January - February 2018

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January - February 2018

TABLE OF CONTENTS

HYDRAULICS 14 AS I SEE IT
How to Make Your Oil Analysis Program Produce More Alerts
Troubleshooting Hydraulic Pumps Don’t be afraid of alerts. Instead, view them as a real opportunity for contin-

2
uous improvement.
OIL RECLAMATION 20

Using Centrifugal Separators

for Oil Reclamation

GREASES 26

Simple as Soap? The Risks of

Grease Mixing

LESSONS IN LUBRICATION 34

8 Lubrication Failure Mechanisms

for Rolling-element Bearings

LUBE-TPS 39

TRAINING AND CERTIFICATION 42 COVER STORY

The Power of Using Multiple Technologies for Machine Inspections
The Benefits of a Lubrication Certification Oil analysis and vibration analysis are powerful tools for identifying defects in machine
components. However, if used together, these tools can become even more beneficial.

6
BACK PAGE BASICS 46

Consider Machine Alignment to Avoid

Equipment Failures

EDITORIAL FEATURES DEPARTMENTS 32 Test Your Knowledge

30 Get to Know 28 Product News 33 Bookstore
25 Now on MachineryLubrication.com 35 Product Supermarket 40 Ask the Experts
 Jim Fitch | Noria Corporation

AS I SEE IT Oil Analysis

How to Make Your

Oil Analysis Program
Produce More Alerts
I want bad news fast. Why?
Problems tend to compound.
Rarely do they heal themselves.
Instead, the worse things get,
the faster they get worse. As time passes, the
cost of repair and lost production can soar
exponentially.
Maintenance resources need focus and
preemptive timing. The longer you wait to
respond to what causes failure, the more
machine conditions take over control of
your schedule and budget. Fix the roof while
the sun is shining. It’s not just about keeping
machines running but rather keeping them
running at the lowest possible cost.
Condition monitoring is an essential
troubleshooting tool. It provides examina-
tion skills to find the cause or source of an
impending problem. When issues are caught
early, you have the luxury of convenience and

“
the option of simple remedies, usually with
minimal (if any) business interruption.

The Wisdom of Early Detec-

tion — Not Just-in-Time
Detection
You can’t Several years ago, I performed a root
fix a cause analysis on a rash of gearbox failures
in helicopters used for the logging industry
problem (heli-logging). These failures were the cause
of serious accidents and human casualties.
that you Because of the high power density of these

can’t see.” gearboxes, mild problems could quickly esca-

late into life-threatening conditions.

2 | January - February 2018 | www.machinerylubrication.com


A helicopter’s planetary gearbox conveys
power between the main drive shaft (from the
engine) to the main rotor, giving the helicopter
aerodynamic lift and thrust. The condition of
the lubricant (the right health, cleanliness and
supply) is essential for reliable, safe operation.
Any failure of the lubricant can quickly start a
disastrous chain of events, from lube failure to
bearing failure to gear failure to rotor failure to
lift failure to helicopter failure (crash and burn).
While the helicopter example may be an
extreme case, it is still an important and vivid
illustration of the seriousness of early detec-
tion and response. What might seem like a
mild condition now (rising varnish potential,
cloudy oil, elevated particle count, uptick in
fuel dilution, out-of-grade viscosity, low oil
level, etc.) can abruptly worsen to a runaway
catastrophic outcome.
Root Cause Alarms
Proactive maintenance should always be
“job one” in condition monitoring. To do well,
it requires a solid understanding of root causes
that are ranked by likelihood (the Pareto prin-
ciple). There is also a need to understand the
criticality of each machine. What you perceive
as “the cause” may be nothing more than a
transitional step in a sequence of many in route
to functional failure. The real root cause you
are seeking is the one that could have been
controlled or prevented. That is not to say your
purpose is to look for someone to blame.
I was once surveying a steel mill and noted
that the needles on most of the pressure-​
differential gauges (used on filters) were in
the yellow or red zones. My escort quickly
commented that the maintenance staff no longer
used the gauge readings to schedule oil changes.
Instead, all oil filters were changed on six-month
intervals regardless of the gauge reading.
Needless to say, I was shocked. On-condition
maintenance should always take precedence over
scheduled maintenance.
See the fault tree in Figure 1 used to trou-
bleshoot the root cause of a large process pump
failure. Asking the “repetitive why” takes you
to the pump (and not the coupling or motor)
that failed. Next, the pump bearings were found
destroyed. An examination of the lubricant
revealed heavy contamination. An effective
functioning filter would have prevented such
contamination. In fact, the filter was found to
be plugged, as indicated by the red-alert pressure
gauge reading that went unnoticed.
Had an operator reported the high gauge
reading and followed up with a filter change, the
pump might have been saved. A red-alert gauge
reading is not a pump failure unless it does not
get reported with corrective action. If the filter
became plugged prematurely, it should have
been examined. Analyze the used filter to deter-
mine the type and source of particles. How have
they invaded the machine and the oil? Don’t just
change the filter. Correct the ingression points,
i.e., the source of particles that plugs the filter.
Many root causes can be detected by oil
analysis. These include various types of contam-
inants, wrong oil and degraded oil. If cleanliness
targets and other alerts are adjusted to promptly
weed out root causes, they won’t advance to even
the earliest state of failure.
I recently finished a case related to diesel
engine failures. The lab was using a 5-percent
alarm limit for fuel dilution. Anything less than
5 percent was reported as normal. No wonder
the many defective fuel injectors were not
detected until catastrophic engine failure had
occurred. Coolant leak detection is also poorly
deployed in diesel engine oil analysis. In my
opinion, even the slightest amount of coolant
leak is cause for concern.
Weak Signal Alarms
Long ago, researchers and tribologists discov-
ered that the strength of signals being emitted
during machine failure depends on the state of
failure. Incipient failure produces weak signals,
while precipitous (advanced) failure creates
strong signals. This applies to various types of
signals, including wear debris generation, vibra-
tion, heat and acoustics. Hence, if you want
to catch failure early, you need to be good at
detecting and responding to weak signals.
Sadly, many oil analysis programs are struc-
tured to do the opposite. You can’t fix a problem
that you can’t see. Rather than setting tight
alarms and limits that are a slight offset from
normal conditions, some programs don’t alarm
until problems advance to a state of imminent
danger, such as two or even three standard devia-
tions over the mean based on data history. Loose
alarms equate to failure blindness.
Some of the best oil analysis programs use
cautionary alarms to alert condition-based main-
tenance (CBM) technicians of abnormal lab data
or a reportable inspection condition. This way,
the alarm results in a more measured or throttled
response. People who wrongly push the panic
button often discredit the value of condition
Machinery
Lubrication ML
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 AS I SEE IT

Pump Failure

Pump Coupling Motor

Impeller Bearing(s)

Poor Design Or Other Wrong Dirt Degraded Incorrect

Misalignment
Specification Contamination Lubricant Contamination Lubricant Installation

Breather Filter Seal Dirty

Failure Failure Failure New Oil

Filter Filter
Full Failed

No Pressure No Inspection Incompleted Pressure

Differential PM to Differential
Gauge PM Change Gauge Failed

Figure 1. Fault tree used to troubleshoot the root cause of a large process pump failure

monitoring. Remember, “if it ain’t broke, don’t fix it.”
A “possible problem” needs to be vetted before you tear
down a machine and cause even more serious or real prob-
lems. Cautionary alarms should start the vetting process.
Nuisance alarms or false positives are always a concern.
Oil analysis is far from perfect, and there are many unavoid-
able data errors, including false negatives. Exception testing
can be extremely useful for confirming an alarm condition
and obtaining a better understanding of severity. It involves
resampling and running more extensive tests by the lab.
Because many exception tests are costly or time-consuming,
it is not practical to use them with routine samples. Good
examples of exception tests are analytical ferrography and
scanning electron microscopy/energy dispersive X-ray
spectroscopy (SEM/EDS).
3 Ways to Produce More Alerts
As discussed many times in Machinery Lubrication,
the primary goal in making lubrication and maintenance
decisions is to achieve the optimum reference state (ORS).
You are trying to optimize reliability, not maximize it.
You seek the reliability you need at the lowest possible
cost and distraction.
This holds true for producing more alerts. You don’t
want “alert overkill” but rather an optimized, effective level
of cautionary and critical alarms. This can best be done with
three methods working in unison:
1. More Frequent Testing and Inspection
It’s a false promise to expect even the best oil analysis
or condition monitoring program to catch incipient faults
and root causes if testing or data collection is conducted
infrequently. Many machines can fail start to finish in
just a matter of hours. Other failure modes may take
weeks, months or years. For instance, if the failure
development period is two months, a test or inspection
interval of two weeks provides real opportunity for early
detection. Conversely, a test or inspection interval of
two months may not offer an advanced warning at all.
Inspection 2.0 is a great strategy for achieving frequent
and effective inspection alerts.
2. More Comprehensive
Examination
You’ve probably heard the expression, “If all you
have is a hammer, everything looks like a nail.” This
also relates to oil analysis and condition monitoring in

4 | January - February 2018 | www.machinerylubrication.com


general. You need bandwidth. Many
companies pretend to save money
by cutting oil analysis to the bone.
This includes reducing the number
of machines that are sampled as well
as conducting fewer and less effective
tests. For good detective work, you
need to cast a wide net. This can be
done by expanding the screening
tests used on routine samples but
also by unifying oil analysis with a
penetrating inspection program and
other condition monitoring technol-
ogies (e.g., vibration).
3. Pin-drop Sensitive
Alarms and Limits
I’ve described the virtues of
recasting your alarms and limits for
greater early detection sensitivity.
You get rid of this data blindness in
some cases by taking away control of
how alarms and limits are set from
commercial laboratories. This is done
through education of CBM personnel
and analysis of each machine based
on failure modes, criticality and reli-
ability history.
In sum, oil analysis needs
to produce more quality alerts.
Perhaps 30 percent of all oil analysis
reports should have some reportable
condition, and certainly no fewer
than 10 percent. Of course, this
statistic depends greatly on the
types of machines and their field
of application. Don’t be afraid of
alerts. Instead, view them as a real
opportunity for continuous improve-
ment. Like most organizations, your
resources for improvement (people
and budget) are probably lean. In the
reliability space, alerts can help you
ML
73%
use these resources in the most effi-
cient and effective way possible. ML
About the Author
Jim Fitch has a wealth of “in of MachineryLubrication.com
the trenches” experience in lubri- visitors use the ISO clean-
cation, oil analysis, tribology and liness code to set target
alarms for system ​
machinery failure investigations.
cleanliness levels
Over the past two decades, he has
presented hundreds of courses on
these subjects. Jim has also published
more than 200 technical articles,
papers and publications. He serves as
a U.S. delegate to the ISO tribology
and oil analysis working group. Since
2002, he has been the director and
a board member of the International
Council for Machinery Lubrication.
He is the CEO and a co-founder of
Noria Corporation. Contact Jim at
jfitch@noria.com.
www.machinerylubrication.com | January - February 2018 | 5
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 COVER STORY

BY ANDY PAGE, ALLIED RELIABILITY GROUP

6 | January - February 2018 | www.machinerylubrication.com
 ML

B
oth oil analysis and 175 Iron
vibration analysis are 180 170
Iron alarm
powerful tools when
160 Iron alert
employed to identify
defects in rotating machine train 140
elements such as bearings and gears.
120
However, if used together, these tools
96
can become even more beneficial. 100
When the oil analyst and vibration
80
analyst compare notes, use one
58
another’s findings to complement 60
their own analysis, and present a
40
cohesive picture of asset health, it 29
18
creates a more complete analysis 20
of the asset’s condition and instills
confidence in the asset owner. 0

However, when the two analysts do

-

-
15

16

16

16
01

01
20

20

20

20
not compare notes and present their
/2

/2
0/

8/

2/

0/
27
19

1
1
/3

/2
9/
1/

4/

7/
results independently, the opposite
10

10
effect is often produced. The asset Figure 1. Iron content of an oil sample trending upward over time
owner may become confused or
frustrated with the apparent lack of
ISO PC>4
coordination or confusion caused by
24 24 24 24 24 24 ISO PC>4 alarm
reports with apparent conflicts.
24 ISO PC>4 alert
This article will provide both
good and bad examples of the 21
coordination between these two
18
powerful inspection methods so
analysts and asset owners alike can 15
see what to do and what not to do in
12
certain situations.
9
THE PREMISE
OF TECHNOLOGY 6

INTERACTION 3

The basic premise of multi-tech- 0

nology inspection programs is that
-

-
15

16

6
01

01

01

01

more than one method should be

20

20
/2

/2

/2

/2
2/

7/

/9
14
23

22
1
/2

6/

used to confirm or corroborate

11/

12
3/

9/
12

the findings of another inspection
method. For example, within the
field of vibration analysis, when the
spectra indicate shaft misalignment,
the analyst can use phase analysis
to validate the data in the spectra.
Likewise, when the vibration signa-
ture indicates an electrical fault in
the rotor of an AC induction motor,
online and offline motor testing
should be used to corroborate the
vibration analysis findings and
provide a more in-depth analysis into
the nature of the problem.
Figure 2. High ISO cleanliness codes for more than a year
Never have two inspection
methods been better suited to
complement each other in the
validation of rotating machine
train defects than have vibration
analysis and oil analysis. For many
bearing and gear faults, when one
technology detects an issue, the
other should as well. The findings
should also be presented together to
form a cohesive narrative about the
nature of the problem. Typically, it
does not matter which technology
was able to find the defect first. In
many cases, it will alternate back
and forth as to which technology
initially discovers the fault.
When oil analysis identifies wear
metals in the oil, vibration analysis
should be spotting the defect as well
as any mechanical forces that might
have produced the wear, such as
misalignment or imbalance. If oil
analysis has been reporting excessive

www.machinerylubrication.com | January - February 2018 | 7

 COVER STORY

ISO PC>6

24 24 ISO PC>6 alarm

24 22 ISO PC>6 alert

21
19
18
18

15

12

6
Figure 5. An example of leaking
3 gearbox seals

0 representative samples of either the

lubricant or the vibration signature
-

-
16

16

16

16

16
20

20

20

20

20

have been captured. The only caveats

5/

2/

4/

8/

3/
4/

8/

/1
/1
1
9/

would be when contaminants in the

12
10

Figure 3. High ISO cleanliness for more than eight months lubricant have just appeared and have
not had time to produce any signif-
110 icant abrasive wear and therefore
Iron have not been seen in the vibration
100 96 94 Iron alarm signature, or when subsurface fatigue
87 Iron alert occurs in bearings where no material
90 84
82 has been liberated from the surface
80 of the races and cannot be detected
in the oil sample. Regardless, if these
70 exceptional conditions exist, the
analysts should be stating it in their
60
reports to the asset owner.
50
EXAMPLES OF
40 POOR INTERACTION
30
In the following example of poor
interaction between oil analysis and
20 vibration analysis, the trend plot
offered by the oil analyst showed iron
10 content in the oil samples as being
high and rising for four months (see
0
Figure 1). The analyst commented
-

that the ferrogram revealed cutting

16

16

16

16

16
20

20

20

20

20

particles, indicating abrasive wear in

5/

2/

4/

8/

3/
4/

8/

/1
/1
1
9/

12
10

the gearbox, and recommended that

Figure 4. High iron content in oil samples for more than eight months the unit be checked for misalignment
and high vibration. At the same time,
contaminants in the oil for more bearing or gear defects, then the oil the vibration analysis for the same
than a month or two, then vibration analysis results should reveal signs of unit found no identifiable defects.
analysis should be detecting wear wear metals in the oil samples. From the perspective of the asset
on the bearings and gears as well. If these complementary condi- owner, some questions at this point
The reverse would also be true. If tions are not being found, then both should have been: Why did the vibra-
the vibration signature is showing analysts should question whether tion signature not show what the oil

8 | January - February 2018 | www.machinerylubrication.com

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 COVER STORY

“
ISO PC>4

24 24 ISO PC>4 alarm

23
24 22 ISO PC>4 alert
21 21
21
Never have 18

two inspection 15

methods been 12

better suited 9

to complement 6

each other in 3

the validation 0
-

-
15

16

16

16
of rotating
01

01
20

20

20

20
/2

/2
6/

5/

2/

8/
/9

15
7/

4/

8/

/1
1/
10

10
machine train Figure 6. High ISO cleanliness for more than 16 months

defects than
have vibration
0.12
analysis and Gear mesh frequency between two
and three shafts with sidebands
0.1
oil analysis.” spaced at the shaft speed indicates
Pk. velocity in in./sec.

a worn intermediate gear

0.08

0.06

0.04

0.02

0
5256 5682 6108 6535 6961 7388
Frequency (CPM)

Figure 7. Intermediate gear wear

analyst thought it might? Does the oil not talk before they submitted their source of contaminant ingression
analyst know what to look for in the reports so I do not have to make the and that the lubricant be filtered
vibration signature? Is there actually connections for them? to a greater degree. On the other
a problem in the vibration signature In a second example, the trend hand, the vibration analysis for the
that the analyst did not recognize or plot from the oil analyst showed unit revealed no identifiable defects
catch? What does misalignment have the ISO cleanliness code of the oil during the past year.
to do with abrasive particles in the samples as high for more than a year These findings should have also
oil? Why did I not get a picture of and steady over that time period (see raised questions for the asset owner,
the ferrogram showing the cutting Figure 2). The analyst recommended such as: How can the oil be dirty
particles? Why did the two analysts that the unit be checked for the (in alarm) for more than a year and

10 | January - February 2018 | www.machinerylubrication.com

Your oil analysis report comes back indicating there
is a problem, but there isn’t. Possible costs include:
Production cost of shutting the equipment off | Cost of
shipping the original sample | Cost to test the original
sample | Cost of shutdown | Cost of the new
replacement component | Cost of procurement | Cost
of maintenance | Costs associated with taking the
original oil sample

What are unreliable

Your oil analysis report comes back indicating
everything is fine, but there is a problem lurking.
Possible costs include: Costs associated with taking

oil samples costing

the original oil sample | Reduced equipment efficiency
Lost production | Cost of maintenance overtime | Cost
of the new replacement component | Cost of

you?
procurement

Your oil analysis report indicates a retake needs to take

place. Possible costs include: Labor of taking the
original sample | Production of shutting the equipment
off | Cost of shipping the original sample | Cost to test
the original sample | Labor of taking the second sample
Production cost of shutting the equipment off | Cost of
shipping the second sample | Cost to test the second
sample | Lost confidence in sample results

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 COVER STORY

Iron
470
For a final example of poor
500 Iron alarm interaction, consider the trend plots
450
Iron alert presented by an oil analyst that
showed the ISO cleanliness code
400
in the oil samples as being high for
350 334 more than 16 months (Figure 6),
while the vibration analyst reported
300
intermediate gear wear (Figure 7).
240
250 These results likely would have
prompted a number of questions
200
from the asset owner, such as:
142 141
150
139 Are these two conditions related?
Where are the analytics on ferrous
100
wear? Are particles in the oil
50 contaminants causing the gear
wear or are there wear particles
0
from the gear wear? If the oil is not
-

-
-

-
dirty, what caused the gear wear?
6

16
15

16
-
01
01

16
20

20

20
/2
/2

20
6/

5/

8/
15

Why did neither analyst discuss the

/9

2/
4/
7/

1/

/1
10

8/

10

Figure 8. High iron counts for more than 16 months implications of the other findings?

