Why State Of Tune 

Few things are guaranteed in life, unless you live in the continental Northeast. Up here, winter living is synonymous with bad driving conditions, lots of snow shoveling, high heating bills and, possibly, critical equipment problems.I recently have been up close and personal with all of the above.

You don’t have to go it alone in building and sustaining lubrication excellence.

This type of contamination removal pays big dividends in terms of improved equipment reliability.

With lubricants, it’s all about control. This article captures the what, why and how of it.

Air Coolant For Machining Operations

EXAIR’s Cold Gun Aircoolant System^TM produces a cold, quiet stream of air to reduce heat buildup on machining operations. According to the company, the product is an alternative to mist systems and helps reduce costs associated with the purchase, filtration and disposal of liquid coolants. Features include an improved hot-air exhaust muffler that reduces the operating noise level to 70 dBA. 

Exair Corp.
Cincinnati, OH

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Cordless Grease Gun

Milwaukee Tool’s M18™ Cordless 2-Speed Grease Gun delivers up to 10,000 psi operating pressure and includes a pre-set grease counter to dispense exact amounts of grease. Other features include an on-board LED light, a lock-on/off trigger and a plunger rod with markings to gauge remaining grease. The tool has a stand-up design and shoulder-strap capability, while a 48” flexible hose offers accessibility to hard-to-reach fittings.  

Milwaukee Tool Corp.
Brookfield, WI

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Compact High-Viscosity Filter Cart

The OilMiser 15V456 High Viscosity Filter Cart features a  compact design and a high-efficiency TEFC motor. Its color-coded Filter Condition Indicator signals a needed filter change. Quick-disconnects comply with ISO-7241-1B Interchange Standards, and are supplied with dust caps on suction and discharge ports. The cart’s low flow rate of 1.9 gpm (7 L/m) minimizes filter media stress and maximizes contamination retention on the oil filter. 

JLM Systems Ltd.
Richmond, BC, Canada

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Ultrasound Data Collector  

SDT has added an acceleration feature to its SDT270 ultrasound data collector, allowing inspectors to measure, log, alarm and analyze vibration data. It also features survey-driven temperature, tachometer and static/dynamic measurements powered by an on-board synchronous database. Data can be further analyzed through the company’s Ultranalysis Suite software.

SDT Ultrasound Solutions
Cobourg, ON, Canada

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Semi-Permanent Spill Containment Solution

New Pig’s crush-resistant Build-A-Berm® Barrier Kit lets facilities create semi-permanent spill containment barriers around machinery or storage areas. This pliable, open-cell barrier can be shaped to suit the application and springs back into shape after being walked on or rolled over with light, wheeled equipment. It features a high-visibility yellow color and 18-oz all-vinyl covering that resists oils, coolants and most chemicals. The kit includes straight sections, corners and sealant, and the barrier is easily removed with a flat-bladed shovel. 

New Pig Corp.
Tipton, PA

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Low-Temp Food Grade Lubricant  

LU™214 Food Grade Low Temperature Lubricant from Sprayon® Products is NSF® H1-rated and suited for extended service under low-temperature conditions (down to -78 F). Its blend of synthetic oils includes extreme-pressure corrosion inhibitors, anti-oxidant, anti-foam and anti-wear additives. Kosher-approved, this non-staining formulation with a high load capacity is suited for use on compressed air systems, gears, chains and more.

Sprayon
Cleveland, OH

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Lube-Additive Diagnostic Tool With Wi-Fi Connectivity 

Fluitec’s RULER View™ diagnostic tool provides the type of critical insight into the health and remaining useful life of the antioxidant additives in lubricants that heretofore hasn’t been available through other condition monitoring and analysis technologies. An advancement of the company’s flagship condition monitoring product, the RULER, it features a microphone for real-time dictation of data relevant to the sample and an integrated camera to capture an image of the MPC patch (Membrane Patch Colorimetry, ASTM D7843) when testing for varnish potential. Technology-friendly Wi-Fi connectivity allows for seamless software upgrades and product support. The built-in report template and integrated software lets users quickly produce high-value, professional reports on the remaining useful life of their critical lubricating assets.

