Lubrication and Lubricants

11:00 -11:50am
Transformed Lubrication Program Boosts Reliability and Reduces Costs
John Gobert, Jim Crissman and Mike Hill, Valero Energy Corporation
In this rotating equipment-oriented case study, you’ll learn how a refinery started a basic lubrication program and transformed it into a money-saving, reliabilityenhancing program. Discover how best-practice handling, contamination control, education and oil testing were implemented throughout the plant, reducing equipment failures and boosting employee morale.

1:30-2:20pm
Lubrication: Maintenance Cost or Opportunity?
Mark Barnes and Drew Troyer, Noria Corporation
With industry demanding increased equipment uptime and improved reliability, predictive technologies such as oil analysis, vibration analysis and thermography have become indispensable tools to the reliability engineer. However, many companies have overlooked what is right in front of their noses - the financial impact and costs associated with antiquated lubrication practices. In this information-packed session, the results of an industry-wide survey on the costs that poor lubrication practices can have will be presented, along with a proven strategy to convince management that lubrication is worth the investment. Learn how to speak the only language managers understand: DOLLARS!

2:30-3:20pm
Development of a World-class Lubrication Program Using a Team Concept
Wayne Ferguson and Tom Hiatt, Eli Lilly and Company
In this case study, you’ll get an in-depth look at the road Eli Lilly and Company took to create a solid lubrication program which is saving each Indiana plant site more than $100,000 per year. Their multifaceted approach incorporates lubrication audits, training, procedures and team development. You’ll benefit from hearing about the successes and pitfalls that were experienced along the way.

2:30-3:20pm
Multiple Technologies Help Find Imminent Failure
Matt Spurlock, Noria Corporation; Mark Kingkade, Allied Reliability; Gregg Wegner, Cargill Oilseeds
Utilizing predictive technologies is a common maintenance practice in this day and age. Some technologies are more suited for a given application than others. Still, there are applications in which the criticality of a component may warrant the use of multiple technologies in order to maximize the ability to catch a potential adverse condition. This case study will show how the collaboration and understanding of multiple technologies helped to identify an imminent failure in highly critical piece of machinery. Presenters include two of the analysts directly involved with the identification of the failure in this case study.

4:30-5:20pm
The Basics of Food-grade Lubricants
Sabrin Gebarin, Noria Corporation
The food processing industry presents unique challenges to lubricant formulation engineers, lubricant marketers, plant lubrication engineers and equipment designers. While it is never desirable for lubricants to be allowed to contaminate raw materials, work-in-progress or finished product, the consequences of a lubricant contaminated product is rarely more acute than in the food processing industry. As such, lubricants used in this industry have requirements, protocols and performance expectations that go well beyond typical industrial lubricants. This session will identify the basic differences between H1, H2 and H3 lubricants, their requirements and formulations as well as proper lubricant selection, which is critical to food safety and machine reliability.

Wednesday, May 17

8:00-8:50am
Effective Lubrication Strategies for Electric Motors
Jeremy Wright, Noria Corporation
Executing precision electric motor bearing lubrication is essential for motor reliability. Yet, information about proper motor bearing lubrication is scarce and sometimes confusing. In this session you’ll learn how to determine the correct type of lubricant, calculate the correct amount of lubricant to use, calculate time intervals for relubrication and much more. Armed with this new information, you will be able to immediately make a difference in your lubrication program.

9:00-9:50am
How to Interpret and Create Lube Specs for Industrial Gearing
Jarrod Potteiger, Noria Corporation
When selecting lubricants for industrial gearing, there are a number of considerations beyond simply selecting a product from the maintenance manual’s QPL (qualified product list), including product availability, operating conditions, the preferred lubricant brand and product consolidation efforts. It is important for those charged with selecting the lubricants to posses at least a fundamental understanding of how to specify lubricants for gearing. In this session, you'll learn to maximize machinery reliability under normal conditions, as well as use lubricant specification as a problem solver in many abnormal conditions.

11:00-11:50am
Boost Detection by Integrating Predictive Technologies
Bill Jacobyansky, Guardian Industries
In this session you’ll hear case studies of how various predictive technologies work together. Examples include sonic greasing and vibration analysis, vibration analysis and infrared technology and lubrication and infrared technology. You’re sure to learn several new tricks that you can incorporate.