EXAMPLE OF GOOD
0.3
INTERACTION
0.2 In the following example of proper
interaction between oil analysis and
Acceleration in Gs

0.1 vibration analysis, the trend plots

0 count in the oil samples for more than
-0.1
-0.2
-0.3
0 4 8 12
Time (Revolutions)
Figure 9. Impacting and looseness in the vibration signature
not cause a mechanical problem? Did
the analyst not recognize or catch a
problem in the vibration signature?
Are the ISO cleanliness alarms set
too tight?
In another example of poor inter-
action between the two technologies,
the trend plots provided by the oil
analyst showed the iron content
and ISO cleanliness codes of the
oil samples as being high for more
than eight months (see Figures 3-4).
Meanwhile, the vibration analyst
only reported leaking seals on the
16
gearbox (Figure 5) and no mechan-
ical defects.
A reliability engineer might
wonder why the two analysts did
not mention that leaking seals allow
for the ingression of contaminants.
This could have been the perfect
opportunity to mention this link
and help the asset owner understand
the importance of fixing the leaks.
The asset owner might also question
the reason for concern if the leaks
and dirty oil are not causing any
other problems.
from the oil analyst showed a high iron
16 months (see Figure 8). The vibration
analyst reported impacting and loose-
ness as well as a possible problem with
a thrust washer (see Figure 9).
From the perspective of a reliability
engineer, this was a well-reported
defect. Both analysts referenced the
other’s findings, and it was apparent
they had communicated and likely
discussed the results before submitting
their report. Although the analysts did
not state that one condition caused the
other, they indicated the high proba-
bility of such an occurrence.
In conclusion, both oil analysis
and vibration analysis are powerful
inspection methods that are capable
of identifying faults that the other
cannot. However, there are also many
defects with bearings and gears in
which these technologies should be in
lockstep. When they are, confidence in
the inspection process grows and the
asset owner can be more certain of the
right action to take. ML

12 | January - February 2018 | www.machinerylubrication.com

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 Al Smiley | GPM Hydraulic Consulting
HYDRAULICS
Troubleshooting
Hydraulic Pumps
When a hydraulic issue occurs, the pump
usually is one of the first components changed
out, but it actually should be the last. Why?
Because a pump is the most time-consuming
part to replace and the most expensive. It should
never be changed before several tests are conducted. The
easiest tests and checks should be made first.
Visual Tests
Is the electric motor running? This sounds like
a no-brainer, but it should not be overlooked. I was
teaching a class at a plant in Kentucky a few years ago
when a student came in one morning and said they had
an overheating problem on the press the previous night.
Inlet line unrestricted - Full flow into pump suction port Inlet line restricted - Air is “pulled” out of hydraulic oil
High vacuum pressure occurs when a pump does not receive adequate oil volume at its suction port.
14 | January - February 2018 | www.machinerylubrication.com
He said they changed the filtering and cooling pump to
only find out later that the motor had been turned off.
Is the pump shaft rotating? Many times this is
difficult to tell because of coupling guards and C-face
mounts. I know of one plant where the pressure at the
pump outlet port was fluctuating. They changed the
pump and found that the worn key on the shaft had
damaged the keyway on the coupling.
Check the oil level. This also should be obvious, as
it often is the only thing checked before the pump is
changed. The oil level should be 3 inches above the pump
suction. Otherwise, a vortex can form in the reservoir,
allowing air into the pump.
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 HYDRAULICS

If the oil level is low, determine where the leak is

in the system. Leaks can be difficult to find. A press-
Crack in mounting roll hydraulic system at a paper mill in South Carolina
bracket found here had a continual problem with low oil levels, but the leak
could not be found. The hydraulic unit was in the base-
ment, and the piping ran up through the deck to the
roll upstairs. To help find the leak, dye was added to the
reservoir. An ultraviolet flashlight and goggles were then
used to locate the leak, which was 30 feet in the air just
below the second level.

A pump with a cracked mounting bracket led to shaft misalignment and
a worn seal.
Sound Checks
What does the pump sound like when it is operating
normally? Vane pumps generally are quieter than piston
and gear pumps. If the pump has a high-pitched whining
sound, it most likely is cavitating. If it has a knocking
sound, like marbles rattling around, then aeration is
probably occurring.

Cavitation
Cavitation is the formation and collapse of air cavi-
ties in the liquid. When the pump cannot get the total
volume of oil it needs, cavitation occurs. Hydraulic oil
contains approximately 9 percent dissolved air. When
the pump does not receive adequate oil volume at its
suction port, high vacuum pressure occurs. This dissolved
air is pulled out of the oil on the suction side and then
collapses or implodes on the pressure side. The implosions
produce a very steady, high-pitched sound. As the air
bubbles collapse, damage is caused inside the pump.

Aeration
An arrow on the gear pump’s housing indicates the Aeration is sometimes known as pseudo cavitation
direction of rotation.
because air is entering the pump suction cavity. However,
the causes of aeration are entirely different than that
Compensator Case Drain of cavitation. While cavitation pulls air out of the oil,
aeration is the result of outside air entering the pump’s
suction line.
A number of things can cause aeration, including an
air leak in the suction line. This could be in the form of
a loose connection, a cracked line or an improper fitting
seal. One method of finding the leak is to squirt oil
around the suction line fittings. The fluid will be momen-
tarily drawn into the suction line, and the knocking
sound inside the pump will stop for a short period of
time once the air flow path is found.
Last year I received a troubleshooting call from
a paper mill in Wisconsin where one of the pressure-​
compensating pumps had been changed because it would
not build and maintain pressure. When the new pump
also did not build pressure, the manual valve in the outlet
line was closed to isolate the pump from the system.
The compensator setting limits the maximum pressure at the outlet port of a variable Pressure still would not build up. Since there were no
displacement pump. other valves in the outlet line, the issue had to be in the

16 | January - February 2018 | www.machinerylubrication.com


suction line. After closer inspection, a crack
was found in the suction line pipe.
A bad shaft seal can also cause aeration
if the system is supplied by one or more
fixed displacement pumps. Oil that bypasses
inside a fixed displacement pump is ported
back to the suction port. If the shaft seal
is worn or damaged, air can flow through
the seal and into the pump’s suction cavity.
This recently occurred on a refiner where
the hydraulic pump was used to maintain
a precise gap between the discs. Several
minutes after the system was turned on,
foam started coming out of the reservoir.
After the pump was changed, a crack was
found in the mounting bracket. This led to
the shaft being out of alignment, wearing
the seal. A misaligned coupling can cause a
shaft seal to wear prematurely as well.
As mentioned previously, if the oil level
is too low, oil can enter the suction line
and flow into the pump. Therefore, always
check the oil level with all cylinders in the
retracted position.
If a new pump is installed and pressure
will not build, the shaft may be rotating
in the wrong direction. Some gear pumps
can be rotated in either direction, but most
have an arrow on the housing indicating the
direction of rotation. Pump rotation should
always be viewed from the shaft end. If the
pump is rotated in the wrong direction,
adequate fluid will not fill the suction port
due to the pump’s internal design.
Testing a Fixed
Displacement Pump
A fixed displacement pump delivers
a constant volume of oil for a given shaft
speed. A relief valve must be included
downstream of the pump to limit the
maximum pressure in the system.
After the visual and sound checks
are made, the next step is to determine
whether you have a volume or pressure
problem. If the pressure will not build to
the desired level, isolate the pump and
relief valve from the system. This can be
done by closing a valve, plugging the line
downstream or blocking the relief valve.
If pressure builds when this is done,
there is a component downstream of the
isolation point that is bypassing. If the
ML
3 Reasons Why a Pump Cavitates
1. The oil viscosity is too high.
Low oil temperature increases the
oil viscosity, making it harder for
the oil to reach the pump. Most
hydraulic systems should not be
started with the oil any colder than
40 degrees F and should not be put
under load until the oil is at least
70 degrees F. Many reservoirs do
not have heaters, particularly in the
South. Even when heaters are avail-
able, they are often disconnected.
While the damage may not be
immediate, if a pump is continually
started up when the oil is too cold,
the pump eventually will
fail prematurely.
A dirty suction strainer is shown.
2. The suction filter or strainer is
wrapped around the screen mesh.
contaminated. The strainer typi-
Apparently, someone had used
cally is 74 or 149 microns and is
the rag to plug the breather cap
used to keep “large” particles out
opening, and it had then fallen into
of the pump. The strainer may be
the tank.
located inside or outside the reser-
voir. Strainers located inside the 3. The electric motor is driving the
reservoir are out of sight and out hydraulic pump at a speed that
of mind. Many times maintenance is higher than the pump’s rating.
personnel are not even aware that All pumps have a recommended
there is a strainer in the reservoir. maximum drive speed. If the speed
The suction strainer should be is too high, a higher volume of oil
removed from the line or reservoir will be needed at the suction port.
and cleaned a minimum of once Due to the size of the suction port,
a year. I was called in to help a adequate oil cannot fill the suction
plant troubleshoot a system where cavity in the pump, resulting in
they had already changed five cavitation. Although this rarely
pumps in a week’s time. I noticed happens, some pumps are rated at
that the breather cap was missing, a maximum drive speed of 1,200
which was allowing dirty air to revolutions per minute (RPM),
flow into the reservoir. A check of while others have a maximum
the hydraulic schematic showed a speed of 3,600 RPM. The drive
strainer in the suction line inside speed should be checked any time
the tank. When the strainer was a pump is replaced with a different
removed, a shop rag was found brand or model.
www.machinerylubrication.com | January - February 2018 | 17
 HYDRAULICS

setting limits the maximum pressure at the pump’s outlet

port. The pump should be isolated as described for the
Hand Valve Closed
fixed displacement pump. If pressure does not build up,
1,200 1,200
PSI the relief valve or pump compensator may be bad. Prior
PSI
to checking either component, perform the necessary
lockout procedures and verify that the pressure at the
outlet port is zero psi. The relief valve and compensator
can then be taken apart and checked for contamination,
1,200 1,200 wear and broken springs.
PSI PSI If a volume problem exists in the system, perform the
following tests:
1. Check the tank line temperature of the relief
valve with a temperature gun or infrared camera.
The tank line should be near ambient tempera-
ture. If the line is hot, the relief valve is either
stuck partially open or is set too low.
To isolate a fixed displacement pump and relief valve from the system, close a valve 2. Install a flow meter in the case drain line and
or plug the line downstream (left). If pressure builds, a component downstream of check the flow rate. Most variable displacement
the isolation point is bypassing (right).
pumps bypass 1-3 percent of the maximum
pressure does not build up, the pump or relief valve pump volume through the case drain line. If the
is bad. flow rate reaches 10 percent, the pump should be
If the system is operating at a slower speed, a volume changed. Permanently installing a flow meter in
problem exists. Pumps wear over time, which results the case drain line is an excellent reliability and
in less oil being delivered. While a flow meter can be
troubleshooting tool.
installed in the pump’s outlet line, this is not always
practical, as the proper fittings and adapters may not 3. Check the current on the drive motor.
be available. 4. Ensure the compensator is 200 psi above the
To determine if the pump is badly worn and maximum load pressure. If set too low, the
bypassing, first check the current to the electric motor. compensator spool will shift and start reducing
If possible, this test should be made when the pump is the pump volume when the system is calling for
new to establish a reference. Electric motor horsepower
maximum volume.
is relative to the hydraulic horsepower required by the
system. This is shown in the following formula: electric Performing these recommended tests should help you
motor horsepower (hp) = gallons per minute (GPM) x make good decisions about the condition of your pumps
pounds per square inch (psi) x 0.00067. For example, if or the cause of pump failures. If you change a pump, have
a 50-GPM pump is used and the maximum pressure is a reason for changing it. Don’t just do it because you have
1,500 psi, a 50-hp motor will be required. If the pump a spare one in stock. Conduct a reliability assessment on
is delivering less oil than when it was new, the current to
each of your hydraulic systems so when an issue occurs,
drive the pump will drop. A 230-volt, 50-hp motor has
an average full load rating of 130 amps. If the amperage you will have current pressure and temperature readings
is considerably lower, the pump is most likely bypassing to consult. ML
and should be changed.
The temperature of the pump housing and suction About the Author
line should also be checked. A severe increase in tempera- Al Smiley is the president of GPM Hydraulic
ture indicates a badly worn pump. Consulting Inc., located in Monroe, Georgia. Since
Testing a Variable 1994, GPM has provided hydraulic training, consulting
Displacement Pump and reliability assessments to companies in the United
The most common type of variable displacement pump States, Canada, the United Kingdom and South
is the pressure-compensating design. The compensator America. Contact Al at gpm@gpmhydraulic.com.

18 | January - February 2018 | www.machinerylubrication.com

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www.machinerylubrication.com | January - February 2018 | 19

 Stephen Chastain | US Filtermaxx
OIL RECLAMATION

Using Centrifugal
Separators for Oil
Reclamation
Oil reclamation offers a number of economic
benefits. For instance, if oil that is discarded
and replaced could be cleaned and put back
into operation, tens or hundreds of thousands
of dollars could be saved every year. This type of cleaning
process frequently involves a centrifuge.
Centrifuges work on the principle of high gravity.
In short, anything that is heavier than the fluid will be
forced out, regardless of size. With these devices, even
small differences in specific gravity are amplified to such
a degree that submicron particles quickly settle out.
Centrifuges can break emulsions and remove particulate,
including graphite, but they will not eliminate particles
held in suspension by Van der Waals forces.

Types of Centrifuges
There is no shortage of centrifuge designs. The
variations generally are based on the type of contami-
nation involved. For particulate cleaning and light water An example of a plate type of bowl
removal, a bowl type of centrifuge is a good option.

“
When there is heavy water contamination, a tube type
of centrifuge is more appropriate. For oils that have
both water and particle contamination, a more complex
centrifuge may be needed to remove and dump solids
while separating the water. Unfortunately, the more
The longer the complex the centrifuge, the higher the cost.
A bowl centrifuge spins the oil, with particulate
oil remains in settling out against an inside wall of the bowl. A layer
of water forms on top of the hard particles, followed by
the centrifuge, a layer of water/oil emulsion and then a layer of oil that
progressively becomes cleaner toward the center of the
the better bowl. The clean oil will spill over the bowl’s top edge
the cleaning and drain from the centrifuge.
There are also a few variations on the solid bowl
will be.” design. For high solids and gentle acceleration, an open
bowl containing no vanes or plates is used. Frequently,
this is a biological type of bowl that does not rupture
cell walls. However, some applications may require
minimum shearing because of delicate polymers
contained in the fluid. A high solids biological type
of open bowl may be used in these situations. A high
solids bowl will also be open with no plates but may
have vanes to provide more acceleration to the fluid,
forcing it deep into the bowl. No plate is used to make
removal of the solids easier.
For difficult cleaning jobs, a plate is added to the
high solids bowl to force fluid to the outer wall so
maximum G-force can be exerted. The area for solids
collection is reduced by the plate. This type of bowl
should be cleaned before the solids block off the plate

20 | January - February 2018 | www.machinerylubrication.com

OIL RECLAMATION
opening next to the bowl wall. Plate
centrifuges are also a little more
work to clean and operate.
Bowl centrifuges must be cycled
to dump water and sludge. The
upper limit for these types of centri-
fuges is 5 percent water. Higher
percentages of water will require
excessive cycling. More than one
pass may be necessary if the cycle
is not well-timed before the bowl
overflows with water.
A tube centrifuge has contin-
uous discharge of both light and
heavy fluids. It also separates partic-
ulate but will quickly fill up with
solid matter when the percentage is
much more than 0.5 percent. This
type of centrifuge must be disas-
sembled to remove particulate and
is more labor-​intensive ​when the
Iron piping is preferred for P-traps. fluid contains a high percentage
of particulate.
From centrifuge Often called oil-water sepa-
rators, tube centrifuges operate
around 15,000 to 20,000 Gs and
can break difficult emulsions. The
To cleaned oil tank separation factor is controlled by
both the flow rate and annular rings
that distribute flow over light and
heavy output ports.
To ensure the fluid is spinning
the entire length of the tube,
Oil removable vanes are added to the
tube bowl. This bowl contains
many parts that must be assembled
in the exact location where the
bowl is balanced. Keep in mind
that a 1-gram imbalance becomes
A P-trap is used to block vapors. 20 kilograms when spinning at
Centrifuge Centrifuge
2 inches
minimum
Sludge
Sludge
Clean oil
If the P-trap is too high, oil flow will be forced to the sludge port.
22 | January - February 2018 | www.machinerylubrication.com
20,000 Gs, so do not operate an
imbalanced centrifuge.
Factors in Centrifugal
Cleaning
The main factors governing
centrifugal cleaning are the size of
the particles, the particles’ specific
gravity, the fluid’s viscosity, the
centrifuge’s power or G-force and the
residence time in the centrifuge. Of
course, you have little control over the
specific gravity of the particles. Some
applications may utilize a flocking
agent to make the particles larger, but
generally this is avoided. The three
factors you can control are the oil’s
viscosity, the centrifuge’s G-force and
the residence time in the centrifuge.
The centrifuge’s power relates to
its relative centrifugal force (RCF),
which is the amount of acceleration
applied. This will depend on the revo-
lutions per minute (RPM) and radius
of the rotor. However, the centrifuge’s
RPM will tell you nothing of value
regarding the device’s cleaning power.
Variable-​speed centrifuges allow you
to adjust the G-force as required for
the application. Fine, light particles
may require a high G-force to sepa-
rate, but heavy particles can separate
at a lower G-force. Test runs should
be made during the design of a new
cleaning process to ensure particles
are not packing so tightly that they
are difficult to remove. Also, don’t
forget that material weighs several
thousand times more in a spinning
centrifuge bowl.
The oil’s viscosity determines how
easily particles will separate from
the fluid. Consider that a handful
of dry sand will quickly sink to the
bottom of a bucket of water, but the
same sand will move very slowly to
the bottom of a bucket of molasses.
Likewise, thin fluids clean more easily
than thick fluids. Gasoline and diesel
clean quickly and easily, while heavy
oils require thinning.
Heat and solvents are two
commonly used methods to reduce

