your program where it needs to go.
Jarrod Potteiger
Product and Educational Services Manager
Des-Case Corporation
o achieve a world-class lubrication program, standards

must be developed for how to modify each common type
of machine for lubrication, contamination control, inspections and oil sampling. While traditional desiccant breathers
work quite well for most applications, they may not always be
the best choice.
Bath-lubricated systems dont normally breathe very
muchthus, they put only a moderate demand on the breather
with respect to dehumidification. The problem with using a traditional disposable desiccant breather for such an application is
that the breather is always exposed to the ambient environment
and always stripping moisture, whether the system is breathing
or not. As a result, the life of the breather is unnecessarily
curtailed, potentially requiring frequent replacement. Many
users choose to continue with the use of standard breathers
in these circumstances as the value is still there, BUT there is
a better way: Seal the breather when the system isnt breathing.
Thats the idea behind hybrid breather technology.
The Better Way/The Best Fit
Hybrid breathers combine the features of traditional desiccant breathers with expansion chambers and low-pressure
check valves so that the system is effectively sealed until it
needs to breathe as a result of expansion or contraction
in the headspace. With the desiccant stage protected from
the ambient environment, the breather only dehumidifies
the incoming air, thereby increasing the life of the breather
significantly. In humid environments, it is common for
hybrid breathers to last five or more times longer than traditional desiccant breathers.
Des-Case Hydroguard Breather
When volumetric changes are relatively small, the bladder

system in a hybrid breathersuch as Des-Cases Hydroguard
inflates or deflates. When this volume is exceeded, the low-pressure check valves on the bottom of the breather open to allow
the exchange of air with the environment, wherein the air is
filtered and dehumidified as with a typical desiccant breather.
For any system that breathes intermittently and has an airflow rate requirement below 2.5 cfm, the hybrid breather is
by far the best option. The use of these breathers, combined
with good seals and good oil-handling practices, will often
reduce the frequency of need for periodic offline filtration
allowing cleanliness targets to be met with minimum effort.
For those applications that are exposed to very humid
environments or washdown activities, but also require large
air-flow capacity, there are breathers equipped with large
check valves, like Des-Cases Extreme Duty breather: It can
accommodate flow rates of up to 16 cfm while still protecting
the desiccant from unnecessary exposure to moisture. The
Extreme Duty breather doesnt have an expansion bladder,
but does offer a rugged, automotive-grade housing for applications exposed to high vibration levels.
When it comes to selecting breathers, the one-size-fits-all
approach is not really ideal. Today, there are many different
designs available and there is definitely a best fit for each
particular application. Breather selection is an important
part of the process of developing a world-class lubrication
program and should not be oversimplified. LMT
E-mail Jarrod Potteiger at jarrod.potteiger@descase.com.
SPONSORED INFORMATION
PROBLEM SOLVERS
Cooling-Lubricant
Supply System
exroths new Rapidstar Supply

Unit (RSU) supply system for
cooling lubricants offers the
advantages of a modular system
for low- and high-pressure supply.
When paired with the companys
KST booster, high-pressure generation is moved into the hydraulic
unit when internally cooled tools are
used. This omits the motor-pump
supply line on the cooling-lubricant
side and reduces energy consumption up to 88%.
Bosch Rexroth AG
Hoffman Estates, IL
Chemical-Resistant Bearing
he iglide C210 bearing from igus delivers superior resistance to a range of acids, solvents and hydrogen peroxide,
and can handle continuous temperatures of 212 F. As with
all iglide products, the bearings tribo-polymer is lubricationfree and corrosion-resistant, making it resistant to the aggressive chemicals used in food and packaging industries.
igus, Inc.
East Providence, RI
Bio-Based Penetrating Lubricant
2 Fuel Technologies Bio-blast is a fast-acting, penetrating lubricant with

patented additives and bio-solvents that wont stain metals. It drives out moisture, providing a high dielectric insulating property in electrical equipment and
removing rust and dirt. This recyclable product contains no VOCs, is USDA-certified
as Bio-Preferred and meets ASTM D-5864 standards for ultimate biodegradability.
G2 Fuel Technologies
Tampa, FL
7-Step Best Practice Lubrication Program

Professional Self-Directed Implementation ToolKit
Tap into your Liquid Gold for

less than $20 per day!*
Whether youre looking to increase asset utilization and maintainability,
reduce contamination, downtime, energy consumption and/or your
carbon footprint, or simply cut your maintenance and operating costs,
youre ready for a 7-Step Best Practice lubrication program!
For more information on this expert in a box approach to
successful lubrication programs, contact ENGTECH Industries
at 519.469.9173 or email info@engtechindustries.com
* Amortized over one year
PROBLEM SOLVERS
Variable-Area Lubrication Flowmeters
Tough Food Grade Lube
niversal Flow Monitors has added compact, noncontact magnetically coupled

transmitters to its line of variable-area lubrication flowmeters, replacing potentiometers that can easily wear out. Optional alarm switches protect machinery and
minimize downtime in the event of flow failure. The entire line can be used when local
flow indication and mechanical flow switching or 4-20 mA transmitters are desired.
Universal Flow Monitors, Inc.
Hazel Park, MI
Dual-Gauge Filter Adapter
he LF-9904 dual-gauge adapter from Schroeder Industries fits in the existing

pressure indicator port of any Schroeder filter, providing a fast and safe way to
take oil samples or test pressures in hydraulic or pneumatic systems under operation. Its two ports can sample upstream and downstream fluid, which allows for the
use of two test points not previously built into the filter. The adapters standard Viton
seal is compatible with most hydraulic fluids and petroleum products.
Schroeder Industries
Leetsdale, PA
&B Industries offers White Guard