11:00-11:50am
Degradation Mechanisms Leading to Sludge and Varnish in Modern Turbine Oil Formulations
Jim Fitch and Sabrin Gebarin, Noria Corporation
In recent years, there have been an unusually large number of reported cases associated with varnish and sludge formation in turbine-generator and compressor applications using Group II turbine oil formulations. Explanations for these problems have varied but typically include Group I/Group II incompatibility, additive instability, bulk oil oxidation, adiabatic compressive heating and electrostatic discharge, among others. This session reviews these failure pathways and analytical methods for detecting and monitoring the sludge and varnish.

1:30-2:20pm
A New Lubricant Identification System
Gerardo Trujillo, Noria Latin America
Until now, there has been no standard coding system for identifying lubricants in machinery, lubricant containers and filtration systems. Noria has developed a new tagging system which uses colors, shapes and alphanumeric characters which end users can use to identify oils and greases according to their application, viscosity and special characteristics. Using this new system should result in fewer instances of wrong oil and cross contamination while creating efficiencies in the lubrication process.

1:30-2:20pm
Lubricant Specifications - What They Are and What They Are Not….
William R. Herguth, Herguth Laboratories
Looking through the myriad of lubricant specifications a user can get confused, really confused and really fast! Looking at the various specifications one needs to know the relevance and validity to their application. This presentation will discuss the various types of lubricant specifications and their relative merits. It will also discuss reading between the lines, what can go wrong and what to avoid when specifying lubricants.

2:30-3:20pm
Operations - The Virtual Maintenance Evolution
Kevan Slater, Schematic Approach Inc.
Total Productive Maintenance (TPM) and the lean maintenance movement have reintroduced the ownership to operations by utilizing operators to assist in the reliability process. Execution of minor maintenance activities to detailed lubrication tasks have been added to the basic operator routines of the “look, listen and feel”. Releasing ownership of traditional maintenance executed lubrication tasks performed on critical plant equipment requires a total commitment from the whole organization to ensure all required training is provided, all work is controlled by the work management system and work tasks are accurate and detailed. This session reviews the process, the basic requirements and an overview of the real commitment of the entire organization to ensure success.

2:30-3:20pm
Maximizing Oil Life and Improving Hydraulic and Lube Reliability with Electrostatic Oil Cleaning
Jon Prescott, Kleentek
Maintenance and operating personnel in all industries face increasing pressure to maximize the reliability of hydraulics and lube systems while reducing costs. Unfortunately, these two goals are often in opposition. The presentation discusses key problems of servo hydraulic and lube systems such as varnish, static discharge and additive depletion and their effects on reliability and performance. The use of Electrostatic Oil
Cleaning technology to address these issues is discussed with multi-year data from Saturn Corp. showing oil life extensions of 4x, significant increases in reliability and long-term oil quality improvements.

4:30-5:20pm
Executing Procedure-based Lubrication
Mark Barnes and Drew Troyer, Noria Corporation
Historically, industrial maintenance organizations have relied upon the skill, knowledge and experience of their team members to decide what work gets done and how it is carried out.  This poses problems for organizations that seek to standardize practices across multiple plants and/or divisions.  Likewise, this skills set has and will continue to degrade as a result of significant staffing cutbacks over the past 15 or so years combined with the fact baby boomers will begin to retire in droves beginning in 2008. The result is that industrial maintenance organization of the future will increasingly come to resemble those maintenance organizations that serve the commercial aviation and nuclear power industries - heavily dependent upon procedures to define what gets done and how it is accomplished.  This paper discusses in detail the key elements of to developing, deploying and delivering an effective procedure-based lubrication program.

4:30-5:20pm
Lubrication Engineering Enables Continuous Improvements and Cost Reductions
Itamaraty Jose’ Costa Sampaio, Cia Suzano Bahia Sul Paper and Pulp, Mauricio Jose Preto, GRUPO SOMMA
In this session you'll hear case studies about how lubrication programs were "re-engineered" to improve reliability, safety, costs and uptime. Learn how lubrication and maintenance job functions were reconfigured to streamline the lubrication program, build teamwork and boost results while making operations more efficient and reliable.