Centrifuge
Sludge
Clean Oil
A P-trap with a spot that is too low can block oil flow.
viscosity. Generally, oils are heated to just below the
boiling point of water. This thins the oil so particles and
water separate quickly. At this temperature, much water
flashes off as steam and is ventilated from the centrifuge.
The remaining moisture is separated as a layer of water
in the centrifuge bowl. Higher temperatures are avoided,
as they can cause spurting and spitting of the oil as the
water boils. Some applications may use a solvent to reduce
the oil’s viscosity. The solvent is removed by distillation or
may remain in the oil if it will be used as a fuel.
Steam and Vapor Ventilation
A centrifuge may be self-ventilating or require a
vacuum to remove steam. A self-ventilating centrifuge
uses a “P-trap” on the clean oil output to block vapors.
This forces steam and vapors to the sludge drain where
they may be condensed or ventilated.
Venting Vapors
During centrifugal cleaning, vapors may be emitted.
Depending on the composition of the oil, these vapors
may contain water, methanol or other light hydrocar-
bons. Larger amounts of vapor are emitted with higher
feedstock temperatures. Some centrifuges are designed
to ventilate these vapors using a fan formed between the
rotor bolts and the grooved lid. The centrifuge typically
can produce air flow of approximately 35 cubic feet per
minute through the output ports before piping losses.
Directing the flow to the waste port vents water vapor,
hydrocarbons or alcohol vapors away from the cleaned
oil. Flow is directed by installing a P-trap.
The liquid in the P-trap blocks the flow of vapors.
This prevents vapors from collecting in the clean oil
tank and condensing. The P-trap may be built from pipe
ML
Centrifuge
Sludge
Clean Oil
Low spot blocks flow
fittings or be as simple as a low place in a hose. The P-trap
must also be lower than the centrifuge. However, a long
line before the P-trap will allow vapors to condense in
the piping before the P-trap. Secondary traps formed by a
sagging hose block the flow of oil and cause the oil output
to back up and flow into the sludge drain. Therefore,
hoses must not kink. Using a 45-degree elbow on the
output minimizes kinking when the clean oil tank is not
located directly under the P-trap.
Residence Time
All good things come in time, and clean oil is no
exception. If oil is left in a tank for months or even years,
eventually a layer of clean oil will form on top. A centri-
fuge speeds up this process. However, the oil must stay in
the centrifuge long enough for the dirt to come out. Oil
that remains in a centrifuge for only a few seconds does
not have sufficient time for good cleaning. The longer the
oil remains in the centrifuge, the better the cleaning will
be. Residence time is controlled by the feed rate. You may
find that a particular oil is cleaned well at 40 gallons per
hour, but another oil can only be cleaned at 15 gallons
per hour. Trial-and-error testing of the initial installation
will quickly determine the best flow rate.
Centrifuge Bowl Cleaning
Knowing what is in your oil before you begin will
allow you to estimate the proper draining or cleaning
intervals for your centrifuge bowl. Lab analysis can be
beneficial but not essential. Tests show that waste motor
oil (WMO) typically contains between 3 to 5 percent
solids. When cleaning WMO, solid particles become
concentrated next to the bowl wall, while clean oil floats
to the center of the bowl, spilling over the top edge and
www.machinerylubrication.com | January - February 2018 | 23
OIL RECLAMATION
moving out of the centrifuge through
the clean oil output port. As the solid
particles move to the bowl wall, some
of the solid matter sticks to the sides of
the bowl, but much of it is concentrated
as a slurry of solid particles in the oil.
If you were to slowly feed the oil for
a long period of time so all the particles
moved to the wall, you could remove
all the particles as solid matter stuck to
the sides of the bowl. However, such a
slow feed rate and the amount of time
spent scraping solid matter from the
centrifuge bowl would be too imprac-
tical and labor-​intensive for actual
production. Much of the solid matter
can be removed before the bowl fills up.
Draining the slurry from the centrifuge
before the bowl fills permits a higher
feed rate without sludge spilling over
into the cleaned oil. This greatly extends
24 | January - February 2018 | www.machinerylubrication.com
the runtime between bowl cleanings
and also reduces or eliminates sludge
spilling into the cleaned oil.
The amount of sludge concentrated
in the centrifuge bowl will depend on
the G-force and the feed rate. A higher
G-force will equal a higher concentra-
tion of sludge. The feed rate must be low
enough for the centrifuge to do its job
and settle the sludge to the outer wall.
At some point, the bowl will fill with
sludge and spill over into the cleaned
oil. When this occurs, the centrifuge
will be removing very little, if any,
contaminants, as they spill over into the
cleaned oil as fast as they are removed.
To remedy this situation, either slow
the feed rate so all particles move to
the outer wall and only cleaned oil is
discharged, or stop the centrifuge and
drain the sludge before it spills over.
How often should the centrifuge
be stopped and the bowl drained? An
approximate starting point is deter-
mined by the bowl size. Operating
any centrifuge longer than the bowl
capacity is like trying to put 10 gallons
of sludge in a 5-gallon bucket. The
runtime between drains will vary by
the G-force, the oil’s viscosity and the
percent of contamination. The volume
between drains will remain about the
same. Programmable centrifuge control-
lers can remove the burden of manually
draining the sludge from the centrifuge,
allowing automatic, one-pass cleaning.
Applications
While results will depend on how
each centrifuge is used, some reports
have shown 99.6 percent of particulate
being removed from used engine oil.
Fleet services have been able to clean
their engine oil and blend it back with
a percentage of new oil, reducing the
cost of replacement oil by 70 percent.
Hydraulic shops have also cleaned
and reused oil that was contaminated
during repairs.
One manufacturer of extruded
aluminum parts in the auto industry
had 5,000 gallons of oil which had
become contaminated with graphite
in the pressing process and needed
to be replaced at $15 per gallon, plus
the cost of disposal. Centrifuging the
oil brought it back into service for a
savings of $75,000. The manufacturer
now maintains its oil with a pair of bowl
centrifuges.
Another company has saved more
than $250,000 annually by switching to
centrifuging and reusing the synthetic
oil in its natural gas compressors after
previously discarding the oil at the
change interval.
As you can see, a centrifuge can
offer many advantages and provide an
effective method of oil reclamation. Be
sure to consider this option the next
time you need to discard or replace your
used oil. ML
 NOW ON MACHINERYLUBRICATION.COM
Find more great articles and content from Machinery Lubrication magazine online. From web exclusives and industry
news to videos, white papers, buyer’s guides and more, everything that relates to machinery lubrication is available
now on www.MachineryLubrication.com.

FEATURED Strategies for Controlling 100 of the Most Effective Ways

WHITE PAPERS Contamination with Proper Filtration to Boost Machine Reliability
MachineryLubrication.
com is the place to
turn for white papers
on a host of lubrica-
tion-​related topics.
Here’s a sampling of
the latest white papers
that are currently
available for download:
• 5-Step Sheave
Pulley Alignment New oils delivered in bulk as well as in drums
Procedure or smaller containers frequently have contamination
• 100 Failure Modes levels higher than what is recommended by the original
of Lubrication equipment manufacturer (OEM). Read this article on
• Moving from Reac- the ML site to discover why it is best to filter oil when
tive to Predictive it is transferred, stored or applied to equipment.
Fluid Maintenance
There’s a clear pathway to improving machine
Check out the full list of Should You Use a Lubricant After Its reliability: lubrication excellence. Organizations
white papers by visiting Expiration Date? worldwide are systematically reaping the benefits of
MachineryLubrication.
Whether you should use a lubricant after its expi- transforming their lubrication programs to best prac-
com and clicking on the
“White Papers” link. ration date will depend on the type of lubricant. tice. Learn 100 ways to get started on your journey
to lubrication excellence by reading this article on
the ML site.

Determining the Right

Greasing Frequency

Check out this article on the ML site to understand

BY THE NUMBERS

59
why additives stratifying or separating out of the oil

%
and settling to the bottom of the container is likely
with a highly additized lubricant like engine oil but
not with other oils that have few additives.

of lubrication professionals use
both synthetic and mineral-based
lubricants at their plant, based on
a recent survey at
MachineryLubrication.com
Dry Cleanup Methods for Oil Spills
Spills will still occur, but the use of dry cleanup
methods can help keep contaminants out of the drain.
Access this 3-minute video to see how to clean small
and large oil spills as well as how you can reduce the
time and effort involved in cleanup.
How often should you regrease your bearings? A
number of variables must be considered, including the
temperature, speed and load. Access this 1-minute,
29-second video to find out why the type of element
in use should not be overlooked and how this can influ-
ence the relubrication frequency. ML

www.machinerylubrication.com | January - February 2018 | 25

 Rich Wurzbach | MRG Labs

GREASES

Simple as Soap?
The Risks of
Grease Mixing
In the amusement park’s maintenance area, I
learned that the park was experiencing a rash
of motor bearing failures. With such a long
operating history, it was surprising to find this
sudden uptick in problems. I brainstormed some possible
reasons with the maintenance team and was told, “Our
motors had been running great ever since Henry took
over the motor rebuild program.” When I asked if we
could discuss the issue with Henry, I was informed that
he had retired the previous year.
With a little more investigation, we discovered that
Henry had been personally sending a new tube of grease
with each motor sent out for rebuild, attaching it to the
motor with duct tape. When Henry retired, this prac-
tice was lost, and the motor rebuild shop reverted to
its standard bulk grease. As you may have guessed, the
amusement park was using a grease that was not compat-
ible with the one at the rebuild shop — not very amusing!
Henry had developed an effective strategy to avoid
the negative consequences of grease mixing: ensuring
that one product — the correct grease for the applica-
tion — was being used by everyone servicing the motors. the greases soften. The thickeners interact and become
This starts by validating the product, including the right runny. In some cases, the thickener bleeds excessively,
base oil viscosity, base oil type, NLGI grade, thickener releasing large amounts of the vital oil and additives,
type and additives. But even when you know the right which leaves behind mostly thickener. In a few instances,
the mixed grease can harden.

53%
of lubrication professionals
say grease compatibility has
caused problems at their plant,
according to a recent poll at
MachineryLubrication.com
grease to use, the opportunities for the wrong grease to
be mixed are many. These would include someone grab-
bing an incorrect grease gun, new machines or bearings
coming supplied with a different grease, contractors
adding the wrong grease during repairs, and grease guns
being incorrectly labeled.
Determining Incompatibility
Just like Henry’s motor shop, those who have experi-
enced grease mixing have seen the impact. Most times,
These most obvious signs of incompatibility of the
“soap” or non-soap thickener have driven an oversimpli-
fication of the approach to grease mixing. An internet
search will return no fewer than 17 different compati-
bility charts which only address families of thickeners. An
article in the January-February 2017 issue of Machinery
Lubrication cited several examples of grease mixtures
that appear to be compatible according to these popular
charts, but after a more thorough review obviously are

26 | January - February 2018 | www.machinerylubrication.com

not. These would include the two
lithium-complex greases shown in
the table above:
It’s more than just the soap that
determines compatibility. Even when
the thickeners are the same, differ-
ences in the base oil types, viscosities
and additives can render a mixture
inadequate or even damaging to
a critical machine. For the two
lithium-​complex greases in the table
above, many of the considerations
matched up, including the base
oil type (PAO), NLGI grade and
even the manufacturer. However,
a mixture of these products would
certainly not produce an optimal
outcome for a given machine, as
each is designed for a very different
application (speed, temperature and
lubricant film type).
In addition to these issues, the
compatibility charts themselves are
often in direct contradiction. For
example, some charts indicate that
“polyurea” grease is compatible with
calcium complex, while others list
them as being incompatible. Barium
complex and clay greases are iden-
tified as being compatible in several
charts, but this is contradicted
by other charts that describe the
mixture as incompatible. After some
review, it becomes clear that basing
your grease mixing decisions on
MANUFACTURER A MANUFACTURER A
PRODUCT ‘BEARING’ GREASE ‘SPECIAL’ SEVERE CONDITION GREASE
Thickener Lithium Complex Lithium Complex
NLGI Grade 2 2
Base Oil Type SHC Polyalphaolefin (PAO) SHC Polyalphaolefin (PAO)
Additives Anti-Wear (AW) 11% graphite/1% moly (EP)
Base Oil Viscosity 100 cSt at 40°C 1,000 cSt at 40°C
Extremely slow speeds, higher temperatures,
Intended Use Higher speed motors
boundary lubrication
supplier’s advice under consideration useful in predicting the performance
but ask for a copy of the testing that of in-service greases. Therefore, after
was performed to determine if the a few minutes of mixing, a test that
product will be compatible in the does not predict how a grease behaves
mixture of concern. in a machine is used to evaluate the
Laboratories that test in-service suitability of a mixture to perform in
grease samples report that one of bearings or gears for months or years
the most frequent causes of failure with constant mixing.
is grease mixing. In electric motor Addressing these concerns, an
repair, it is quite common to receive ASTM committee has created a
reports of “overlubrication” leading working group to evaluate more
to grease being found in the motor advanced approaches used by some
windings instead of the bearing laboratories to test grease compati-
housing. However, this sometimes bility and decide if improvements in
may be a result of grease mixing, the D6185 standard are warranted.
which produces a thinning of the Some of these enhanced tests include
grease mixture and allows it to be extended grease mixing and working
drawn past the housing shields and prior to testing, as well as using
into the windings where it is distrib- techniques such as a stress rheom-
uted by movement and air flow. eter to predict performance issues
The risks and incidents of grease like hardening, separation of the oil
mixing are widespread, so how do and thickener, and tendencies of the
you know if two greases are incom- mixture to tunnel or channel in the

these charts is fraught with danger.
Trust but Verify
Some turn to lubricant suppliers
for guidance. Although most
suppliers are quite familiar with the
performance capabilities of their
products, few have conducted testing
on the thousands of competing
lubricants to establish which are
compatible and which present prob-
lems. A “trust but verify” policy
can be a sound strategy to ensure
success. If you are consulting with
a lubricant supplier on a product
changeover and are concerned about
the impact of grease mixing, take the
patible? In 2011, ASTM issued
D6185, the “Standard Practice for
Evaluating Compatibility of Binary
Mixtures of Lubricating Greases.”
It involves preparing ratios of the
greases in question and performing
three tests. The mixtures are 50-50,
10-90 and 90-10, but could also be
50-50, 75-25 and 25-75. The tests are
cone penetration (D217), dropping
point (D566 or D2265) and storage
stability at an elevated temperature,
which is also determined by cone
penetration. It is interesting to
note that these methods are cited
in ASTM standards as not being
“
machine housing.
Certainly, avoiding grease
mixtures should be the strategy
employed whenever possible. Of
course, sometimes it is not cost-​
effective to do so, such as when Even when
products in use are discontinued or
when lubricant consolidation has
you know the
been implemented as a cost-savings right grease
initiative. Successful organizations to use, the
will carefully consider all the perfor- opportunities
mance parameters and differences for the wrong
between the greases in question.
Simply checking a box on a compati-
grease to be
bility chart is not sufficient to protect mixed are
your critical machinery. ML many.”

www.machinerylubrication.com | January - February 2018 | 27

 PRODUCT NEWS
CORROSION-
INHIBITING ADDITIVE
1
Cortec’s new VpCI-706
is a fuel additive created
for the protection of
diesel fuel tanks and systems.
It is compatible with diesel and
biodiesel fuel and offers corro-
sion protection for ferrous metal
surfaces both in contact with the
fuel and above the fuel level. The
additive does not contain trace
metals, chlorides, chromates,
nitrites or phosphates and can
provide protection in liquid and
vapor phases as well as at the
liquid/air interface.
Cortec
www.cortecvci.com
800-426-7832
28 | January - February 2018 | www.machinerylubrication.com
COALESCE SKIDS
2 3
The new coalesce skids
(COS) from FilSon
Filters are engineered
to remove water and particles in
hydraulic and lubricating oils.
The high-tech design includes a
series of pre-filters, separators,
coalescers and particulate
removal filters. Each coalesce skid
is also equipped with a differen-
tial pressure indicator to indicate
when the filter elements are worn
out and need replacement. A drip
tray helps to control oil spillage
and ensure a safe working area,
while the energy-efficient motors
and pumps are designed to offer
quiet operation, long service and
high suction capacity.
FilSon Filters
www.filsonfilters.com
86-1573-695-8886
1 3
1
MOTOR OILS
Champion Modern
Muscle (CMM) motor
oils are formulated to
offer fuel economy performance,
cleaning power and engine
protection, even during extended
oil change intervals. A premium
mixture of synthetic base fluids
and additives includes special
lubricity modifiers and anti-wear
additives to provide maximum
durability and protection from
wear and viscosity breakdown.
Licensed by the American
Petroleum Institute (API) with
viscosity grades of 5W-30, 0W-40
and 5W-50, CMM motor oils
are intended for most types
of modern vehicles, including
high-performance turbo-charged
engines, supercharged gasoline
engines and multi-valve fuel-​
injected engines.
Champion
www.championbrands.com
800-821-5693
OIL ANALYZER
4
The new MiniLab EL
Series from Spectro
Scientific is an oil
analysis tool for non-destructive
testing of high-performance
engines in aircraft, racing cars
and railway environments.
With integrated hardware and a
software suite, the oil analyzers
can provide lab-quality results in
less than 5 minutes using only
a 5-milliliter sample of oil. No
sample preparation, solvents or
chemicals are required. Tests
include elemental analysis,
viscosity, oil chemistry, fuel dilu-
tion and total ferrous wear.
Spectro Scientific
www.spectrosci.com
978-486-0123
4

AUTOMATIC
LUBE SYSTEM
5 7
Graco’s Electric Grease
Jockey is a new automatic
lubrication system for
the trucking and fleet industry.
It incorporates a lubrication
pump with integrated controls
to offer system health, status and
low-level alerts as well as motor
burnout protection. The system
flushes and blocks contaminants
with a consistent supply of fresh
grease during the vehicle’s oper-
ation. The distribution meters
allow the electric-powered system
to reliably deliver NLGI #2
grease, while the low-level sensor
automatically alerts the operator
when lubricant is low.
Graco
www.graco.com
844-241-9504
5 7
FLUID EXTRACTOR
6
The new fluid extractors
from Lumax are
designed to move fluids
through dipstick tubes and
filler ports. The extractors work
by manual pump operation
to create a vacuum, which is
intended to provide greater
mobility without the need for
electricity or compressed air.
Suitable for brake fluid, engine
oil, gear oil, transmission fluid
and water, the transfer pumps
can be used for extracting
fluids and changing engine oils
and lubricants in gearboxes,
all-​terrain vehicles, farm
equipment, motor bikes, snow-
mobiles, boats and watercraft.
Lumax
www.lumax.com
844-660-6876
6
PORTABLE
FILTRATION SYSTEM
The Pneumatic Fuel Tank
Sweeper from Innovative
Products of America is a
new filtration system for removing
debris, impurities and water from
contaminated diesel fuel, fuel
oil and kerosene in fleet trucks,
off-road equipment and stationary
holding tanks. The portable unit
employs a diaphragm pump and
panel mount controls along with
a spill-free, drain-down design. It
can transfer up to 26 gallons per
minute and includes extra 17- and
30-micron filters, 11-foot intake
and output hoses, rigid and flex
wands, a flow-through brush, and
quick-disconnect ball valve.
Innovative Products
of America
www.ipatools.com
888-786-7899
8
ML
ULTRASOUND
DETECTORS
8
SDT’s new Checker
range of ultrasound
detectors is engineered
to provide a low-cost solution
for every potential problem,
with the LEAKChecker for
pinpointing pressure and vacuum
leaks, the LUBEChecker for
optimizing bearing lubrication,
the TRAPChecker for assessing
the condition of steam traps and
valves, and the TIGHTChecker
for verifying the tightness of
closed volumes. Users simply
choose the right tool for the job
at hand and then perform a fast,
troubleshooting inspection. Each
detector can identify defects early
and quickly while also enabling
deeper analysis and trending.
SDT
www.sdtultrasound.com
800-667-5325
 GET TO KNOW

Bennett Brings
Lubrication Experience
to Mosaic
Gary Bennett has worked for Mosaic and its preceding companies in the phosphate mining
industry for more than 43 years. After starting as a laborer when he was 18 years old, he spent the
next six years in various operations positions, including as a sizer operator, locomotive operator
and flotation plant operator. Bennett began working in machinery lubrication when he entered
the maintenance apprenticeship trainee program. Following a few years as a general mechanic, he
started performing preventive maintenance (PM) tasks and became more involved in lubrication.
Over the past two years, he has helped the Four Corners Mine make tremendous improvements
in its PM process by establishing a lube room, filtering oil, using best practices for contamination
control, greasing motors using ultrasound technology and performing oil sampling.