Fluitec International
Jersey City, NJ

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Belgium’s Port of Antwerp (“Antwerp”) is Europe’s second largest and the fourth largest in the world. Thousands upon thousands of ocean-going vessels call at this busy facility each year, and containers are a huge (and growing) component of its maritime traffic. As it is around any port, each hour saved in handling freight that moves through this one—even an hour spent maintaining freight-handling equipment—can be important to the bottom lines of the companies doing it. That includes MSC (Mediterranean Shipping Company), one of the biggest players in the container-transport arena. MSC’s terminal operation in Antwerp is the site of a notable lubrication success story.  

Over the holidays, I was one of the thousands upon thousands of passengers who boarded planes on the busiest air-travel day of the year and flew across the country or globe to visit family and friends. It takes a hectic day like that to truly appreciate how much we (both as travelers and maintenance professionals), as well as other industries, owe the aviation industry—and how well the airlines’ systems and processes work when stressed to the max. Despite my personal lack of control over the situation, my plane departed on time, flew smoothly and arrived safely at the right destination. Moreover, even my luggage showed up exactly when and where it should have!

This year, we explore lubrication trends, techniques and benefits using the scale of proven success. 

Packing Solution Reduces Flush Rates

Chesterton’s SuperSet has been specifically designed to increase packing and equipment service life while dramatically reducing flush rates. It combines the sealing capabilities of the company’s Mechanical Packing products (including enhanced performance, sealibility, leak prevention, chemical compatibility, strength, toughness and thermal characteristics) with the patented design of the EnviroSeal SpiralTrac™ Version P Environmental Controller for Packed Stuffing Boxes. The SpiralTrac Version P enhances the utilization of the flow and centrifugal effects around the shaft by performing like a centrifugal separator. The built-in tangential lantern ring and helical grooving system impart motion to the flush, and the resulting centrifugal force throws the particulates in the fluid to the outside of the bushing. The SpiralTrac grooving system then hydrodynamically pumps the solids to the bottom of the stuffing box and back into the pump casing.

A.W. Chesterton Co.
Woburn, MA

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AODD Accessories Boost Pump Efficiency  

Warren Rupp’s SANDPIPER brand has launched a new, improved line of Air Filter/Regulators and Lubricators for air-operated double-diaphragm (AODD) pumps. Features include a liquid-filled pressure gauge, as well as accessories such as lockout valves and mounting bracket kits. These point-of-use Air Filter/Regulators have been specifically developed to reduce maintenance and lower operating costs. The addition of a Filter/Regulator will help prevent dirty, wet and contaminated compressed air from decreasing the performance of an AODD unit, and SANDPIPER recommends the use of these items with all of their pumps. Although the company’s AODD pumping equipment is designed to operate without lubrication, in applications with poor-quality air supplies or where nitrogen runs the pump, lubrication of the compressed air is required. For these situations, SANPIPER offers a full-line of Lubricators that easily connect to its Filter/Regulators.

Warren Rupp, Inc. 
A Unit of IDEX Corp.
Mansfield, OH

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Next-Generation, Eco-Friendly PAGs 

Lubriplate®’s PGO & PGO-FGL Series products are 100% polyalkylene glycol (PAG) fluids for gearboxes, bearings and chains operating in the most demanding conditions. They provide outstanding thermal stability, excellent extreme-pressure and anti-wear performance, protection against micropitting and exceed 13 stages of the FZG test. With their extremely low coefficient of friction, fluids in this series have been shown to reduce worm-gear energy use up to 7%. Free of zinc and other additives that could be undesirable in environmentally sensitive areas, they offer long service life and work well over extended fluid-change intervals, which conserves resources and helps ease waste-oil disposal problems. They’re available by the gallon, as well as in 5-gal. pails and 55-gal. drums. 

Lubriplate® Lubricants
Newark, NJ

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Synthetic Improves Equipment Efficiency 

Royal Purple’s SYNFILM® GT is recommended for use in gas and steam turbines, blowers and vacuum pumps, bearings, gears, air tools, etc. It should be considered instead of SYNFILM® in applications where oil reservoir temperatures exceed 200 F, improved low-temperature fluidity is desired or when a viscosity grade is unavailable. Formulated with a superior blend of synthetic base oils plus Royal Purple’s proprietary SYNERLEC® additive technology that’s been proven to make equipment run smoother, cooler, quieter, longer and more efficiently, Synfilm GT rapidly and completely separates from water and has a very low-temperature fluidity. According to the company, the product offers excellent protection against rust and corrosion and is extremely oxidation-stable, which leads to long oil life and extended oil-drain intervals. It typically replaces conventional, low-film-strength R & O (rust and oxidation inhibited) oils that rely solely on their viscosity to protect equipment against wear.