Thursday, May 18

8:00-8:50am
Best Practices for Lubricating API Centrifugal Pump Bearing Housings
Rojean Thomas, Trico Mfg. Corp.
In this session you will learn about optimal ways of lubricating the bearings in API process pumps and receive data on discs versus oil ring lubrication, maintaining the proper level and contamination control. Bearings that are properly lubricated with minimal contamination will operate at lower temperatures and for longer periods of time.

8:00-8:50am
How Certification Can Boost Profitability at Your Plant - An ICML State of the Industry Report
Suzy Jamieson, The International Council for Machinery Lubrication (ICML)
Professional certification is present in every corner of the world today.  Professions as wide ranging as cleaning, nursing, sales, auditing, IT, engineering and even machinery lubrication are turning to certification programs for competence assurance of their workforce.  In fact, industries in general have come to rely so much in certification of their personnel as part of risk lowering and profitability boosting processes that the Organization for International Standardization has set out to normalize the processes utilized by certification bodies worldwide in hopes of benchmarking the certification industry.

9:00-9:50am
Leveraging Internal Assets to Create and Oil Analysis Program - An Energizer Case Study
Tom Odendaal, Energizer Manufacturing, Inc.
In this session you'll hear how Energizer implemented a successful oil analysis program from the ground-up. Hear how they leveraged existing assets and developed internal expertise to create a results-producing program. Each element of the program, from sampling hardware installation, internal oil testing, challenges, pitfalls experienced and successes will be discussed.

9:00-9:50am
Maintaining Grease Lubricity and Cleanliness with Automatic Relubrication
Vedran Tadic and Michael Weigand, LubCon USA
Every chain is as strong as the weakest link. The lubricant film of rolling bearings in complex machinery is exposed to various environmental and operational conditions. Contamination from the manufacturing process or during manual maintenance intervals affect the grease service life and overall bearing performance. In this session you'll learn how automatic relubrication with the optimum grease quantity, the quality of the lubricant as
well as the cleanliness within the bearing environment is significantly improved, reducing machine downtime.

10:00-10:50am
Using Thermal Imaging to Help Solve Lubrication Problems
Leith Hitchcock, Pall Corp.
Temperature is one of the key causes and symptoms, of lubricant degradation and loss of lubrication function within a machine. As such, thermal imaging is a useful tool for solving such problems. In this session you’ll learn how maximize the use of your infrared camera in your lubrication and condition monitoring programs.

10:00-10:50am
New Generation High Temperature Lubricants
Jerry Enyeart, Progressive Maintenance Technologies, Inc. and Patrick Dessert, Advanced Lubrication Technology, Inc.
In this session you'll hear how a new lubricant chemistry was created to meet the needs of a high temperature chain application. You'll hear how various products were tested using modified ASTM methods and why this new lubricant chemistry works while other products don't. Through the discussion you'll gain valuable knowledge and insight on the chemistry and formulation of lubricants.

1:30-2:20pm
Tips for Cost-Effective Maintenance and Cleaning of Bulk Oils, Lubricants and Fuels
Phillip Johnson and Greg LaValle, Donaldson Co.
If you are challenged with keeping bulk lubricants and fuels clean and dry, this session is a must-attend. You’ll learn how to deal with issues such as filtering high-viscosity fluids, lubricant and fuel dispensing equipment, pump types and their effect on filtration cost and cleanliness, starting up large bulk lube systems and understanding minimum flushing requirements. You’ll also learn different approaches for removing water from oils and fuels. Specific reservoir design features and reticulation designs will also be explored with a view to minimizing filtration requirements and costs.

2:30-3:20pm
Not All Hydraulic Fluids are Created Equal: How to Minimize Operating Problems and Maximize Operating Profits
Debra Light, Lubrizol
In this session you’ll learn how using a correctly formulated hydraulic fluid, it is possible to minimize operating costs and maximize profits. Through selection of the right additives at appropriate treat rates, it is possible to extend the useful life of the hydraulic fluid and minimize expensive downtime. Costs associated with the replacement of blocked filters, worn pumps and valves, plus costs due to system clean up to remove sludges and varnishes can all be minimized through the use of the correct additive formulation. Learn what hydraulic fluid additive content to select and how to manage in-service fluids for improved performance.