Name: Gary Bennett
Age: 61
Job Title: Washer Maintenance then, I have completed Mosaic’s Precision Main-
PM Mechanic
Company: The Mosaic Co.
Location: Bradley, Florida
Length of Service: 43 years
Be Featured in the
Next ‘Get to Know’
Section
Would you like to be featured in
the next “Get to Know” section
or know someone who should be
profiled in an upcoming issue of
Machinery Lubrication magazine?
Nominate yourself or fellow lubri-
cation professionals by emailing a
photo and contact information to
editor@noria.com.
Q: What types of training have you taken to
get to your current position?
A: I completed a four-year maintenance appren-
ticeship program to become a mechanic. Since
tenance training course, Machine Lubrication
Technician Level I training, and Machine Lubri-
cant Analyst Level II training.
Q: What professional certifications have
you attained?
A: I have obtained the Machine Lubrication Tech-
nician Level I (MLTI) and the Machine Lubricant
Analyst Level II (MLAII) certifications.
Q: What’s a normal work day like for you?
A: I clock in at 7 a.m. and attend the morning
maintenance meeting with my fellow mechanics
to get the day’s assignments. If I am not assigned
anything specific to repair, I start my PM route
by checking the oil level and condition of my
pumps. I set up my filter cart and generator on
a pump bearing assembly to be filtered for that
day. During my PM route, I make small repairs
to equipment as needed. I record temperature
and vibration readings, report my findings on a
PM sheet and enter follow-up work orders. Once
a week I do PMs on a hydraulic system in the
washer, which involves checking the reservoir’s
oil condition, the kidney-loop filter for proper
operation, the breather condition and for leaks in
the system. I also perform monthly oil sampling,
grease motors using ultrasound every three
months and complete the daily 5-S check of the
lube room.
Q: What is the amount and range of
equipment that you help service through
lubrication/oil analysis tasks?
A: I maintain more than 30 pumps, one
hydraulic system that powers more than 20
valves, and use two oil-filtering units. The 30
pumps are a mixture of horizontal slurry pumps
(direct and belt driven) and vertical water
pumps, with motors that have oil-lubricated
bearings and an automatic grease system for the
pump bushings.
Q: On what lubrication-related projects are
you currently working?
A: I am currently assembling a trailer that will house
a generator and second filter cart for pump bearings.
I am also actively installing oil sample ports and
quick connects on the pump bearing assemblies.
In addition, I am continuing to help develop our
motor greasing program using ultrasound tech-

30 | January - February 2018 | www.machinerylubrication.com

 ML

nology. Soon I will be gathering special

START YOUR
sets of samples and, based on the results,
establishing oil change intervals for specific

FREE SUBSCRIPTION
pumps.

Q: What have been some of the biggest

project successes in which you’ve played www.machinerylubrication.com
a part?
A: An overall success we’ve had is tran-
sitioning from a reactive maintenance
organization to a proactive organization by
utilizing oil analysis and oil filtering, estab-
lishing a lube room and implementing best
practices in contamination control from the
MLT training. The hydraulic system PM
played a part in helping reduce our plant-
wide hydraulic oil contaminant particle
count by 95 percent in six months.

Q: How doe s you r c ompa ny

view machiner y lubricat ion in
terms of importance and overall
business strategy?
A: After safety, lubrication is the most crit-
RAMs Supply Fluid Access
ical aspect of our maintenance program so for Reliable Hydraulics!
that equipment doesn’t fail unexpectedly
and cause downtime. All of our improve-
ment efforts will help save money and
enable Mosaic to be a low-cost producer
by reducing equipment failures, downtime
and costs/spending, as well as increase
planned/scheduled work.

Q: What do you see as some of the more

important trends taking place in the Filter Before Use! Off-Line Filtering!
lubrication and oil analysis field?
A: An important trend I’ve witnessed
over the last couple of years at my plant is
bringing lubrication education to the hourly
RAM (Reservoir Access Manifold) S o lSuotliuo tniso nb sy bDy e D
s i ge sni g n
Reservoir, Drum and Gearbox Adapters
level of an organization so mechanics can supply large permanent down tubes into fluids using the
look at and understand oil sample reports
existing breather port with no fabrication. Hydraulic and lube
and then implement corrective actions as
fluids must be clean, cool and dry for machine reliability. RAMs
needed without having to wait on someone
supply simple oil access for filtering fluids while maintaining a
else to interpret the report. Training
closed-system and your ISO oil cleanliness codes.
everyone is the opposite of the “way we’ve
always done it” mentality and will provide www.c-changeinc.com • info@c-changeinc.com • 916.752.2984
benefit to any company. ML

www.machinerylubrication.com | January - February 2018 | 31

 TEST YOUR KNOWLEDGE
This month, Machinery Lubrication continues its “Test Your Knowledge” section in which we focus on a group of questions from Noria’s
Practice Exam for Level I Machine Lubrication Technician and Machine Lubricant Analyst. The answers are located at the bottom of this
page. The complete 126-question practice test with expanded answers is available at store.noria.com.

Stay Connected With Noria

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1. The primary reason that machinery is replaced is due to:

Only use blue and/or white.

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Brand Guidelines.

A) Erosion
B) Accidents
C) Obsolescence
D) Surface degradation of the metal
E) Corrosion
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2. Sampling crankcase oil from an engine should be done:
A) Through the dipstick hole with a drop-tube
B) From a valve mounted after the pump and after the filter
with the engine running
C) From a valve mounted after the pump, before the filter with
the engine running
D) From a valve mounted after the pump, before the filter
with the engine shut off
E) From the drain plug

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3. Elastohydrodynamic lubrication (EHL) is considered http://www.facebook.com/noriacorp
to occur primarily in:
A) Piston rings and liners
B) Journal bearings
C) Rolling bearings, gears and cams
D) Slow-moving pins and bushings
E) Worm gears

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namic lubrication. https://www.linkedin.com/company
deform elastically to enlarge the contact area, which is why it is called elastohydrody- /noria-corporation
as rolling-element bearings, gears (at the pitch line) and cams. The mating surfaces
EHL occurs in systems where the contact area is small and the pressure is high, such
3. C

nants and wear metals are captured by the filter.

This will help assess the actual condition of the oil and the engine before the contami-
2. C

metal includes all types of wear such as abrasion, adhesion, erosion, corrosion, etc.

Continue learning with us on

Wear is the primary cause of machinery replacement. Surface degradation of the
1. D
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32 | January - February 2018 | www.machinerylubrication.com

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

Oil Analysis Basics Lubrication Basics

– Second Edition for Machinery Oper-
Publisher: Noria Corporation
ators Training Video
The new Second Edition Format: DVD
Publisher: Noria Corporation
includes more detailed
Train your team on the
i n format ion on oi l
basics of lubrication and
sampling, filtration and how to recognize early
contaminant removal, base signs of lubrication-related
oils and additives, water- problems with this convenient video training
in-oil contamination and DVD. Your operators will learn the basics of
removal, ASTM standards, operator-based lubrication inspections and gain
Use the Correct Oil glycol testing, flash point tests, and 14 additional oil the knowledge to ensure that routine inspec-
Poster analysis tests. tions and top-offs are performed with precision
and accuracy.

Lubrication Handbook of
Fundamentals — Lubrication
Second Edition and Tribology -
Authors: D. M. Pirro and Volume II: Theory
A. A. Wessol and Design - 2nd
This newly revised and Edition
expanded reference book Author: Robert W. Bruce
emphasizes the need for Sponsored by the Society
lubrication and careful lubri- of Tribologists and Lubri-
cant selection. Thoroughly updated and rewritten, the cation Engineers, this handbook incorporates
Second Edition of Lubrication Fundamentals discusses up-to-date, peer-reviewed information for tackling
Home Sweet Home product basics, machine elements that require lubri- tribological problems and improving lubricants and
Poster cation, methods of application, lubrication, lubricant tribological systems. It demonstrates how the prin-
storage and handling, lubricant conservation and ciples of tribology can address cost savings, energy
much more. conservation and environmental protection.

Machinery Lubrication I Study Pack

• • Flash Card Pack
• • 125-question Practice Exam
• • How to Take a Multiple-Choice Exam
• • Machinery Lubrication Reference Guide
•• Oil Analysis Basics
• • The Practical Handbook of
Machinery Lubrication
Keep Our
Machines Clean See page 45 for the next scheduled training class.
Poster

www.machinerylubrication.com | January - February 2018 | 33

 Bennett Fitch | Noria Corporation
LESSONS IN LUBRICATION Bearing Lubrication

8 Lubrication Failure
Mechanisms for
Rolling-element Bearings
Rolling-element bearings are some of
the most frequently used mechanical
components that require a lubricant. Their
application is very broad, ranging from
small, non-critical knob-adjuster support bearings to large,
critical wind-turbine main bearings. In general, bearings
tend to fail well before their design life. This is often
because the environmental and operating factors are not
controlled or taken into consideration when the lubricant is
selected. In this article, I will refer to rolling-element bear-

“
ings simply as bearings. However, this does not necessarily
address the topic as it relates to journal bearings.
Regardless of whether a bearing reaches its design life,
the life you should strive to achieve from your bearings
should be based on the optimum reference state (ORS).
When considering a bearing’s application and its associ-
Whether it’s ated reliability objectives, a certain maintenance strategy
excessive should be deployed to help attain an optimized return
on investment. For example, if the result of a bearing
contamination failure does not lead to any immediate downtime and the
corrective action costs are insignificant when compared
or an incorrectly to using regular proactive and predictive maintenance
over the life of the bearing, then a run-to-failure strategy
applied lubricant, may be the ORS.
it is important to It’s not uncommon for small bearings (with low speed
factors) to be kept sealed without any relubrication and
understand the very little maintenance required. However, in most cases,
a carefully selected relubrication schedule and a mainte-
root causes that nance strategy that is more comprehensive than simply
reactive maintenance will be recommended, depending
can contribute to on the optimum reference state.
lubrication failure When performing a failure modes and effects analysis
(FMEA) on a bearing, a series of questions must be asked.
mechanisms.” These would include the following:

34 | January - February 2018 | www.machinerylubrication.com

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www.machinerylubrication.com | January - February 2018 | 35

 LESSONS IN LUBRICATION
42%
of lubrication professionals
say contamination is the
most common cause of
bearing failures at their plant,
according to a recent poll at
MachineryLubrication.com
36 | January - February 2018 |
• • To what type of application is the bearing subjected?
• • What function does the application perform for the
organizational goals? (How critical is the piece of
equipment containing the bearing?)
• • What are the potential failure modes? (In what ways
can the machine fail?)
• • What are the effects of the failure modes? (What is
the consequence of failure on operations?)
•
• What is the severity of each of these effects?
(What’s the relative impact of these failure modes
on operations?)
• • What are the failure mechanisms for each failure
mode? (What is the underlying root cause?)
• • How likely is it for the failure mechanism to exist?
(What is the probability of the failure mechanism?)
• • What failure detection mechanisms are deployed?
(What methods are there to predict the failure?)
• • How effective is the detection mechanism? (What is
the probability of detecting the failure early?)
With the answers to these questions, a risk/priority
number can be calculated and recommendations for the
best maintenance strategy determined.
This article will highlight the most common failure
mechanisms for a bearing as a result of lubrication (or
lack thereof ). When analyzing these failure mecha-
www.machinerylubrication.com
nisms, one can perform a lubricant FMEA. With this
approach, questions are asked similar to those in the
machine FMEA discussed earlier, but in this case the
lubricant’s failure root causes are identified as well as
how they can result in a failure to provide lubrication
to the machine.
In his book, Machinery Failure Analysis and Trouble-
shooting Vol. 2, Heinz Bloch states, “Lubrication-related
bearing problems, according to our experience, are
most frequently caused by lack of lubrication or lubri-
cant contamination.” This information is not new and
has been reiterated by bearing manufacturers and end
users through countless failure root cause analyses
(FRCA). But why?
Consider that rolling elements in bearings ride on a
thin film of lubricant (often less than 1 micron) at the
mating surface of the bearing race. With small contact
areas, the pressure exerted on the surfaces can exceed
500,000 pounds per square inch (psi). If any lubricant
is displaced by a foreign contaminant, such as dirt or
water, at these critical load zones, the bearing eventually
will experience increased wear. If the wear is excessive,
the life of the bearing will be reduced significantly. The
result is a contamination-induced bearing failure.
But even when contamination is minimized, if the
lubricant selected for the application does not meet the
operating and environmental requirements, a lubri-
cant-​induced bearing failure will occur. Therefore,
whether it’s excessive contamination or an incorrectly
 ML

applied lubricant, it is important must work harder to overcome the 4. Hot Running
to understand the root causes that
can contribute to lubrication failure
fluid friction. As the temperature rises Conditions
for the excessive grease charge, the A bearing running at a higher
mechanisms along with the most viscosity will drop and other adverse than expected temperature can be
common reasons why bearings
effects will ensue. either a root cause or a symptom. If
prematurely reach the end of their
life. Following are the top eight
lubrication failure mechanisms for
rolling-​element bearings:
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First, you must choose the
correct lubricant for the applica-
tion. Fundamental properties, such
as the viscosity, additive package
and consistency (for grease), should
be carefully selected based on the
bearing type, speed factor and oper-
ating conditions. If these factors are
not thoroughly considered and an
unsuitable lubricant is applied, the
lubricant may become overly stressed
or be insufficient for the machine’s
lubrication needs. In either situa-
tion, the bearing will likely undergo
premature wear and failure.

2. Lack of Lubricant
For greased bearing applications,
the correct regreasing volume and
frequency must be established to
ensure the bearing load zones are
lubricated properly. Too much time
between regreasing intervals or
applying too little grease will cause
Quality
excessive boundary conditions and Service
bearing wear. This type of failure
mechanism also tends to trigger Expertise
a chain reaction of other failure
mechanisms, such as hot running
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cles, further perpetuating the failure Don’t Risk Your Equipment with Inferior Oil
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3. Excess Lubricant online at klsummit.com/products.
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a bearing in medium to high-speed Klüber Lubrication NA LP
applications, the temperature will rise Summit products are made in U.S.

from the churning, and the machine

www.machinerylubrication.com | January - February 2018 | 37

 LESSONS IN LUBRICATION
the bearing is exposed to an external
environment that is exceptionally
hot, this would indicate a root
cause. If the temperature increase
is from an internal condition,
then this would be a symptom
with possible root causes such as
excessive lubricant, lack of lubri-
cant or misalignment. Regardless
of the source of the hot running
conditions, the heat will lead to
increased lubricant oxidation,
thermal degradation, additive deple-
tion, viscosity changes and other
failure modes. If the source of the
higher temperatures is mechanical,
this can be identified as part of the
FMEA process.
5. Solid
Contamination
Solid contaminants can enter
a system in a number of ways,
including through a new lubricant,
ingested from a headspace port or
hatch, via defective seals, etc. The
type of solid contaminants can vary
depending on the source, but typical
airborne dust/dirt will consist
primarily of silica and alumina.
Excessive contamination will
result in lubrication failure, as the
lubricant likely will not be able to
overcome the various wear modes,
like three-body abrasion. Addition-
ally, if the contaminants are metal
catalysts, they can contribute to
lubricant degradation in the form
of oxidation, particularly when in
combination with water, higher
temperatures and air.
6. Moisture
Contamination
Similar to solid contaminants,
moisture can enter a system in many
different ways, including through
the headspace entry point, seals
or new oil. When the headspace is
humid, thermal cycles can cause
moisture to escape the air, sweat
onto surfaces and find its way into
the oil through gravity. Moisture
38 | January - February 2018 | www.machinerylubrication.com
may exist in a lubricant as dissolved,
emulsified or free water. Emulsified
water has the most destructive
potential in oil. Water is not a
good lubricant, so when it displaces
oil in a bearing’s load zones, the
water collapses, producing a lubri-
cation failure and mechanical
wear. Water also contributes to
oxidation and hydrolysis, with the
lubricant undergoing permanent
chemical degradation and addi-
tive depletion. These can lead to
a lubrication failure by changing
the lubricant’s viscosity, removing
additive functionality, and forming
other contaminants, insolubles and
acids. Of course, when considering
the machine, water is the primary
cause of rust.
7. Mixed Lubricant
Topping up (if oil) or regreasing
(if grease) a bearing with the wrong
lubricant can drastically change the
physical and chemical properties
of the resulting lubricant mixture.
Not only can factors like the
wrong viscosity impact lubrication,
but additives can also react nega-
tively with each other, impeding
their functionality.
8. Other Contaminants
Depending on the machine
type, bearings may be introduced
to other process chemicals, blow-by
contaminants, glycol, etc. Based
on the type of contaminant, the
lubricant can change chemically
or physically, resulting in a lubri-
cation failure.
In conclusion, regardless of
whether you have a lubricant- or
contaminant-induced failure mech-
anism, the result will either lead
to lubrication failure modes or
contribute directly to mechanical
failure modes of the bearing. When
multiple failure mechanisms are
combined, there is greater potential
for a lubricant failure. A machine
FMEA performed on a failed bearing
can frequently reveal mechanical
wear signatures that indicate whether
the failure was lubricant-related,
although often the damage during
the final stages of a catastrophic
failure will destroy or overshadow
the evidence of the failure’s true root
cause. In these cases, it usually is best
to perform lubricant analysis (either
grease or oil) to detect clues of the
root cause, like a thermally degraded
lubricant, abnormal levels of contam-
inants, changes in viscosity, etc.
When developing a conclusion, it
also helps to include available mainte-
nance records or condition monitoring
data, such as vibration analysis, ther-
mography or maintenance logs on
relubrication and inspections.
Again, just because a lubrica-
tion failure has occurred doesn’t
necessarily mean the lubricant was
insufficient in volume. Many fail-
ures are associated with too much
of something, like the lubricant’s
viscosity or amount. Moreover, if a
contaminant is taking the place of
the lubricant or disrupts the function
of the lubricant, the contaminant
will be the ultimate cause of the
lubrication failure. ML
References
Troyer, D. (2000, May). “FMEA
Process for Lubrication Failures.” Practicing
Oil Analysis.
Bloch, H.P. (1999). Machinery Failure
Analysis and Troubleshooting. Vol. 2. pp. 79.
About the Author
Bennett Fitch is a senior technical
consultant with Noria Corporation.
He is a mechanical engineer who
holds a Machine Lubricant Analyst
(MLA) Level III certification and
a Machine Lubrication Techni-
cian (MLT) Level II certification
through the International Council
for Machinery Lubrication (ICML).
Contact Bennett at bfitch@noria.
com to learn how Noria can help
you implement effective lubrication
strategies that prevent failure.
 LUBE-TIPS
The “Lube-Tips” section of Machinery
Lubrication magazine features innovative
ideas submitted by our readers.

New Grease Gun Caution

Before installing grease into a new grease gun, consider disassembling the gun and cleaning it thoroughly.
Metal shavings have been found in new grease guns. These metal shavings appear to be from the manufacturing
process of the grease gun.

Did You Know?

Avoiding Contamination Additional tips can be

in Dirty Environments found in our Lube-Tips

email newsletter. To receive
Machines operating in an extremely dirty environ- the Lube-Tips newsletter,
subscribe now at
ment, such as in a forge or foundry, require extra care
to prevent contamination. Try to keep the equipment MachineryLubrication.com.
sealed and avoid unnecessary opening of the reser-
voirs. Install quick disconnects in tanks and on fill
vessels for filling or topping up hydraulic tanks. Add
mainstream sampling taps on all equipment. This Have Some Tips?
will result in a true indication of the oil’s condition, If you have a tip to share,
email it to
avoiding any bottom sampling. editor@noria.com.