Royal Purple
Porter, TX

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Analyze Power And Quantify Energy Losses 

According to Fluke, its 430 Series II Three-Phase Power Quality and Energy Analyzers not only offer exceptional power-quality analysis capabilities, they introduce, for the first time, the ability to monetarily quantify energy losses. The models in the Series II (the 434, 435 and 437) help locate, predict, prevent and troubleshoot power-quality problems in three-phase and single-phase power-distribution systems. Incorporating what the company calls revolutionary functions, they can help a facility reduce electrical-power consumption and improve the performance and lifespan of its electro-mechanical equipment. Capabilities include: 

• Frontline troubleshooting: Quickly diagnose problems on-screen. 
• Energy loss management: Measure and quantify causes of energy losses to enablesimple ROI, calculation of harmonics and unbalance mitigation. 
• Power inverter efficiency: Simultaneously measure AC inputand DC out-put forpower electronics systems.
• Dynamic load testing: Capture instantaneous values to see the effect of load switch on generators and UPS systems.
• Capture fast RMS data: Show halfcycle and waveforms to characterize electrical system dynamics.
• Predictive maintenance: Detect and prevent power-quality issues before they cause downtime.
• Quality of service compliance: Validate incoming power quality at the service entrance.
• Long-term analysis: Uncover hard-to-find or intermittentissues.
• Load studies: Verify electrical system capacity before adding loads.

Fluke Corp.
Everette, WA

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Certification matters. The more certified lube professionals there are, the stronger the ‘voice’ of lubrication will be throughout industry.

Techno-Sommer’s Sharpshooter system addresses a number of lube challenges, including, among others, hard-to-reach lubrication points and the unacceptability of mist lubrication. Working off standard shop air at up to 90 psi, it can place a drop of lubricant at up to 1m away with pinpoint accuracy. A pressurized tank generates internal pressures up to 750 psi. When a pulse is generated, a fixed drop size is dispensed. Up to eight dispensing nozzles ranging in size from 5mm³ to 100mm³ can be attached to one tank. 

Techno-Sommer
New Hyde Park, NY

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NSF H1-Registered Spray Lubricant 

Klüberpaste UH1 96-402 from Klüber Lubrication is a light-colored, high-temperature paste available as a spray. Designed for assembly purposes and the lubrication of screws at temperatures between 392 and 2192 F, it’s registered as NSF H1, making it suitable for food-processing and pharmaceutical use. The product adheres to metals and is water-resistant. 

Klüber Lubrication North America L.P.
Londonderry, NH

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Compact And Easy-To-Clean CNC Oil Skimmer 

Abanaki’s Mighty Mini® SST is intended for the removal of unwanted oil in coolants and parts washers. Capabilities include removal rates of up to two gallons of medium-weight oil per hour, depending on belt selection. An improved wiper blade system fits securely in the trough and allows for cleaning on both sides of the belt. Its light-weight and small footprint allow it to fit underneath most CNC machines.

Abanaki Corp.
Cleveland, OH

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Multi-Point Lubrication Delivery System 

Oil-Rite’s Hydracision multi-point lubrication system can distribute to as few as 12 or up to hundreds of separate points. It combines efficient hydraulic movement of fluid with the precision of positive displacement injection. The reservoir housing contains a gear pump motor which pressurizes the outlet for uniform fluid distribution. A PLC with programmable display allows selection of lube cycles, while a low-level switch prevents operation when oil supply is depleted.   

Oil-Rite Corp.
Manitowoc, WI

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Bio-Based Oil With No VOCs

Master Chemical’s TRIM® OV 2200 is a bio-based straight oil free of volatile organic compounds. Developed to machine difficult alloys and stainless steel, the chlorine-free oil contains no sulfurized EP additives and protects aluminum and copper alloys. It also has improved oxidation inhibition compared with other vegetable oils, according to the company.