Supreme H-1 Food Grade lubricant
(fortified with PTFE) for use in a
number of applications, including food
processing and packaging. According
to the company, the product is highly
resistant to heat, water washout, acid
and alkaline cleaners such as those
found in meatpacking plants, water
and wastewater treatment facilities,
bottling operations, bakeries and
canneries. With its rust and corrosion
inhibitors, White Guard Supreme is
well suited for conveyors, rollers, slides,
bearings, chains, sprockets and guide
rails. It has a Timken load of 40 and a
drop point of 510 F.
J&B Industries
Rio Hondo, TX
Additions To Machine-Safety Line
Customized,
Targeted Lists For
Your Marketing Needs
ATP List Services
lobaus machine-safety line now includes solenoid

interlocks, emergency stop buttons and standstill
monitors that complement the companys safety
sensors and control units for applications up to SIL 3 and
PLe. Safety sensors in SS housings for food processing
applications also are available.
Elobau Sensor Technology, Inc.
Gurnee, IL
Ellen Sandkam
www.atplists.com
1300 S. Grove Ave., Suite 105, Barrington, IL 60010
847-382-8100 x110 / 800-223-3423 x110
info@atplists.com / esandkam@atplists.com
CLASSIFIED
ACHIEVING EFFICIENCIES
THROUGH PRACTICES & PRODUCTS
1300 South Grove Avenue, Suite 105

PH 847-382-8100 FX 847-304-8603
Specializing In
Machinery Health Personnel

PM & PdM
Field Service Mgt Sales Hrly
www.LMTinfo.com
SALES STAFF
Nationwide Condential All Fees Company Paid
OH, KY, TN
135 N. Rocky River Road
Berea, OH 44017
440-463-0907; Fax 440-891-1254
JOHN DAVIS
jdavis@atpnetwork.com
www.lineal.com lisalineal@lineal.com
TOLL FREE 877-386-1091

For rate information on advertising
in the Classified Section
Contact your Sales Rep or
JERRY PRESTON: Phone: (480) 396-9585
e-mail: jpreston@atpnetwork.com
Customized, Targeted Lists

For Your Marketing Needs
Ellen Sandkam www.atplists.com
ATP
List
Services
847-382-8100 x110 / 800-223-3423 x110 info@atplists.com / esandkam@atplists.com
Index
ADVERTISER
JANUARY/FEBRUARY 2011 Volume 12, No. 1
WEBSITE
CIRCLE #
PAGE #
A2 Technologies ................................ www.a2technologies.com ....................... 62..................... 5

ATP Lists ............................................ www.atplists.com .................................... 72................... 29
AL, SoCA,** DC, DE, FL, GA, MD,

MS, NC, NJ, PA, SC, VA, WV
1750 Holmes Drive
West Chester, PA 19382
610-793-3093; Fax 610-793-3094
JIM HANLEY
jhanley@atpnetwork.com
AR, AZ, CA,* CO, KS, NV, NM, OK, UT
3629 N.Sonoran Heights
Mesa, AZ 85207
480-396-9585
JERRY PRESTON
jpreston@atpnetwork.com
CT, ME, MA, NH, NY, RI, VT, ON, QC
P.O. Box 1059
Osterville, MA 02655
508-428-3331; Fax 508-428-2545
VINCENT LeGENDRE
vlegendre@atpnetwork.com
Baldor Electric Company................. www.dodge-pt.com................................. 68................... 23

Bel-Ray Company ............................. www.belray.com ...................................... 61.................IFC
Des-Case Corporation ..................... www.descase.com/flowguard ................. 70................... 27
Engtech Industries Inc...................... www.engtechindustries.com .................. 71................... 28
EXAIR Corporation ......................... www.exair.com ........................................ 67................... 22
Herguth Laboratories, Inc................ www.herguth.com................................... 69................... 25
Hy-Pro Filtration .............................. www.hyprofiltration.com....................... 63..................... 7
Lanxess Corporation ........................ www.mpp.us.lanxess.com ...................... 64..................... 9
Lube Starz .......................................... www.lmtinfo.com/lubestarz................... 66................... 17
MARTS .............................................. www.martsconference.com.................... 73................... 31
Royal Purple ...................................... www.royal-purple-industrial.com......... 74..................BC
Access LMTfreeinfo.com and enter the circle number

of the product in which you are interested, or you can search
even deeper and link directly to the advertisers Website.
Submissions Policy: Lubrication Management &Technology gladly
welcomes submissions. By sending us your submission, unless otherwise negotiated in writing with our editor(s), you grant Applied Technology Publications,
Inc., permission, by an irrevocable license, to edit, reproduce, distribute, publish,
and adapt your submission in any medium, including via Internet, on multiple
occasions. You are, of course, free to publish your submission yourself or to allow
others to republish your submission. Submissions will not be returned.
30 |
LUBRICATION MANAGEMENT & TECHNOLOGY
IL, IN, KS, LA, MI, MN,