Preventive Measures
Make Sense
Catastrophic pump failure on circulating
and hydraulic systems can damage more than
just the pump. Consider using oil strainers or
filters upstream of all equipment components
to prevent pump failure debris from damaging
these machines. This is also important for
kidney-loop systems with expensive heaters
and oil/water separators. ML

www.machinerylubrication.com | January - February 2018 | 39

 ASK THE EXPERTS
“Do you have any suggestions for problems with the
solubility of oxidation products in turbine oil at
low temperatures?
Recently, my clients have
had a problem with the
solubility of oxidized
products in turbine
and hydraulic oils. At operating
temperatures (60-80 degrees C),
they are dissolved, but in stop-
page (i.e., temperatures below 25
degrees C), they become insoluble
and begin to deposit on working
surfaces. This is a problem with
the hydraulic piston pumps, and it
does not matter the type of turbine
(gas/steam/etc. or manufacturer) or
the working hours.”
Based on your comments, you
may be dealing with varnish forma-
tion, which is a frequent problem in
high-temperature and high-pressure
systems such as steam turbines or
high-performance hydraulic systems.
Varnish is the accumulation
of oil oxidation and degradation
compounds on machine surfaces
or components. It can be the result
of several possible root causes,
including high temperatures,
“Why aren’t more machine shops using natural biode-
gradable oils? Is it the cost, availability or marketing?
Don’t they outperform
the others? I am confused
why more machin-
ists don’t use them.”
Much of the reason for this may
be due to old practices and mind-
sets. If your mineral oil worked for
you yesterday, why would you want
to change to a vegetable-based oil
40 | January - February 2018 | www.machinerylubrication.com
electrostatic discharges, lubricant
degradation and microdieseling.
Varnish can produce a number
of problems related to machine
operation, such as valve stiction,
lubricant flow restriction, clogged
filters, etc.
Varnish begins as dissolved
impurities. When these impurities
accumulate and reach the satu-
ration point, they migrate to the
surfaces of the lubrication system.
If these deposits remain on the
surfaces, they cure (harden) with
time, causing failure of the lube
system and lubricated components.
Oxidation resistance and solu-
bility are two important lubricant
properties to consider. Oxidation
resistance refers to how molecules
resist the chemical reaction with the
oxygen in the air. Oxidation degrades
oil and is one of the main reasons to
change it. The greater the oxidation
resistance, the longer the oil life.
Solubility is the property
that allows a lubricant to hold
today and take a chance that the
new product won’t perform as well?
People often fall into a routine,
and unless something upsets that
routine, the current practices tend
to stay the same. It’s usually not
until an event like a discharge,
government agency involvement or
new personnel entering the facility
polar substances like varnish in
suspension without damage to the
machine. Oil solubility increases
at higher temperatures. Group
III oils also have lower solubility
than Group II and Group I oils.
There have been many instances
of machines experiencing varnish
deposits due to lower solubility
of the oil after switching from a
Group I oil to a Group II or III oil.
If you are facing varnish
deposits, two actions are recom-
mended to control it. First, identify
the root causes. This will require
a systematic study of the possible
factors supported by oil anal-
ysis. Next, remove the existing
varnish in the machine. This can
be achieved by adding solvent
or detergent additives to the oil,
using a synthetic product with
high natural solvency or installing
varnish removal systems. In cases
of hardened varnish, the solution
will be mechanical and may simply
involve changing the components.
that old practices are questioned
and new ideas are considered.
Many machinists may not even
be aware of the other products on
the market. In today’s economy, it
seems as if no one wears just one hat
on the job anymore. The pressing
issues at hand must be addressed,
so the thought of looking for new
 ML

products frequently gets pushed aside. Of your company values. Some industries may biodegradable fluid. Whatever the case, be
course, there are those who are constantly have policies on environmental impacts or sure to evaluate all of your options. ML
looking for the best-​performing products on be forced to adhere to government regu- If you have a question for one of Noria’s
the market and taking proactive steps to save
lations. The process might even demand a experts, email it to editor@noria.com.
the environment.
The other issue is that biodegradable oils
usually have a higher cost than mineral oils.
This hinders smaller shops from changing
to environmentally friendly lubricants.
The cost not only involves the oils but also
ensuring that all equipment is cleaned out
completely before making the switch, since
most vegetable oils and mineral oils don’t
mix well.

WE
Changing to biodegradable oils can be
costly and take time away from production.
Obviously, additional costs and downtime
are two things most plants never want to

OPTIMIZE
hear and will be put off until absolutely
necessary unless financial justification can
be made.

YOUR
Biodegradable oils have many advantages
over mineral-based oils. Anyone working in
a machine shop knows of the dreaded oil
mist. This mist consists of harmful volatile

MACHINES
organic compounds (VOCs) and can cause
dermatitis. With biodegradable oils, the
oil misting is lessened, which means fewer
VOCs entering the air and minimal skin-​
related issues. Using a vegetable oil may also
improve lubricity.
When deciding which lubricant is right
for you, consider the application as well as

ALIGNMENT
VIBRATION
BALANCING
ULTRASOUND

www.pruftechnik.com

www.machinerylubrication.com | January - February 2018 | 41

 By Rendela Wenzel
TRAINING AND CERTIFICATION
The Benefits
of a Lubrication
Certification
Certif ication is an
To check the dates important step for anyone
and locations of practicing in the field of
upcoming MLT exam machinery lubrication.
sessions or to apply It acknowledges your expertise in
for an exam, visit the lubrication and your ability to trou-
ICML website at
bleshoot lubricated equipment. A
lubecouncil.org.
certification also shows that you are a
professional with the ability to utilize
lubrication successfully to enhance
and improve reliability programs
within your plant or through a
client. The lubrication and oil anal-
ysis community, your employer and
peers will recognize this credential as
a symbol of the skills and knowledge
you have gained through experience.
However, certification not only
benefits the individual but also his
42 | January - February 2018 | www.machinerylubrication.com
or her company. Through certifica-
tion, employers can maximize their
return on investment in oil anal-
ysis, help to create synergy in their
organizations around lubrication
best practices, develop a stan-
dardized method of determining
training needs and measuring
results, as well as devise a reliable
benchmark for hiring, promoting
and career planning.
The International Council for
Machinery Lubrication (ICML)
offers multiple certifications for
those in both professional and
technical roles. The organization’s
Machine Lubrication Technician
(MLT) certification has two levels.
Level I targets in-plant technicians
who perform daily lubrication
tasks, such as oil changes, top-ups,
greasing bearings, lubricant
receiving and dispensing, and
lubricant storage and handling.
Level II is intended for in-plant
technicians or engineers who are
responsible for managing their
lube team, selecting lubricants,
troubleshooting abnormal lubri-
cant performance and supporting
machine design activities.
Certified MLT Level I practi-
tioners have demonstrated a working
knowledge of applying best lubrica-
tion practices and products. With
Lubrication Programs
this certification, technicians can
move away from outdated methods
of vague, non-specific lubrication
procedures and job plans, and
implement an effective lubrication
program in any industrial workplace.
Individuals with this certification
have proven their knowledge of
industry methods for selecting,
storing, filtering and testing lubri-
cants to boost reliability and generate
lasting results in machine availability
and overall reliability. They also have
an understanding of oil analysis,
which enables them to align their
efforts with those of maintenance
professionals or oil analysis experts.
Certified MLT Level II tech-
nicians have advanced knowledge
of lubrication topics like lubricant
selection, troubleshooting, predic-
tive maintenance and advanced
lubrication techniques. They
also understand the benefits and
potential of excellent lubrication
practices and can assist others in
making comprehensive improve-
ments in the workplace that save
significant time, money, storage
space and training resources.
To check the dates and locations
of upcoming MLT exam sessions or
to apply for an exam, visit the ICML
website at www.lubecouncil.org. ML

Recent Recipients of ICML Certifications
Adam Taylor, MLT I
Ahmed Magdy Mosbah, MLA I
Amr Fares Mersal, MLT I
DaCoda Walker, MLT I
Dylan Williams, MLT I
Islam Ramy Zakaria Hosny, MLA I
Jhair Medina Carrillo, MLT I
Jonathan Moller, MLA I
Moustafa Samir Helmy, MLA I
Sameh Radwan Osman, MLA I
Scott Flegel, MLT I
Vladislav Vladimirovich
Shestakov, MLA I
ADM Europoort
Demis Zwaneveld, MLT I
Alexandria Mineral Oil Co.
Mohamed Fawzy El-Shamy, MLA I
Arizona Public Service
Jeremie Wood, MLT I
Shelby Reese, MLT I
Arkema
Hoang Le, MLA II
Thomas Dees, MLT I
ARQ Asset Solutions
Conor O’Sullivan, MLA III
Ascend Performance
Materials
Hudson Woodfin, MLA II
Ash Grove Cement
Josiah Pratt, MLA I
Zon Cowan, MLA I
ATI Metals
Derrick Wodtli, MLA I
Eric Steinbrink, MLT I
John Batrouny, MLA II
Matthew Kragness, MLA I
Patrick Vasfaret, MLA II
Shawn Heuberger, MLA I
Atlasco Egypt
Aly Bendary, MLA I
AV Technology
Terry Harrington, MLA I
Boral
Paul Buckley, MLA I
Paul Hazeltine, MLA I
Braskem
Pedro Henrique Ortiz de Sa
Menezes, MLA II
Bureau Veritas
Jennifer Anweiler, MLA I
C.C. Jensen
Lars Bo Andersen, MLT I
The International Council for Machinery Lubrication (ICML) continues to provide skill certi-
fication testing for professionals in the areas of oil analysis and machinery lubrication.
The organization offers three certifications: Machine Lubricant Analyst (MLA), Machine
Lubrication Technician (MLT) and Laboratory Lubricant Analyst (LLA). ICML congratu-
lates the following individuals who recently achieved certified status in one of the three
certification areas.
Cargill
Roc Tainsh, MLT I
Carpenter Technology
Andrew Harakel, MLT I
Andrew Trygar, MLT I
Dave Lerch, MLT I
Kevin Kulp, MLT I
Steve Stull, MLA I
Tyler Quinn, MLT I
William Bidden, MLT I
Cascades
Bruno St-Pierre, MLT I
Frederic Ouellet, MLT I
Certified Laboratories
Loren Hyman, MLT I
Thomas Pekarik, MLA I & MLT I
Chevron
Roshaimi Ninggal, MLA I
Colbun
Ivan Medrano C., MLA I
Daniel Rojas Zuniga, MLA I
Hector Parra Ibanez, MLA I
Luis Gonzalez Lepe, MLA I
Maria Magdalena Ossa Hurtado,
MLA I
Oscar Jeldres Fonseca, MLA I
Pedro Orellana Jara, MLA I
Rodrigo Alejandro Mieres
Smaniotto, MLA I
Compania Minera Milpo
Jaime Levano Munayco, MLT I
Compressor Technologies
Petr Linev, MLA I
Confialub/Noria Brasil
Lisandra Nascimento Cobu,
MLA II
Crown Equipment Corp.
Jimmy Tester, MLA I
Keith Phillips, MLA I
Steve Wade, MLA I
Den Hartog
Gilbert Pastink, MLT I
Job Stigter, MLT I
Sven van der Kaden, MLT I
Wim Noorland, MLT I
Drummond
Daniel Eduardo Davila Aaron,
MLA II
Iader Juvinao Riquett, MLA II
Roberto Saade Fernandez, MLA II
DSB Vedligehold
Sarah Pedersen, MLA I
DTE Energy
Eric Berger, MLA I
DuPont
Andrew Wiff, MLA I & MLT I
Philip Hedlesky, MLT I & MLA I
Eco-Services Operations
Cleve Daigle, MLA I
Egyptian Steel
Emad Helmy Borham, MLT I
EPROM
Karim Mamdouh Youssef, MLA I
Tarek Mohamed Hatem Badr,
MLA I
Fleury Engineering
Mark Fleury, MLA III
Fortescue Metals Group
Abimarh Corpuz, MLT I
Cameron Elliot, MLT I
Derek Gaw, MLT I
Eagen Nyathi, MLA I
Hamish Stubbs, MLT I
John Kicielinski, MLA I
Jolyon Gardner, MLT I
Matthew Burley, MLA I
Melanie Jackson, MLA I
Paul Leeson, MLA I
Robert Manangan, MLT I
Troy Jackson, MLA I
Gamma Solutions
Angel Ronald Valenzuela, MLT I
Gerdau
Michel Junio de Almeida Diniz,
MLA II
Rafael Souza Felicio, MLA II
Graymont
Jeffrey Hanlon, MLT I
Thomas Bird, MLT I
Toby Dugal, MLT I
Trevor Danko, MLT I
Hexion
Jeff Rentfrow, MLT I
Michael Harmata, MLT I
Hitma Ultra Pure
Ben Gaarthuis, MLT I
Corne Bavert, MLT I
Huntsman
Alex Marse, MLA I
Hy-Pro Filtration
Peter Creet, MLA I
Ilim Group
Evgeniy Vitalyevich Kolesnikov,
MLA I & MLT I
Gleb Alexandrovich Astafev, MLT
I & MLA I
Ivan Nikolaevich Karnaukhov,
MLT I & MLA I
CERTIFICATION NEWS
Vitaliy Shihov, MLT I
Ineos
Justin Rhodes, MLA II
Ingredion
Brian Wilmesmeier, MLT I
Bryan Cole, MLT I
Ethan Wagner, MLT I
George Warwick, MLT I
James Chestnut, MLT I
Matthew King, MLT I
Sean Smith, MLT I
Shane Smith, MLT I
Steven Willetts, MLT I
Thomas Schulte, MLT I Need to take
International Paper an exam?
Bobby Edwards, MLA II
Charles Chavis, MLT I
ICML regularly holds
Christopher Humphries, MLT I exam sessions throughout
Daniel Baker, MLT I the United States and the
Devin Martin, MLT I
Donald Reed, MLA I world. Upcoming dates
James Anderson, MLT I and locations for ICML
Jeffrey Koch, MLT I
Justin Byrdic, MLT I
exams can be found at
Micheal Johnson, MLT I www.lubecouncil.org.
William Davis, MLA I
JW Aluminum
Richard Reeder, MLT I
Koch Industries
Mason Grittman, MLT II
Komatsu
ICML Certifications
Roy Zanabria Campos, MLA I
Kraft LLA I
L aboratory Lubricant
Darren Maloney, MLA I
Kraton
A nalyst Level I
Aaron Vaughn, MLT I
Andrew Cline, MLT I MLA I
Ashlee Jones, MLT I
M achine Lubricant
Chuck Lipscomb, MLT I
Dean Strahler, MLT I
A nalyst Level I
Eric Morrison, MLT I
Erica Ohler, MLT I MLA II
Ethan Wolfe, MLT I
M achine Lubricant
Greg Allen, MLT I
James Bailey, MLT I A nalyst Level II
Joshua Middleton, MLT I
Joshua Sargent, MLT I
Kevin Miihlbach, MLT I
MLA III
Mark Huck, MLT I M achine Lubricant
Neal Morrison, MLT I A nalyst Level III
Robert Delaney, MLT I
Ryan Strahler, MLT I
William Smith, MLT I MLT I
M achine Lubrication
LafargeHolcim
Corey Green, MLT I Technician Level I
Laurentide Controls
David Nollet, MLA II
MLT II
M achine Lubrication
Technician Level II
CERTIFICATION NEWS
Marco Diaz, MLT I
Rosana Reyes, MLT I
Liberty OneSteel
Jamie Schweitzer, MLA I
Jian Le Liew, MLA I
Kenneth Smith, MLA I
Luke Lambeth, MLA I
Logan Aluminum
Timothy Hunt, MLA I
Lott Oil Co.
Amanda Nicholas, MLA II
Mississippi Lime Co.
Collins Alexander, MLT I
Dennis Roth, MLT I
Larry Naeger, MLT I
Mondi Syktyvkar
Arvid Aleksandrovich Erlikh, MLA I
Igor Vasilievich Mironyuk, MLA I
Monition
Ben Maloney, MLA I
Carl Boyce, MLA I
John Kelly, MLA I
START YOUR
FREE SUBSCRIPTION
44 | January - February 2018 |
NAES Corp.
Mike Walker, MLA II
NCH
Joe Rountree, MLT I
Noria
Scott Martin, MLA I
NRG Energy
Keith Von Anderson, MLA I
Obras de Ingenieria
Juan Manuel Ramos Maldonado,
MLT I
OCP
Abdallah Khalil, MLT I
Ahmed Baggar, MLT I
El Bouchti Zineb, MLT I
Safwane Bendaikh, MLT I
Youness Elhidaoui, MLT I
Pec Ltd.
Daniel De Leon Cabanilla, MLA I
Kyaw Moe Htut, MLT I
Soe Thi Ha, MLT I
Sze Tung Sim, MLA I
www.machinerylubrication.com
www.machinerylubrication.com
Thachaparambil Ouseph Jinto,
MLT I
Penn State University
Anthony Villella, MLT I
Michael Grubbs, MLT I
Sean Harris, MLT I
Petromaint
Mohamed Gheaty Hussein, MLA I
RelaDyne
Coty Thibodeaux, MLA I
Ethan Schexnider, MLA I
Gene Wagenseller, MLA III
Sakhalin Energy
Investment Co.
Nikolay Lukyanov, MLA I
Sappi
Bob Laporte, MLT I
Matthew Holman, MLT II
Sarawak Energy
Anielson Bin Mamin, MLA I
Bracewell Anak Miga, MLA I
Kho Siaw Peah, MLA I
Micheal Clinsman Anak Andy,
MLT I
Mohammad Najib Bin Mornie,
MLA I
Schaeffer Manufacturing
Alexander Wolff, MLA I
Schenck Process
Jonard Collera Delos Santos,
MLA I
Shermco Industries
Todd Graham, MLT II
SKF
Edwin Alonso Solís Tinoco, MLT I
Kenny Rogers, MLA I
Kevin Lane, MLA I
Miller Ollukaran, MLA I
Paulo Cipriano, MLA I
Soltrak
Mayra Marlene Beltran Cotera,
MLA II
Vicky Magaly Tito Zuniga, MLA II
Steinweg
Johan de Kok, MLT I
Suez Environment
Eslam Mostafa Kamal Hafez, MLA I
Sumar
Wilmer Navarro Moina, MLT I
T.E. Laboratories
John McGrath, MLA III
TOSL Engineering
Kevan Ragoonath, MLT I
Unified Lubricants Co.
Abdalrahman Hamid, MLA II
Westlake Chemical Co.
Caleb Redmond, MLA I
Jarren Cornner, MLA I
Wolf Creek Nuclear
Operating Corp.
Michael Tatton, MLA II
Yanbu Cement Co.
Torki Ibrahim, MLA I & MLT I
Global Training Calendar
March INDUSTRIAL LUBRICATION MACHINERY LUBRICATION I
Mexico City, Mexico • March 13 – 14, 2018 Firenze, Italy • March 14 – 15, 2018
MACHINERY LUBRICATION I
Woodmead, South Africa • March 5 – 9, 2018 MACHINERY LUBRICATION I
OIL ANALYSIS II
Albuquerque, New Mexico • March 13 – 15, 2018
MACHINERY LUBRICATION I São Paulo, Brazil • March 19 – 21, 2018
OIL ANALYSIS II
Quito, Ecuador March • 6 – 8, 2018
Mexico City, Mexico • March 13 – 15, 2018 MACHINERY LUBRICATION I
INDUSTRIAL LUBRICATION FUNDAMENTALS Daegu, South Korea • March 19 – 22, 2018
MACHINERY LUBRICATION I
Wanica, Suriname • March 6 – 8, 2018 Amsterdam, Netherlands • March 13 – 15, 2018
MACHINERY LUBRICATION I
MACHINERY LUBRICATION I MACHINERY LUBRICATION I
Zaragoza, Spain • March 6 – 6, 2018 Santiago, Chile • March 20 – 22, 2018
Mexico City, Mexico • March 13 – 15, 2018
FUNDAMENTALS OF MACHINERY LUBRICATION MACHINERY LUBRICATION I MACHINERY LUBRICATION I
São Paulo, Brazil • March 10 – 11, 2018 Koege, Denmark • March 14 – 16, 2018 Buenos Aires, Argentina • March 20 – 23, 2018

ICML certification testing is available for most of the courses listed.