Master Chemical Corp.
Perrysburg, OH

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Air-Operated Piston Pumps

ARO Fluid Products’ AFX™ line of air-operated piston pumps and systems features air motors in five sizes from 4.25” to 12”. Each includes ARO’s Progressive Exhaust™, True Link Valve™ and integrated regulator technology used on 2-ball, 4-ball and chop-check pumps. The pumps are well suited for transfer of shear-sensitive, viscous, corrosive and abrasive fluids in a range of applications.

ARO Fluid Products
An Ingersoll Rand Co. Brand
Davidson, NC

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Cost-Effective ‘Check-Engine-Light’ Technology For Monitoring Semi-Critical Equipment  

SKF’s new CMSS 200 Machine Condition Indicator is a low-cost, battery-powered, stand-alone monitoring solution for semi-critical machines with constant operating conditions that usually aren’t evaluated on a regular basis. Independent and self-sufficient, it periodically measures vibration and velocity, and monitors for problems relating to misalignment, imbalance, etc. It also measures enveloped acceleration to detect bearing degradation and keeps a running check on operating temperatures. Built-in intelligence evaluates data and helps avoid false alarms. Performing like a car’s check-engine light, the device indicates alarm status on three LEDs. Individual units can be stud-mounted or epoxied to the monitored equipment. 

SKF
Lansdale, PA

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What We Need

We begin 2013 with a number of challenges and opportunities. On one hand, some of the strongest headwinds we face are associated with government indecision (the debt ceiling, sequestration and wrangling over too many regulations vs. too few, for example). On the other hand, most of us are looking forward to what onshoring/reshoring trends and improving economic conditions could hold for our businesses and communities.

Go Ahead And Try It: A Little More Tenderness

The last Friday of 2012 found me listening to the Afternoon Shift, a program produced by Chicago’s WBEZ Public Radio station. In his wonderful voice, the host Rick Kogan was discussing New Year’s resolutions and how people tend to make them. Needing all the help I could get along those lines, I turned up the volume. 

An ASD controls the speed of an induction motor by adjusting the voltage and frequency that supply the motor. Affinity laws—which show that change in power consumption is proportional to the cube of the change in speed—illustrate energy-savings potential through the use of adjustable speed technology. What you may not have heard, however, is that in addition to saving energy, ASDs can improve operational processes and reduce motor maintenance costs. 

Is ASD Technology Right for You?
Adjustable speed drives can be very useful in applications with variable torque loads like centrifugal pumps, fans and blowers, as well as in HVAC and compressed air systems. However, ASDs are not a plug-in solution. In some cases, such as constant-power or constant-speed applications and high-static-pressure pumps, ASDs will NOT save energy.  

How can you find out if ASDs will be a boon to your facility budget? Motor Decisions Matter^SM (MDM) has you covered. On the MDM Website (www.motorsmatter.org), you’ll find an entire section focused on this topic. Two resources, in particular, can help you assess whether ASDs are appropriate for your operations and also help you develop a preliminary estimate of your energy savings and payback to identify and screen potential projects.

Get Answers to Your Questions
The National Electrical Manufacturers Association (NEMA) Application Guide for AC Adjustable Speed Drive Systems is the first resource you should review. Key selection and application factors include the motor, drive type, electrical supply, mechanical insulation and controls. The Guide also includes important safety and operational considerations that help you make a smart decision.

Second, to help assess the economics of this investment, you’ll need to estimate how much energy can be saved—and what the payback period will be. The Bonneville Power Administration (BPA) developed an ASD Calculator to help you estimate the installed cost of an adjustable speed drive, including materials and labor, energy savings and simple payback for installations on fans and pumps. Users have the option of selecting from specific fan and pump types or providing measured power (kW) entries for application types not included in the calculator. Developed for the Department of Energy (DOE), the BPA ASD Calculator is an excellent tool. 

With these resources, you’ll be in a better, more informed position to talk with an expert such as a utility account rep, motor distributor or your local service center about installing a drive. LMT

The Motor Decisions Matter (MDM) campaign is managed by the Consortium for Energy Efficiency (CEE), a North American nonprofit organization that promotes energy-saving products, equipment and technologies. For further information, contact MDM staff at mdminfo@cee1.org  or (617) 589-3949.

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A lot goes into being on the cutting edge of something. Here’s how a leading machine-tool manufacturer got there and stays there.