MO, OR, TX, WA,WI, BC
847-382-8100 x108; Fax 847-304-8603
TOM MADDING
tmadding@atpnetwork.com
IA, MT, NE, ND, SD, WY,
AB, MB, SK
847-382-8100 x106; Fax 847-304-8603
ARTHUR L. RICE
arice@atpnetwork.com
CLASSIFIED ADVERTISING
3629 N.Sonoran Heights
Mesa, AZ 85207
480-396-9585
JERRY PRESTON
jpreston@atpnetwork.com
* CA (from LA North)
**SoCA (from Orange County South)
Reliability Is Gold
Meet The Experts At
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
The
Capacity Assurance Conference!
APRIL 26-29, 2011

MARTS 2011 Attendees Will Enjoy...
A four-day educational experience created exclusively
for reliability professionals
30 hour-long Conferences over two days

Wednesday, April 27 and Thursday, April 28
kicked off by international reliability expert
and best-selling author James Reyes-Picknell
7 full-day Workshops on Tuesday, April 26
6 full-day Workshops on Friday, April 29
Two professional certification opportunities
Now entering its eighth year, MARTS is an exciting learning event in a great
location that helps reliability professionals at all levels improve their skills
and excel on the job. Pricing and attendance options for every budget
make it easy for individuals or groups to share the MARTS experience.
Registration is open at www.martsconference.com
The
Capacity Assurance
Conference!
MAINTENANCE and RELIABILITY TECHNOLOGY SUMMIT
APRIL 26-29, 2011
Hyatt Regency OHare, Rosemont (Chicago), IL
www.MARTSconference.com
...we extended drain intervals

from every 15 days to every
three months AND reduced
engine repairs and
replacements.
Luis Garza
Kingfisher Marine
Most efforts to improve operating efficiency and lower
maintenance costs are labor intensive and involve painful
cultural changes. Numerous progressive companies have
experienced significant cost savings simply by upgrading
lubricants. You can learn how by reading the special report
Lowest Total Cost of Ownership. This special report
includes extensive case studies that document real-world
savings through lubricant upgrades.
Get your FREE copy of the Lowest Total Cost of
Ownership today by calling 866-447-5173 . . .
For more information on Royal Purple, visit royal-purple-industrial.com today.

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JAnUARY/feBRUARY 2011 vOL 12, nO. 1 www.LMTinfo.com

AchIevInG effIcIencIeS ThROUGh PRAcTIceS & PRODUcTS

Ray Thibault, Contributing Editor

DeLIveRInG The GOODS

The Anatomy Of A centralized Lubrication System:

Which centralized, automated lube-delivery system is best for an application?

n Big money Talks

n Part I: making energy Savings happen Through People

Introduction To common Oil-Analysis Tests

Ray Thibault, Contributing Editor

Bill Kiesel, Publisher

Alive & Kicking. . .

ou may have read about the recent release of Mark Twains

January/February 2011 Volume 12, No. 1

Director of Creative Services

lubrication management & technology

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Jane Alexander, Editor-In-Chief

Its About Time!

6 | LUBRICATION MANAGEMENT & technology

Lube Oil Contamination Solutions

Remove Water & Particulate Contamination

Drum Top Filter Tote

Fluid Contamination Under Control with

Made in U.S.A., ISO 9001 Certified

FCL Filter Cart

FROM OUR PERSPECTIVE

Ken Bannister, Contributing Editor

Chasing An Optimal State?

irtually every continuous-improvement

LUBRICATION MANAGEMENT & TECHNOLOGY

every time; and (3) he/she lubricates to a strict

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PROFESSIONAL DEVELOPMENT SERIES

lmost every professional group has certification

10 | LUBRICATION MANAGEMENT & TECHNOLOGY

PROFESSIONAL DEVELOPMENT SERIES

Table I. Certifications Offered by the International Council of Machinery Lubrication (ICML)

of lubrication concepts. One lubricant company, Lubrication

PROFESSIONAL DEVELOPMENT SERIES

Two years post-secondary education

16 hours of documented training

Achieve a 70% score on 100question multiple-choice exam.

Three years post-secondary

32 hours of documented formal

Achieve a 70% score on 100question multiple-choice exam.

24 hours of documented formal

Achieve a 70% score on 100question multiple-choice exam.

24 hours of documented formal

Achieve a 70% score on 100question multiple-choice exam.

24 months experience in lubricationanalysis-based machinery condition

32 hours of documented formal

Achieve a 70% score on 100question multiple-choice exam.

36 months experience in lubricationanalysis-based machinery condition

16 hours of documented formal

Achieve a 70% score on 100question multiple-choice exam.

Two years post-secondary education

Lubricant Contamination Measurement and Control (25%)

# Certified Year Introduced