Visit www.lubecouncil.org for certification information and test dates.
For updated dates and locations visit Noria.com/train
 Garrett Bapp | Noria Corporation
BACK PAGE BASICS
Consider Machine
Alignment to Avoid
Equipment Failures
After several years of
“
working in mainte-
nance, I have found
that there’s no replace-
ment for proper machine alignment. In
every training course I teach for Noria,
I explain that there isn’t a lubricant
There isn’t a that can protect against misalign-
ment. With this in mind, along with
lubricant that the thousands of machines that die
can protect every year due to improper alignment,
it’s time to take the necessary steps to
against further your reliability program.
When performed correctly, an
misalignment.” alignment can be an essential part
46 | January - February 2018 | www.machinerylubrication.com
Maintenance and Reliability
of a proactive maintenance plan.
The variety of methods and tools
available makes it easy to justify
investing the time to do the job
right. With that said, my first align-
ment experience involved following
an old-timer around as he showed
me the ropes. After we set the new
motor atop our hydraulic press and
cleaned out the old grease from
the grid coupling, he used a small
6-inch ruler or straight edge and
laid it across the coupling halves.
There was some shimming of the
motor to get it parallel with the
hydraulic pump shaft, but the whole
process was “eyeballed.”
Over time, what I learned from
this experience was that the drive end
of the motor ran hotter, the grease was
almost always hardened or turned to
dust, and we had to replace a broken
coupling quite often. From this prac-
tice, it’s safe to assume that we were a
reactive maintenance culture, and we
were. We never questioned why the
coupling disintegrated or why the
motors kept failing.
With a change of employers
came a new culture and the desire

to have a reliable plant. One of the
first steps was purchasing a laser
alignment tool, but this was only
the start. Once we received formal
training and began performing
more machine alignments, we were
able to achieve proper alignment
quicker each time. It sure beat the
previous methods of using straight
edges and dial indicators. We also
saw a reduction in failed bearings
and couplings across the plant.
IDENTIFYING
MISALIGNMENT
Proper machine alignment can
be summed up in a simple state-
ment: The shafts are aligned in both
the horizontal and vertical planes.
Misalignment takes place when the
shafts are not parallel or a shaft has
an angular misalignment. Parallel
misalignment means that an offset
of the shafts has occurred. Angular
misalignment refers to when the
shafts run at an angle to one another.
Sometimes both parallel and angular
misalignment may be present and
need to be corrected.
Parallel misalignment can be seen
in the horizonal and vertical planes.
Vertical misalignment usually can be
remedied by adding or subtracting
shims from the motor or machine feet.
Horizontal misalignment requires
side-to-side movement of the motor or
machine until the centerlines match.
Angular misalignment can also occur
in the vertical and horizontal planes.
EFFECTS OF
MISALIGNMENT
The effects of misalignment
can be catastrophic to a machine.
Coupling damage is the most common
symptom. When a technician pulls
the coupling halves apart for internal
inspection, the grid or teeth may be
affected, resulting in replacement of
the entire coupling. Of course, this
only masks the true problem hidden
inside the motor or machine.
Misalignment also increases
friction along the bearing surfaces,
which then turns into increased wear,
energy consumption and premature
breakdown of the machine. Seals can
be damaged during any part of the
process and lead to leakage. If the
issue exists for an extended period
of time, the shaft may be impaired
as well.
Once the components begin to
wear, a simple swap-and-replace is
no longer sufficient. If the underlying
cause of misalignment is not recog-
nized and corrected, the problem will
present itself again and again. It’s my
opinion that misalignment is often
overlooked as a root cause of failure.
Frequently, the problem is blamed on
faulty seals or the bearing installation.
It’s not until the maintenance profes-
sional receives proper training and
gains a better understanding of how
detrimental shaft alignment is that
the issue can be addressed through
corrective alignment.
ML
PREDICTIVE
TECHNOLOGIES
There are several predictive
technologies that can detect misalign-
ment. The most popular options are
laser alignment, vibration analysis, oil
analysis and thermography.
Laser Alignment
Laser alignment makes it simple
to align shafts with precision and
accuracy. It works by using a laser
that is directed into another sensor.
This sensor feeds data to a device that
deciphers the information and then
provides you with accurate data to
adjust your equipment. Once the
laser and sensor are strapped to the
driver and driven machine, the shafts
are rotated and multiple points are
read to determine which direction
the driver must move.
Laser alignment tools can
take into account the equipment’s
metallurgy and offer relative metal
expansion rates to consider how
the machine will expand during
operation. A live alignment is also
a possibility. For this, the techni-
cian aligns the machine as much as
possible, then starts the equipment
and allows it to reach its operating
temperature. After a shutdown,
a measurement is immediately
taken to establish the machine’s
thermal expansion.
By routinely using laser align-
ment on critical equipment, you
can make the necessary adjust-
www.machinerylubrication.com | January - February 2018 | 47
 BACK PAGE BASICS
ments and address other potential
issues. However, it isn’t the most
practical method for equipment in
operation, as it requires a shutdown
as well as dedicated hours for main-
tenance personnel to perform the
task. With an increased focus on
uptime, you may wish to select a
different option when shorter inter-
vals are required.
Vibration Analysis
Vibration analysis can also detect
misalignment by analyzing the
changes in vibration response, critical
speeds and machinery stability when
compared to an established baseline.
Vibration readings usually are in the
1X range for axial vibration or 2X
for radial vibration. An abnormal
result doesn’t always mean there is an
alignment problem. Different samples
must be taken from both the drive and
driven ends to eliminate other possibil-
ities and to determine if misalignment
is the issue.
Depending on the extent of the
misalignment, vibration analysis
may not detect it until a larger
problem with the bearings occurs.
Therefore, a proper alignment must
always be performed first. Screening
48 | January - February 2018 | www.machinerylubrication.com
tools should only be used for detec-
tion purposes.
Thermography
Thermography is another method
that can provide early detection
of alignment issues. Due to the
increased friction that exists with
misalignment, a rise in temperature
will follow. By taking a heat map of
the bearing areas, a technician can
identify any abnormal hot spots.
When machines are inspected,
an increase in temperature is not
always alarming. This puts a little
more responsibility on the user to
compare similar machines and be
consistent with spot checks.
Oil Analysis
Oil analysis may also be useful
in detecting misalignment by
providing the overall condition of
the machine, oil and contaminants.
It can identify active machine wear
earlier than vibration analysis if
performed correctly, i.e., sampling
from the right location, flushing
sample lines, using new sampling
hardware, etc. However, without
knowing the metallurgy of the
machine’s bearings, it can be diffi-
cult to establish a direct correlation
to misalignment.
Testing for elemental anal-
ysis can reveal slight increases in
common bearing materials such
as iron, aluminum, copper, lead
and chromium. This data may
serve as the first indication that a
problem exists within the machine.
Coupling oil analysis with vibra-
tion analysis can be an effective
combination for detecting issues
early and pinpointing their exact
causes. The microscopic appearance
of particles related to misalignment
will show shapes, sizes, textures and
colors commonly associated with
two-body abrasion, scuffing and
surface fatigue.
FINAL THOUGHTS
When setting up machines and
trying to determine the root causes
of failure, a proper alignment is often
overlooked. Even if your team has the
appropriate tools and training, you
must have detail-oriented people who
will stick with the job until it is done
right. I have been on alignment jobs
that only took 10 minutes to achieve
an accurate alignment. Others have
taken the better part of a day or two,
depending on whether the motor had
to be removed for machining.
Employing the right personnel
can make all the difference in an
acceptable alignment or a great
alignment – and there is a difference.
It comes down to how much of a
variance you will allow. On small,
low-cost or redundant machinery,
being within a few thousandths of
an inch may be all that’s necessary.
On larger machines that can shut
down your plant, your goal might
be as close to zero as possible.
Focus on proactive alignment
and doing it correctly the first time,
no matter what it takes. The best
maintenance programs also docu-
ment their results and have back-up
measures to predict when something
goes awry. By combining different
condition monitoring tools, proper
training and the right personnel,
you should see a decrease in overall
failures due to misalignment. ML
About the Author
Garrett Bapp is a technical
consultant with Noria Corporation,
focusing on machinery lubrication
and maintenance in support of Noria’s
Lubrication Program Development
(LPD). He is a certified lubrication
specialist through the Society of
Tribologists and Lubrication Engineers
(STLE) and holds Level II Machine
Lubrication Technician (MLT) and
Level II Machine Lubricant Analyst
(MLA) certifications through the
International Council for Machinery
Lubrication (ICML). Contact Garrett
at gbapp@noria.com to learn how
Noria can help you implement
proactive maintenance practices at
your plant.
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Conference.ReliablePlant.com

Attend. Learn. Apply.

BROUGHT TO YOU BY
WHAT IS RELIABLE PLANT?
Noria’s Reliable Plant Conference & Exhibition provides
exhibitors and attendees with a world-class event
featuring cutting-edge technical insight and high-level
networking opportunities across the maintenance and
reliability industry. For 2018, Reliable Plant heads to
Indianapolis, Indiana, for the 19th year of this must-
attend event.
With an established and global reputation for
technical excellence, Reliable Plant brings together
key plant and maintenance managers, as well as
reliability and lubrication professionals, from across
the world. Spanning four days, Reliable Plant 2018
includes workshops, learning sessions and case
studies designed to upgrade the skills and knowledge
of attendees. The conference will also feature
approximately 100 exhibitors in a 100,000-square-
foot exhibit hall inside the recently-expanded Indiana
Convention Center in Indianapolis.
In 2017, more than 1,500 attendees from 47 states, 27
countries and 112 exhibiting companies came together
to share ideas, solutions and information. Make plans
now to join us at Reliable Plant 2018. We will see you
in Indy!
INDIANAPOLIS, INDIANA INDIANA CONVENTION CENTER
SCHEDULE
Monday, April 16
7:00 a.m. – 5:00 p.m. ......................... Onsite Registration
8:00 a.m. – 4:30 p.m. ............. Pre-conference Workshops
5:30 p.m. – 8:30 p.m. ...............ICML Certification Testing
Tuesday, April 17
7:00 a.m. – 5:00 p.m. ......................... Onsite Registration
7:30 a.m. – 8:00 a.m. ..................... Continental Breakfast
8:00 a.m. – 9:20 a.m. .............................Opening Keynote
9:30 a.m. – 10:50 a.m. ............Exhibit Hall Grand Opening
11:00 a.m. – 11:50 a.m. ................... Conference Sessions
12:00 p.m. – 1:20 p.m....................... Lunch in Exhibit Hall
1:30 p.m. – 5:20 p.m. ...................... Conference Sessions
3:20 p.m. – 4:20 p.m. ....Refreshment Break in Exhibit Hall
5:30 p.m. – 7:30 p.m. ...............Meet and Greet Reception
6:00 p.m. – 8:00 p.m. ..............SMRP Certification Testing
9:30 a.m. – 5:30 p.m. .............................Exhibition Hours
Wednesday, April 18
7:00 a.m. – 7:50 a.m. ..................Offsite Prayer Breakfast
7:30 a.m. – 5:00 p.m. ......................... Onsite Registration
7:30 a.m. – 8:00 a.m. ..................... Continental Breakfast
8:00 a.m. – 9:50 a.m. ...................... Conference Sessions
10:00 a.m. – 10:50 a.m..Refreshment Break in Exhibit Hall
11:00 a.m. – 11:50 a.m. ................... Conference Sessions
12:00 p.m. – 1:20 p.m....................... Lunch in Exhibit Hall
1:30 p.m. – 3:20 p.m. ...................... Conference Sessions
3:20 p.m. – 4:20 p.m. ....Refreshment Break in Exhibit Hall
4:30 p.m – 5:20 p.m. ....................... Conference Sessions
5:30 p.m. – 7:30 p.m. .....................Networking Reception
6:00 p.m. – 9:00 p.m. ...............ICML Certification Testing
9:30 a.m. – 5:30 p.m. .............................Exhibition Hours
Thursday, April 19
7:30 a.m. – 11:00 a.m. ........................ Onsite Registration
7:30 a.m. – 8:00 a.m. ..................... Continental Breakfast
8:00 a.m. – 8:50 a.m. ...................... Conference Sessions
8:50 a.m. – 9:20 a.m. ....Refreshment Break in Exhibit Hall
9:20 a.m. – 11:10 a.m. ..................... Conference Sessions
11:30 a.m. ..................................Giveaways in Exhibit Hall
1:00 p.m. – 4:30 p.m. ........... Post-conference Workshops
8:50 a.m. – 11:30 a.m. ............................Exhibition Hours
 Why Attend?
TOP 10 REASONS TO ATTEND WHO ATTENDS?
Reliable Plant covers every facet of reliability in one As a reliability professional, you value best practices to
four-day event. Realize immediate bottom-line results by ensure bottom-line results. Whether you’re entry-level
obtaining real-world information and processes that you or a seasoned member of your plant’s management
can put into practice as soon as you get home. team, you’ll benefit from the comprehensive schedule of
sessions, case studies and peer interactions. Make plans
1. Improve your plant’s reliability – learn about now to attend the 19th annual Reliable Plant Conference
& Exhibition to network with and gather information from
real-world deployment processes to sustain your the following attendees:
plant’s reliability program
Asset Care Planners Managers of Maintenance
2. Develop powerful connections – exchange ideas
CBM Coordinators and and Reliability
with peers, share best practices and expand Specialists Mechanical Engineers
professional relationships
Chief Engineers Operations Managers
3. Stay up-to-date on new technologies – make Design Engineers PdM Analysts and
your job easier Engineers & Engineering Specialists
Managers
4. Become more valuable to your company – learn Planners and Schedulers
processes to reduce downtime and control costs Facility Managers
Plant Managers & Engineers
Hydraulic Specialists
5. Discover solutions that you can implement right Project Leaders
away – address specific issues Industrial Maintenance
Supervisors Quality Managers
6. Save money – deduct conference expenses Industrial Mechanics Reliability Coordinators
on your taxes
Infrared/Vibration Reliability Engineers
7. Find new customers, suppliers and resources – Technicians
Reliability Team Leaders
generate leads and develop partnerships Lab Managers
Reliability Technicians
Lube Analysts
8. Attend specialized half-day workshops – offered
Safety Managers and
before AND after the conference Lubrication Technicians &
Directors
Specialists
9. Share what you learn with co-workers – Machinery Engineers Senior Reliability Engineers
technical papers and presentations provided TPM Coordinators and
Maintenance Engineers &
10. Invest in your company – capture information Managers Facilitators
and apply what you’ve learned on the job Maintenance Planners ….and more
Opening Keynote
FLYING IN
FORMATION
Greg “Boss” Wooldridge
Tuesday, April 17th
8:00 - 9:20 a.m.
Greg “Boss” Wooldridge is the
only commanding officer to
lead the Blue Angels for three
separate tours. He was first
selected because of his demonstrated ability to build
teams where communication, trust and teamwork took
precedence over rank and status. His heart-driven
approach proved a perfect match for the Blue Angels‘
culture of excellence, and he was called back to lead two
more teams through times of difficult transition. Since his
success with the Blues, Greg has been inspired to share
his methods in order to empower individuals and teams
on their journey toward high performance. From the very
start of his career in the Navy, Greg was immersed in
the building of great teams. In flight candidate school,
he learned from the camaraderie of his class, an
emotion that elevated individuals by first elevating the
performance of the team. Later, acting as a commander
of a carrier squadron, Greg discovered that teams which
drive toward something greater than themselves unlock
an ability to perform at extreme levels. And finally, when
he was selected as the commanding officer of the Blue
Angels, the Navy’s—and the world’s—premier flight
demonstration squadron, Greg experienced what it was
like to take one’s dreams and beliefs on an upward spiral,
into the beyond.
For more about Reliable Plant 2018, visit Conference.
ReliablePlant.com.
 Certificate Programs

NEW FOR 2018

Along with the 90+ learning sessions, Reliable Plant offers conference attendees the unique opportunity to
participate in certificate programs. Conducted by industry experts, the certificate programs are specialized
learning paths consisting of a half-day pre-conference workshop and four required learning sessions on key
topics that every maintenance and reliability professional needs to become a top performer in the field. In
addition to a full-conference registration and workshop, program participants receive:
> Certificate of Completion > $125 Noria Bookstore Voucher
> Access to the VIP Lounge > Private Reception
Visit Conference.ReliablePlant.com for more information, pricing and details for the certificate programs.

MAINTENANCE MANAGEMENT CONTAMINATION CONTROL

Achieving Better Maintenance Management with Proven Identifying the Causes of SPONSORED BY:

Leadership Tactics Contamination and the Actions

Doc Palmer, Richard Palmer & Associates That Mitigate Them
Monday, April 16 | 8-11:30 a.m. Henry Neicamp and Randy Clark, Polaris
Learning Sessions: Laboratories | Monday, April 16 | 1-4:30 p.m.
> From Firefighting to First-class Maintenance: A Case Study - Learning Sessions:
Don McDaniel and George Miconi, Worthington Industries > How to Spot the Clues of Air Entrapment and Foaming in Oil -
> How to Apply Reliability-centered Maintenance Concepts in Randy Clark, Polaris Laboratories
Your Daily Work - Jeff Shiver, People and Processes > Best Ways to Detect Water in Oil - David Swanson, Polaris
> Next-generation Prescriptive Maintenance: A Case Study - Laboratories
Rendela Wenzel, Associate Senior Consultant Engineer, Eli Lilly > Pinpointing the Root Causes of Particle Contamination - Scott
> Case Study: Planning and Scheduling an Improvement Project - Howard, Hy-Pro Filtration
Scott Roth, Pierce County Planning and Public Works > Why You Should Be Testing for Varnish - Elaine Hepley, Polaris
Laboratories

CONDITION MONITORING LUBRICANT SELECTION

How to Integrate Multiple Condition SPONSORED BY
How to Get Lubricant Selection Right SPONSORED BY:
Monitoring Technologies for Every Time
Maximum Reliability Bennett Fitch, Noria Corporation
Walter Barringer, Allied Reliability Group Monday, April 16 | 8-11:30 a.m.
Monday, April 16 | 1-4:30 p.m.
Learning Sessions:
Learning Sessions:
> How to Properly Identify Your Lubrication Requirements -
> The Power of Correlating Oil Analysis and Vibration Analysis Nick Stolz, Chevron
Results - Andy Page, Allied Reliability Group
> How to Match the Lubricant to the Application -
> How to Use Vibration Analysis to Identify Equipment Problems - Brian Schmidt, Chevron
Walter Barringer, Allied Reliability Group
> Most Effective Ways to Evaluate Your Lubricants -
> Understanding the Complexities of Ultrasound for Machine Dan Holdmeyer, Chevron
Condition Monitoring - Andy Page, Allied Reliability Group
> Maximizing the Lubricant Supplier Relationship -
> Common Misconceptions for Using Infrared Thermography Jason Gerig, Chevron
to Inspect Plant Equipment - T.J. Garten, Allied Reliability Group
Attend Reliable Plant 2018 and you could win one of two
sensational getaways! The winners will choose to head north
to the Last Frontier for an eight-day Alaskan cruise or west to
the Paradise of the Pacific for a six-day Hawaiian getaway.

Visit Conference.ReliablePlant.com for

official rules and more information.

PRE-CONFERENCE WORKSHOPS - Monday, April 16
Achieving Better Maintenance
Management with Proven Leadership
Tactics - Doc Palmer, Richard Palmer &
Associates Inc.
Many organizations struggle to control the
most important areas of their maintenance
program as well as the roles of individuals
within it. This workshop by Doc Palmer, author of the Maintenance
Planning and Scheduling Handbook, will help managers and leaders
understand key concepts and develop essential skills to make their
maintenance programs more successful. Different organizational
styles will be covered along with change management tactics
and personality issues. Discover how to apply proven leadership
techniques from W. Edwards Deming, Peter Drucker and Jim Collins
to maintenance but also take home principles and practices to make
a good maintenance organization great.
PRE-CONFERENCE WORKSHOPS - Monday, April 16
How to Integrate Multiple Condition
Monitoring Technologies for Maximum
Reliability - Walter Barringer, Allied Reliability
Group
How do the “big four” condition monitoring
technologies work and what can they tell you
about your machinery and your equipment’s
condition? This workshop will focus on the four primary condition
monitoring technologies: vibration, infrared thermography, ultrasound
and oil analysis. Beginning with an explanation of the applications for
each technology, Walter Barringer will cover what the technologies
can and cannot do when integrated into a condition monitoring
program. Attendees will learn how each of the four primary
technologies works, when and where to apply each technology,
which technologies to start with first in a new condition monitoring
program, and how to choose equipment for inclusion in the program.
POST-CONFERENCE WORKSHOPS - Thursday, April 19
Lubrication Excellence Essentials for
Leaders - Jim Fitch, Noria Corporation
There’s a revolution occurring. Managers who
once desired machine reliability now demand
it. It’s a matter of corporate survival in the
global economy, and effective machinery
lubrication is an essential enabler to success.
This movement has led companies in all industries to take control
of reliability by reinventing their lubrication programs. Those who
are responding to the challenge are seeing amazing results – on the
bottom line, where it counts most. The change goes beyond simply
using better lubricants. The leaders are employing technologies,
empowering employees and building ultramodern new practices –
creating a new and energized reliability culture.
Conference Workshops
| 8-11:30 a.m.
How to Get Lubricant Selection Right
Every Time - Bennett Fitch, Noria Corporation
All lubricants have an optimum reference
state. This includes the right quality,
performance, viscosity, thermal range, etc. To
achieve this optimum state, you must avoid the
classic false economies of lubricant selection
and the lure of cheap oil. Join Noria’s Bennett Fitch as he explains
why you shouldn’t try to save money by purchasing economy-
formulated lubricants or attempt to remedy bad lubrication practices
by buying expensive premium lubricants. Attendees will discover
how to select the optimum lubricant for a machine application as
well as how small differences in lubricant performance can translate
into huge differences in machine reliability.
| 1-4:30 p.m.
Identifying the Causes of Contamination
and the Actions That Mitigate Them
Henry Neicamp and Randy Clark, Polaris
Laboratories
When faced with oil contamination problems,
do you know which maintenance practices
fall into the good, better and best categories?
Have you identified the equipment critical to
your operations and the ones that could be run
to failure? What actions can reduce the lifetime
maintenance costs of the components?
Corrosion and mechanical wear account for
75 to 80 percent of the reasons components
fail. This workshop will investigate the causes of contamination, the
damage that contaminants generate and the predictive maintenance
techniques that can mitigate problems or avoid them entirely.
| 1-4:30 p.m.
Designing and Procuring Equipment
to Increase Reliability - Jerry Putt, Noria
Corporation
Most efforts to meet reliability goals generally
come from the maintenance organization.
Often the inherent reliability of the system is
determined by the design and procurement
practices employed long before the equipment becomes the
responsibility of the plant. Design and procurement personnel usually
are focused on meeting functionality requirements within cost and
delivery time constraints. This workshop will provide suggestions for
designers and procurement professionals that can result in higher
potential reliability and give maintenance teams opportunities to
consistently achieve the optimum capability of the equipment.
Learning Sessions
Here’s a quick look at some of the more than 90+ learning sessions. New sessions are being added weekly, so stay up-
to-date by visiting Conference.ReliablePlant.com.
Case Study Certificate Program Sessions:
Why Employee Engagement Is the Key to Successful In many organizations, supervisors schedule their staff’s work week,
Maintenance Programs - Patrick Garin, Plant Manager, Cabka
You can have the best technicians in the world, but if they are not
engaged, they will produce only average results. This presentation
will explain how to fully empower and engage your techs to bring your
maintenance department to the next level. This simple approach offers
a huge payback and does not require a financial investment. Attendees
will learn how to bring out the lost potential of their team members and
make them feel more like an asset to achieve maximum results.
Growing a Maintenance Organization: A Farm System Approach
Douglas Smith, Reliability Engineer, Pinnacle Foods; Tony Fraise,
Maintenance Manager, Pinnacle Foods
This case-study presentation will detail how Pinnacle Foods addressed
its skilled trades shortage by using an approach similar to a baseball
farm system. See how the company built its program, grew and
developed its workforce, and leveraged skill-based pay to retain the
major-league players on its team. You will hear how online education
was employed to train technicians, how young people were engaged to
make them aware of the careers available through skilled trades, and
what the benefits and drawbacks have been.
How to Start or Revive a Maintenance and Reliability Program develop a team of first-class maintenance technicians.
Dale Deem, Reliability Engineer, Oerlikon Fairfield Manufacturing
Starting a maintenance and reliability program can be a bit
overwhelming. This case-study presentation will provide the basic
steps for developing a well-thought-out plan and a logical approach
for a new or revived program, with each key step building upon the
preceding one. Join reliability engineer Dale Deem as he explains
that you are not alone in this journey as well as why not all initiatives
must occur at the same time and which resources and collaboration
opportunities are available to you.
Goodyear’s Journey to Lubrication Excellence: A Case Study some of the most common mistakes made by lubricant analysts and
Andrei Melo, Lubrication Competence Leader, Goodyear;
Rafael Jordão, Reliability Manager, Goodyear
The Goodyear Americas tire plant in Americana, Brazil, was facing a
number of serious lubrication issues. As with most plants, personnel
didn’t know where to begin; they only knew they had a problem. This
case-study presentation will detail Goodyear’s journey to lubrication
excellence. Attendees will see how the plant was able to implement and
sustain its lubrication program, reduce downtime and save money, as
well as how these same steps can be used to achieve similar results in
any organization.
Case Study: Planning and Scheduling an Improvement been able to attain four of the five levels, with the fifth level steadily
Project - Scott Roth, Maintenance Program Manager, Pierce
County Planning and Public Works, Sewer Division
Condition Monitoring Lubricant Selection
Contamination Control Maintenance Management
which often is not the most effective approach. This case-study
presentation will detail how the Pierce County Planning and Public
Works’ Sewer Division employed lean and Six Sigma processes to
save its team time while also providing supervisors with a better
understanding of which tasks are being completed and how long each
takes. Join Scott Roth as he shares how supervisors and staff can
work together on a common goal to put the best person in place to
accomplish the task at hand. You will see how dynamic work can be
planned and scheduled, how to obtain buy-in from your staff and how
technology can be used to maximize effectiveness.
From Firefighting to First-class Maintenance: A Case Study
Don McDaniel, Maintenance Lead/Manager, Worthington
Industries (Steel Division); George Miconi, Maintenance Planner,
Worthington Industries (Steel Division)
This case-study presentation will provide a detailed roadmap to a
sound maintenance program so you can improve machine uptime at
your organization. Join Worthington Industries’ Don McDaniel and
George Miconi as they share the path their company took to transition
from being reactive to becoming more proactive and achieving greater
uptime. You will hear why communication is key, how to determine the
root cause of problems, why change is your friend and how anyone can
The Power of Correlating Oil Analysis and Vibration Analysis
Results - Andy Page, Principal Consultant, Allied Reliability Group
Many people apply both oil analysis and vibration analysis to the
same machine components, but often the results are presented
independently, with some details lost in the process. This session
will explain how much can be gained from comparing the findings
of both oil analysis and vibration analysis before maintenance
recommendations are made. Attendees will gain a better understanding
of how different technologies can corroborate each other as well as
vibration analysts when they do not compare notes.
Mastering the 5 Levels of Maintenance for Maximum Equipment
Availability - Carl Stevens, District Equipment Manager, Virginia
Department of Transportation
Prior to re-evaluating its maintenance strategy, the Virginia Department
of Transportation (VDOT) had been utilizing a scheduled maintenance
program and in some cases a “failure” maintenance program. In 2003,
the VDOT changed its strategy and began focusing on five key levels of
maintenance to achieve a reliability-centered program. This case-study
presentation will describe how the VDOT’s maintenance program has
evolving. Join Carl Stevens as he shares the rationale and benefits of
this approach as well as the results of the program.

Key Principles of Maintenance Planning and Scheduling
Doc Palmer, Managing Partner, Richard Palmer & Associates
In this case-study presentation, Doc Palmer, author of McGraw-Hill’s
Maintenance Planning and Scheduling Handbook, will detail the steps
the Jacksonville Electric Authority used to turn around its maintenance
planning department, including how crews were able to work down
their entire backlog, free up time to perform proactive work, replace
contract labor and assist other stations. Attendees will gain a better
understanding of the six key principles of effective planning and
scheduling along with how a proper system can transform a reactive
work environment for maintenance success.
How to Interpret an Oil Analysis Report - Evan Zabawski, Senior
Technical Advisor, TestOil
Oil analysis data can often be confusing and difficult to understand.
This presentation will help to provide some clarity through detailed
explanations of typical oil analysis tests and results, common causes
for changes in the data, and pitfalls to avoid. Attendees will find out how
to better interpret the oil analysis reports they receive from their lab,
what the standard tests are designed to measure and reveal, the most
likely reasons for values being too high or low, and the most frequently
made mistakes and misconceptions regarding data interpretation.
How to Commission Equipment for Better Asset Management
Saul Cizek, Senior Maintenance Planner, Upper Occoquan
Service Authority
With fast-approaching deadlines and mounting pressures, most
practitioners must work hard to put equipment into service. This
case-study presentation will provide some peace of mind and coping
resources to help make the commissioning process more efficient. Join
Saul Cizek as he shares how the Upper Occoquan Service Authority
improved its approach for commissioning equipment and asset
98%
of attendees said they
would recommend
the event to others in
the industry.
management with real-world examples of successes and lessons
learned. Find out how to develop a commissioning plan, select a
commissioning leader and convince supervisors to allow adequate time
for commissioning, as well as which follow-up steps must be taken.
How to Design, Implement and Manage an Effective Oil Analysis
Program - Alejandro Meza, Senior Technical Consultant, Noria
Corporation
Too often the individual responsible for the oil analysis program has
simply accepted a program proposed by the lubricant vendor or a
third-party laboratory, assuming it will be suitable for the organization’s
needs. While this assumption is not always wrong, the question
becomes whether the program has been appropriately customized for
the plant’s machine conditions, equipment criticality and reliability
objectives. This session will detail the enhanced capabilities of oil
analysis when used in combination with a proper program design.
You will learn how to perform a self-assessment to evaluate the
effectiveness of your current program, how to choose test slates based
on program objectives and equipment criticality, and how to revitalize
your oil analysis program to maximize its potential.
How to Implement a Preventive Maintenance Program
Abdul Alami, Professional Engineer, Alberta Infrastructure
Many organizations have a preventive maintenance (PM) program, but
few are implemented effectively. This presentation will reveal some of
the most common failures associated with deploying a PM program,
as well as a number of tips and strategies to help overcome the typical
implementation challenges. Join Alberta Infrastructure’s Abdul Alami
as he explains a back-to-basics approach to help attendees understand
the key concepts and methods for turning around a failing preventive
maintenance program.
Learning Sessions
Choosing the Right Failure Analysis Tool for the Job
Thomas Brown, Principal Engineer, Reliability Solutions
A variety of problem-solving methods can be used to analyze
equipment and process failures. Each has its own strengths and
weaknesses that must be matched to the problem for maximum
effectiveness. This session will reveal which failure analysis methods
and tools work best in different situations. You will gain a better
understanding of how to identify the training, time and financial
resources required to utilize each method, as well as which types of
situations, failures and issues each method is best suited to solve.
Understanding the Changing Requirements for Food-grade Lubricants
Wes Cash, Director of Technical Services, Noria Corporation
With the deadline for compliance with the Food Safety Modernization
Act (FSMA) already passed, it is increasingly important for all food and
beverage plants to understand the scope of this legislation. Complying
with food-grade lubrication principles is no longer voluntary but is now
the law and must be followed. This session will reveal what this act
means for your organization and lubrication program. You will learn the
risks that must be addressed, some simple strategies to help ensure
compliance and the potential penalties for those who don’t conform to
this legislation.
How to Apply Reliability-centered Maintenance Concepts in Michael Johnson, Maintenance Execution Senior Manager,
Your Daily Work - Jeff Shiver, Founder/CEO, People and Processes
Many maintenance teams struggle to break the reactive cycle of chaos
with regards to driving reliability. Not only are there financial costs, but
there are human costs, too. In this learning session, join Jeff Shiver
as he shares his insights and experiences to deliver asset reliability
and end the chaos. He will show you how to use reliability-centered
maintenance (RCM) concepts and apply them in your daily work. You
will learn how to build partnerships, evaluate proactive maintenance
strategies, balance planning and scheduling, ensure you have the right
parts and materials, and then get it all done.
How to Write More Effective Maintenance Work Orders and Best Ways to Capture Knowledge from an Aging Workforce
Task Descriptions - Michael Mazur, Maintenance
Trainer/Mechanic, Schwan’s Global Supply Chain
Preventive maintenance (PM) descriptions, emergency work orders
and operational checklists are frequently written without any review
or standardization. This often leads to misinterpretation, inefficient
DON’T MISS INSIGHTFUL CASE STUDIES FROM THESE INDUSTRY LEADERS…
application of work and even confusion as to what needs to be
accomplished. This session will offer examples of ineffective PMs
and work orders as well as show how tasks can be rewritten for more
efficient work. You will learn how to standardize the task format, use
clear and concise language, and define a systematic work flow for more
repeatable maintenance actions and greater equipment reliability.
Using Oil Analysis as a Condition Monitoring Tool
Muhammad Ali Qureshi, Reliability Engineer, Saudi Aramco
This case-study presentation will reveal the results and benefits
that Saudi Aramco has seen from its corporate-wide oil condition
monitoring program. Find out how the oil company was able to detect
permanent shear of oil molecules in certain applications, which
was reducing the oil’s viscosity, as well as what actions were taken.
Attendees not only will hear recommendations for improving the
viscosity index based on oil analysis but also see how Saudi Aramco’s
condition monitoring program allows samples and analysis of the
company’s machinery to be contained in one location.
MAINTENANCE MANAGEMENT
How to Make Your Plant Safer Through Worker Engagement
Paul Durko, Reliability and Maintainability Manager, CNS Y12;
Y-12 Infrastructure
Recognizing the Dangers of Hazardous Chemicals in
Your Facility - Rose Wilson, PSM/RMP Coordinator, George’s Inc.
Advantages of Centralized Asset Management
Guadalupe Rodriguez, Maintenance and Planning Specialist,
Metso Minerals - Canada
How and Why You Should Quantify Your Maintenance Tasks
Roger Collard, Engineering, Maintenance & Reliability Manager,
Calumet Specialty Products Partners
Paul Dufresne, President and CEO, Reliability Playbook
Is Reliability-centered Maintenance for You?
Nancy Regan, President, The Force Inc.
10 Keys for Improved Plant Reliability
Shon Isenhour, Founding Partner, Eruditio LLC

Using Data Science to Prevent Machine Failures and Plant Disruptions
Michael Brooks, Senior Director, AspenTech
A Day in the Life of a Maintenance Planner
Steven Tuttle, Senior Maintenance Planner, C&W Services
Embracing Data Management to Prevent a Plant Disaster
David Bell, Principal Digital Product Manager, GE Digital
How to Manage Critical Spares to Achieve Plant Reliability
Donald Shoemaker, Vice President, Asset Services, Synovos
Procedure-based Maintenance: Taking Maintenance to the Next Level
James Kovacevic, Principal Consultant, HP Reliability
Next-generation Prescriptive Maintenance: A Case Study
Rendela Wenzel, Associate Senior Consultant Engineer, Eli Lilly
How to Prepare for a Plant Shutdown
Mohammed Alismail, Planning and Material Section Head, Saudi
Electricity Co.
RELIABILITY ENGINEERING
Reliability Engineering in the Wind Industry: A Case Study
Matthew Carney, Engineer, Exelon Generation
Creating a Reliability Culture for Power Systems
Alan Ross, Vice President of Reliability, SDMyers
How to Turn Around a Poor-performing Reliability Program
Jeremy Wright, Director of Product Management; Mark Young, Director
of Reliability, Advanced Technology Services
Why Data Collection Is More Important Than Reliability Modeling
Carles CG - Senior Fleet Performance Engineer, Reliable Dynamics
Learning Sessions
ROOT CAUSE ANALYSIS
Case Study: Lessons Learned from a Failure Analysis
Daniel Sherbert, Reliability Engineer, EJ
Case Study: How to Uncover the Root Cause of Failures
and Improve Hydraulic System Reliability
William Abernathy, Technical Manager, Rehrig Pacific
LUBRICATION PROGRAM MANAGEMENT
How ISO 55000 Is Changing the Definition of Lubrication Excellence
Jim Fitch, CEO, Noria Corporation
How to Design Effective Lubricant Storage
Terry Harris, President, Reliable Process Solutions
Overcoming the Risks of Cold Machine Starts
Bennett Fitch, Senior Technical Consultant, Noria Corporation
Best Practices for Topping up Small Sumps and Reservoirs
Garrett Bapp, Technical Consultant, Noria Corporation
10 Common Grease Problems and How to Solve Them
Joe Goecke, Senior Technical Services Advisor, Petro-Canada
Case Study: How to Implement Lubrication Best Practices
Ishanth Sameera, RCM Senior Manager, Camso Loadstar;
Mahesh Goonesekere, Director of Engineering, Camso Loadstar
OIL ANALYSIS
Optimizing the Lifespan of Turbine Oil Through Proper
Maintenance: A Case Study - David Turner, Product Specialist,
CITGO Petroleum Corp.; Leeann Wimer, Mechanical Engineer, U.S. Army
Corps of Engineers
Learning Sessions
Using Drones for Remote Oil Sampling Common Misconceptions for Using Infrared Thermography to
Michael Holloway, Strategic Accounts & External Training, ALS Tribology Inspect Plant Equipment
T.J. Garten, SME, Allied Reliability Group
How to Inspect the Health and State of Your Oil
Tom Fitch, Luneta How to Lower Maintenance Costs with a Condition Monitoring
Program - Steffen Nyman, Corporate Trainer & Consultant, C.C. Jensen
New Oil Analysis Methods for Identifying Varnish
Ruediger Krethe, OilDoc GmbH The Benefits and Limitations of Wireless Vibration Technology
Rich Pratt, Asset Reliability Consultant, Cornerstone Controls
How to Determine When New Oil Is Needed - Andrés Lantos, Analytical
Developments & Technology, Laboratorio Dr. Lantos, Wearcheck Understanding the Complexities of Ultrasound for Machine
Argentina; Dave Wooton, Consultant, Wooton-Consulting Condition Monitoring - Andy Page, Principal Consultant, Allied
Reliability Group
Taking Oil Sampling to the Next Level
Bernie Hall, General Manager, Checkfluid How to Maximize the Value of IoT-based Condition Monitoring
Jeremy Drury, Vice President, IoT Diagnostics
How to Properly Manage Your Oil Analysis Data
Cary Forgeron, General Manager, Bureau Veritas Ultrasound-assisted Lubrication: 3 Approaches to Improving Bearing
Lubrication Practices - Adrian Messer, Manager of U.S. Operations,
5 Things That Will Change Oil Analysis
UE Systems
Jorge Alarcon, Consultant, Tekniker
Using Infrared Thermography for Successful Condition Monitoring
New Thermal Techniques for Grease Analysis
Leonard Harrington, Channel Partner Manager, FLIR Systems
Cory Schomburg, Principal Scientist, PerkinElmer
The Power of Remote Condition Monitoring in Optimizing
How to Analyze Grease with FTIR Spectroscopy
Maintenance Practices - Eric Krause, Technical Specialist, Pall Corp.
Dave Wooton, Consultant, Wooton-Consulting
Latest Advances in Vibration Analysis for Low-speed Machines
CONDITION MONITORING Ron Kittle, Sales & Service Engineer, SPM Instrument

Vibration Analysis Techniques for Identifying Failure Root HYDRAULICS

Causes: A Case Study - Zeeshan Iqbal, Reliability & Performance
Engineer; Arifur Rahman, Assets Manager, Territory Generation Pump System Optimization: The Key to Improving Plant Reliability
Mark Sullivan, Director of Education; William Livoti, Senior Engineer &
How to Use Vibration Analysis to Identify Equipment Problems Trainer, Hydraulic Institute
Walter Barringer, Senior Reliability Professional, Allied
Reliability Group Is a Fill-for-Life Lubrication Strategy Right for You?
Jatin Mehta, Research Engineer, Fluitec International
Improving Equipment Reliability Through Condition Monitoring
How to Ensure Hydraulic System Reliability
Girish Chandra, Manager of Reliability and Planning,
Martin Migliori, Fluid Systems Engineering Manager; Joe Lisowski,
Yara Fertilizers India
Applications Engineer, Airline Hydraulics
Why Machine Alignment Should Not Be Overlooked
Garrett Bapp, Technical Consultant, Noria Corporation
CONTAMINATION CONTROL
Best Methods for Reducing Vibration Levels in Mechanical Systems
Robert Sayer, President, Vibration Institute New Alternatives for Mitigating Varnish in Turbine Oil:
A Case Study - Russell Flagg, CBM Program Owner, Duke Energy

GET A FREE NORIA TRAINING COUPON

Valued at $1,295!*
Full-conference registration includes a $1,295 training
coupon which can be used toward Noria’s lubrication
or oil analysis training courses for up to one year. Use
it yourself or give it to a co-worker. It’s like attending
the conference and getting Noria training for free!

*Terms and Conditions: Only one coupon issued per person. Coupon is transferable within your organization and must be presented when registering for the training. Coupon is valid for Noria
public training courses in the United States taking place between April 2018 and April 2019, or online courses purchased prior to April 2019. Coupons are given to full-conference (Tuesday-
Thursday) attendees who pay their conference registration fee and attend the conference. Speakers and exhibitors are not eligible unless paying full-conference registration fees. Coupons
may not be used for private onsite training.

I attended
every session
I could, and they
were all good.”
Elvis Reid, Saint-Gobain Abrasives
Controlling Dirt Ingression in Engine Oil Extending Equipment Life Through Better Lubricant Selection
Nnamdi Achebe, Petrosave Integrated Services
Why You Should Be Testing for Varnish
Elaine Hepley, Data Analyst, Polaris Laboratories
How to Spot the Clues of Air Entrapment and Foaming in Oil
Randy Clark, Technical Business Consultant, Polaris Laboratories
Best Ways to Detect Water in Oil
David Swanson, Director of Technical Services, Polaris Laboratories
Pinpointing the Root Causes of Particle Contamination
Scott Howard, Training Director, Hy-Pro Filtration
LUBRICANT SELECTION
How to Match the Lubricant to the Application
Brian Schmidt, Reliability Based Lubrication Manager,
Chevron Lubricants
Learning Sessions
Diane Closser, Technical Service; David Kesterson, Lubrication/
Mechanical Technician, Chemours
Most Effective Ways to Evaluate Your Lubricants
Dan Holdmeyer, Industrial Sector Manager, Chevron
How to Get the Most Out of Your Engine Oil
Wes Cash, Noria Corporation
Maximizing the Lubricant Supplier Relationship
Jason Gerig, Business Development Manager, Chevron Lubricants
What You Should Know About Lubricant Film Strength and Thickness
Bennett Fitch, Senior Technical Consultant, Noria Corporation
How to Properly Identify Your Lubrication Requirements
Nick Stolz, Reliability Based Lubrication Coordinator, Chevron
Global Lubricants
Selecting Lubricants for Pharmaceutical Facilities
Alejandro Meza, Senior Technical Consultant, Noria Corporation
For more information, visit
Conference.ReliablePlant.com.
Special Events

INDY TRACK TOUR

Monday, April 16, 12-3:30 p.m.
Want an insider’s look behind the scenes of the
Indianapolis Motor Speedway? Check out the Indy Track
Tour. Participants will enjoy a narrated tour that features
stops at places normally open to only officials, drivers
and teams. This one-of-a-kind museum excursion and
Indy track/VIP grounds tour includes:
>> Round-trip transportation to/from the Westin Indianapolis
Hotel (approximately 15 minutes each way)
>> Admission to the Indy Hall of Fame Museum
SPONSORED BY: >> Lap of speedway and delivery to front straightaway at start/
finish line and official “Yard of Bricks”
>> Visit to the victory podium overlooking racetrack, drivers’
interview room, etc.
>> Tour of the pagoda and a ride through gasoline alley
>> Lunch provided
>> $95 per person, limited to the first 50 registrants!

NOTE: Add to your conference registration

POLARIS LABORATORIES® FACILITY TOUR

Wednesday, April 18, 5:30-8:30 p.m.
Join us for a private, after-hours guided tour through the
Polaris Laboratories® facility.
>> Round-trip transportation included
>> Dinner provided
>> $19.95 per person, limited to the first 90 registrants!

NOTE: Add to your conference registration. All participants must

SPONSORED BY:
wear full-coverage, close-toed shoes and pants that cover your
ankles. Safety eyewear provided.

NON-DENOMINATIONAL OFFSITE
PRAYER BREAKFAST
Wednesday, April 18, 7-7:50 a.m.
>> Westin Indianapolis - directly across from
the Indiana Convention Center
>> Full, hot buffet breakfast, coffee, juices
>> Opening remarks, prayer and closing ceremony
>> Keynote address by Indy Car Racer, Davey Hamilton
>> Free entry with pre-registration
SPONSORED BY:
NOTE: Add to your conference registration
 Exhibition Hall & Exhibitors
Make your conference experience as valuable as possible. Wander the expansive exhibit hall and discover tools and
solutions among a comprehensive group of global suppliers representing various disciplines of reliability and industrial
lubrication. With over 100,000 square feet of exhibit hall space, attendees can meet with more than 100 exhibitors
highlighting innovative products and services over the course of three days. Unwind in the “Relaxation Station,”
network with colleagues during lunch breaks and receptions, gather hands-on information and generate ideas to
address specific needs.
LUNCHEON EXPANSION

231 232 331 332 431 432 531 532 631 632 731

129 130 229 230 329 330 429 430 529 530 629 630 729 730 829 830

127 128 227 328 427 428 527 528 627 728 827 828

Show Prize
125 826
Giveaway
Display
123 124 223 224 324 423 424 523 524 623 624 724 823 824

121 822

Relaxation
119 120 219 220 319 720 819 820
Massage
Noria Corporation Station
117 118 217 218 317 618 718 817 818

115 116 215 216 315 316 616 716 815 816

113 814

111 812

109 110 209 210 310 410 510 610 710 809 810

107 808

105 106 205 206 305 606 705 706 805 806

104 803

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ENTRANCE

EXHIBITOR LIST - KEY SPONSORS SHOWN IN BLUE (AS OF 1/19/18)

Advanced Technical Solutions FS-Elliott Midland Manufacturing Co., Inc. Schroeder Industries/HYDAC
Allied Reliability Group Gateway Analytical Mighty lube SD Myers, Inc.
ALS Tribology Generation Systems Monroe Infrared Technology SGS North America (Herguth)
Andromeda Systems Inc. GenesisSolutions, An ABS Group MP Filtri USA SMRP
Arizona Instrument, LLC Company MSC Filtration Technologies Specialty Manufacturing, Inc.
Aviation Industry (Xin Xiang) Gill Sensors & Controls Ltd No Limit Oil Filtration Spectro Scientific
Metrology and Test Science Graco Technologies LLC Spectronics Corporation
Technology Co. Ltd. GTI Predictive Technology, Inc. Noria Corporation SPM Instrument, Inc.
Beckman Coulter Life Sciences OilDoc GmbH
Hamar Laser Instruments Swift Filters, Inc.
Bekaworld LP Oil Filtration Systems, Inc.
Hanil Lubtec CO., LTD Tannas Co.
C.C. Jensen, Inc. Pall Corporation
Harvard Corporation TEKNIKER
Cannon Instrument Company PdMA Corporation
HBM Prenscia Tennessee Bottle Company/
CheckFluid, Inc. Pentair Filtration Solutions, Inc. Indiana Bottle Company
Hy-Pro Filtration
Chemours (The Chemours People and Processes, Inc. TestOil
Company) ICML
IFH Group PerkinElmer Total Specialties USA, Inc.
Chevron Lubricants
IMI Sensors, a PCB Piezotronics Petroleum Tank Company Triad Unlimited
Closed Loop Recycling
Division PFPUSA (Precision Filtration) Turner Industries Group –
Connection Technology Center MobilOps Mobility System
(CTC) Inpro/Seal Polaris Laboratories
Intertek UE Systems, Inc.
Coupling Corporation of America Prometheus Group
IoT Diagnostics University of Tennessee/
Dexsil Corporation PRUFTECHNIK, Inc. Reliability and Maintainability
DropsA USA IOW Group, LLC R&G Laboratories, Inc. Center (RMC)
Ecol North America, LLC I-Rod Pipe Supports RDI Technologies, Inc. Vacudyne
Engineered Lubricants Loctite RelaDyne, Inc. Valicor
Enviropeel, USA LubricationPlus Reliability Solutions Vibration Institute
Eruditio Ludeca, Inc. Reliable Process Solutions Whitmore
Esco Products, Inc. Luneta, LLC Retif Oil & Fuel / LSG Wilcoxon Sensing Technologies
Fluid Technologies, Inc. Maintenance Connection Royal Manufacturing Co. Wolflube Equipment
FS-Curtis Metro Fluid Power Royal Purple Y2K Fluid Power
Networking

I was able to
network with
many people and
companies...”
Marty Migliori, Airline Hydraulics

EVENING RECEPTION
Wednesday, April 18, 5:30-7:30 p.m.
Join us for an unforgettable night of networking and fun
at the Lucas Oil Stadium Plaza, home of the Indianapolis
Colts. Overlooking the field, the plaza features views of
the Indianapolis skyline and is conveniently connected
to the Indiana Convention Center via an enclosed
pedestrian corridor.
>> Appetizers, bars and entertainment
>> Open to all Reliable Plant attendees and exhibitors
>> Overlooks the home of the Indianapolis Colts

For more information, visit

Conference.ReliablePlant.com
INDIANAPOLIS, INDIANA

Reliable Plant Conference & Exhibition 2018 will be held at the Indiana
Convention Center in Indianapolis, Indiana. Specially rated blocks of rooms
are reserved at the Westin Indianapolis Downtown. You can take advantage
of these discounted rates by booking your room(s) directly with the Westin
Indianapolis Downtown using the group code “RELIABLE PLANT” at the time
of your reservation. Availability is limited, so you are encouraged to make
reservations early.
GET TO KNOW
INDIANAPOLIS
Known as the racing capital
HOST HOTEL - WESTIN of the world, Indianapolis
INDIANAPOLIS DOWNTOWN boasts a variety of
241 W. Washington St., Indianapolis, IN 46204 attractions and activities.
1-317-262-8100 Whether you want to see
>> Call toll-free 1-800-881-1523 to reserve the largest shark touch
your room by March 26, 2018 tank at the Indianapolis Zoo
>> Single occupancy is $175 & White River Gardens or
>> Use group code: RELIABLE PLANT visit the Indianapolis Motor
>> Make all hotel reservation changes and Speedway & Hall of Fame
cancellations directly with your hotel Museum, Indy has you
covered. For a complete
>> Visit Conference.ReliablePlant.com for
guide, go to VisitIndy.com.
a shortcut to the hotel registration site

TOP 10 MUST-DOS IN INDIANAPOLIS:

1. Pet sharks in the nation’s largest shark touch tank
at the Indianapolis Zoo & White River Gardens
2. The Indianapolis Motor Speedway & Hall of Fame Museum
are home to the world’s largest single-day sporting event
3. View one of the finest collections of American Indian and
Western art at the Eiteljorg Museum
4. Discover the world’s largest children’s museum
5. Explore White River State Park’s Central Canal in a Venetian- 10. Experience an eagle-eye view of the city from atop the Soldiers
style gondola, surrey, bike, Segway, pedalboat or on foot
6. Uncover Indiana’s secrets through hands-on exhibits at the
Indiana State Museum & IMAX Theater
7. Beat on drums or a wide variety of instruments at Rhythm!
Discovery Center
8. Take your family and friends out for some fun at Victory Field
9. Visit the world-renowned Indianapolis Museum of Art featuring
54,000 works spanning 5,000 years
& Sailors Monument or visit the Indiana War Memorial Plaza
2018 Pricing & Discounts

REGISTER NOW & SAVE $300 (UNTIL FEB.14)

Individual Individual Group (3-9) Group (10+)

$995 $1,295 $795 $695

REGULARLY $1,295 REGULARLY $1,595 REGULARLY $845 REGULARLY $745

With a certificate program Groups get 30% off all workshops

Add a Workshop $225 REGULARLY $295 Additional with paid full registration

HOW TO REGISTER
Online: Find the most up-to- Phone: Call Monday – Friday, Fax: Send your completed
date information by visiting 8 a.m. – 5 p.m. (CST) registration form to:
Conference.ReliablePlant.com 918-392-5038 918-746-0925

WHAT’S INCLUDED?
FULL-CONFERENCE REGISTRATION INCLUDES:
>> Admission to all conference sessions
>> Conference proceedings
>> Opening general session and keynote address
>> Exhibition hall access
>> Daily breakfasts, refreshments and lunches
>> Networking receptions
>> FREE Noria training coupon, valued at $1,295 BRINGING THE CREW? GET A DISCOUNT.
3 to 9 attendees: Get three or more full-conference
WORKSHOP REGISTRATION INCLUDES: registrations for only $795 each, plus a 30% discount on
>> Course materials all pre- and post-conference workshop fees.
>> Refreshment breaks 10 or more attendees: Get 10 or more full-conference
>> Opening general session (Tuesday only) registrations for only $695 each, plus a 30% discount on
>> Exhibition hall access all pre- and post-conference workshop fees.

WANT TO SPONSOR? READY TO EXHIBIT?

It’s not too late to consider a sponsorship. Sponsorship
packages are sold on a first-come, first-served basis. A
few premier sponsorships remain. Increase your visibility
and put your marketing dollars to work for you by joining
our prestigious group of Reliable Plant 2018 sponsors.
Prime booth locations go fast, so reserve your exhibition
space now! Spending three days on the Reliable Plant
exhibit hall floor is equivalent to months of travel and
hours of phone calls and meetings. Reliable Plant 2018
will provide the perfect setting for prospective customers
to come to you.

Register online at
Conference.ReliablePlant.com
REGISTRANT INFORMATION
Please print your name clearly. Your name and company will
appear on your badge. Please photocopy this form for additional
registrants.
Name _________________________________________________
Title ___________________________________________________
Company ______________________________________________
Address 1 _____________________________________________
Address 2 _____________________________________________
City _______________________ State/Province ____________
Zip/Postal Code ___________ Country ___________________
E-mail (required) _______________________________________
Phone # (required) _____________________________________
METHOD OF PAYMENT
Full payment due upon receipt of invoice and prior to
conference. Customers outside the U.S.: We accept
checks drawn on U.S. banks in U.S. dollars.
Check: Check # _________________ is enclosed or will be
mailed. Please make check payable to: Noria Corporation
Credit Card:  Visa  MasterCard  AmEx  Discover
Noria Corporation is authorized to charge the credit card
below for my conference registration fees in the amount
indicated on this form.
Card # _________________________________ Exp. ________
Name on Card _________________________________________
Cardholder’s Signature ________________________________
Bill Me/Company: P.O. # _______________________________
Total number of people registering:_____________________
TOTAL PAYMENT DUE: $ ________________________________
Cancellations must be in writing and postmarked by March 1, 2018. All cancellations received after this date are subject to a $75 administrative fee, but you will also receive a $75
coupon good for use against the cost of a Noria training or conference. If you don’t cancel and you don’t attend, you will be charged the full registration fee. However, a company may
substitute one attendee for another, without penalty. Written notice prior to the event is required for substitute attendees.
Registration Form
Call (M-F, 8-5 p.m. CST) Fax your registration form to:
918-392-5038 918-746-0925
CONFERENCE FEES
INDIVIDUALS
Full-Conference Registration (until Feb. 14, 2018)
 Full-Conference Registration .....................................$995
 Full-Conference Registration + Certificate Program . $1,295
1-Day Registration
 Individual 1-Day .........................................................$395
 Individual Exhibition Hall Only ......................................$95
Spouse/Family Members (Must accompany full-conference
registration attendee, see website for more details)
____ (Qty.) Spouse/Family ........................................ $195 each
GROUPS
Group discounts include a 30-percent discount on pre- and
post-conference workshop fees and must be purchased at the
same time. (Save until March 14, 2018)
____ (Qty.) 3-9 Full-Conference Registrations ..........$795 each
____ (Qty.) 10+ Full-Conference Registrations ..........$695 each
WORKSHOPS
Without Full Registration ........................................$295 each
With Full Registration .............................................$225 each
Pre-Conference Workshop (Limited Availability)
____ (Qty.) How to Get Lubricant Selection Right Every Time
____ (Qty.) Achieving Better Maintenance Management with
Proven Leadership Tactics
____ (Qty.) How to Integrate Multiple Condition Monitoring
Technologies for Maximum Reliability
____ (Qty.) Identifying the Causes of Contamination and the
Actions That Mitigate Them
Post-Conference Workshop (Limited Availability)
____ (Qty.) Lubrication Excellence Essentials for Leaders
____ (Qty.) Designing and Procuring Equipment to Increase
Reliability
SPECIAL EVENTS
Indy Track Tour (Limited Availability)
____ (Qty.) Monday, April 16, 12-3:30 p.m. ...................$95 each
Polaris Laboratories® Facility Tour (Limited Availability)
____ (Qty.) Wednesday, April 18, 5:30-8:30 p.m. ...... $19.95 each
Non-Denominational Offsite Prayer Breakfast
____ (Qty.) Wednesday, April 18, 7-7:50 a.m. ......................FREE
 1328 E. 43rd Ct. | Tulsa, OK 74105
Noria.com | 800-597-5460

Attend. Learn. Apply.

> 90+ Learning Sessions
> 100+ Exhibitors
> 30+ Case Studies
> Four Certificate Programs
> 7+ Networking Events
> 6 Workshops
> Plus Much More!

80%
of attendees said
they learned something new For more information, visit
they wanted to implement
when they returned home
Conference.ReliablePlant.com.
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Sponsors
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