Noria is the worldwide leader in providing lubrication consulting services and training. We deliver accurate, high-quality services to a range of companies – large and small. Here’s a sample of companies we’ve helped:
Case Studies from Customers
Manufacturer Transforms Lubrication ProgramA manufacturing company had no formal lubrication program and wanted to implement a Lubrication Excellence program in 14 plants in the United States. The company was experiencing lubrication-related machinery failures that were affecting its ability to meet its customers’ demands. Noria helped transform each plant’s lubrication to world-class status. Areas of emphasis were detailed lubrication procedures, accessorizing machinery for lubrication excellence, lubricant identification systems and training.
Varnish Problems at a Combined-Cycle Power PlantNumerous efforts were made to remedy chronic varnish problems at a combined-cycle power plant. The varnish led to stiction of inlet guide valves and gas control valves, which in turn resulted in no-start conditions at unit startup and trip conditions on running units. Numerous efforts were made by the utility to filter the oil clean of varnish potential. However, the root cause remained, and the failures were recurrent. The problem was finally corrected when Noria investigated the situation and recommended the use of heat trace tape and a lubricant less prone to agglomerate soft impurities at cooler temperatures.
Wind Turbine Bearing FailuresA large wind turbine manufacturer was experiencing generator bearing failures in its wind turbines worldwide. Noria was hired to conduct a root cause analysis and determine if a change to a different lubricant was needed. Contaminant analysis, tribological studies and analytical ferrography were employed, and the root cause was identified.
Phosphate Ore ProcessingNoria helped a major phosphate ore processing plant improve lubricant contamination control, oil analysis and lubricant-related inspections. Before these changes, the plant was at 67-percent asset utilization. As a result of this transformation success, the plant achieved 91-percent utilization.
Paper Mill LubricationA large paper mill hired Noria to audit its lubrication program and make recommendations for employing lubrication and oil sampling best practices. After a benchmarking assessment and SWOT analysis, Noria helped identify optimum locations for oil sampling ports, provided oil sampling best practices training, made contamination control recommendations and created a detailed lubrication manual.
Corrosion Cause of Coal Pulverizer Gearbox FailuresNumerous customers of a manufacturer of coal pulverizer gearboxes were experiencing premature failures. Noria conducted root cause failure analysis and traced the problem to static corrosion and false brinelling during storage and transport prior to commissioning. Better storage conditions were developed along with the prescribed use of a vapor phase rust inhibitor to mitigate the onset of corrosion. The corrective measures were found to be an effective remedy, as there were no reoccurrences of premature corrosion failures.
Tire Manufacturing MachineryA tire manufacturing plant hired Noria to develop a lubrication plan and detailed procedures for its highly customized tire manufacturing systems. This customer also recognized the value of training and brought in Noria instructors to train more than 100 of its operators, craftsmen and lubrication technicians on lubrication best practices.
Lubricant Supplier SelectionA fertilizer company with multiple plants was seeking a new oil supplier for its compressor and turbine lubricants. It engaged Noria to assess various lubricant suppliers and their products. Noria developed a test slate for the candidate oils, facilitated the lubricant testing and made recommendations based on laboratory testing.
Severe Foaming of Paper Machine Main Lube SystemA pulp and paper mill encountered such severe foaming conditions that the foam was spewing out the reservoir vents. Oil analysis did not report anything unusual. However, a more thorough investigation by Noria found minute amounts of zinc in the paper machine oil, which was not normal in the formulation chemistry. This was traced to cross-contamination of a preservative used in the calender rolls. The problem was resolved by draining and flushing followed by a recharge of fresh, new oil.
Oil Analysis Program DevelopmentA processing plant wanted to develop an effective oil analysis program to help extend machine and oil life and reduce unscheduled downtime. The existing oil analysis program was centered around very basic lubricant health monitoring. Noria helped establish proper test slates, sample locations, strategic alarms and key performance indicators (KPIs).
Turbine Failure Caused by STPNoria was hired to help a hydroelectric power plant that was experiencing emulsified water problems in all four of its turbine-generator lube oil systems. Oil analysis found trace amounts of calcium and phosphorous among other elements. Plant personnel revealed that STP was periodically used as a prelube dressing on journal and thrust bearings. STP contains polar additives that readily emulsify water in oil. The solution required a drain and flush to remove the STP residue from all internal oil zones.
Hydrolysis Failure of Synthetic Bearing GreasePolyol ester synthetic lubricants are widely known to hydrolyze in the presence of water. This chemical breaks down the lubricant. Polyol esters are also known to be hygroscopic, meaning they can absorb moisture directly from contact with the air. A high-speed electric motor manufacturer uses polyol ester grease in its bearings. Noria was hired to help determine why the vast majority of the motor bearings were failing in less than a year. Analysis of the used grease with infrared spectroscopy revealed hydrolytic degradation from water contamination. The problem was solved by changing the grease’s base oil type.
Large Electric Utility Changes Lubricant SupplierA large U.S.-based electric utility was concerned about recent changes in turbine oil formulations coming from their current supplier. They decided the time was right to review their supplier agreement and turbine oil brand and type selection. Noria organized a comprehensive study to survey the larger suppliers of turbine oils including both major oil companies and independents. After many meetings with stakeholders at the utility (corporate and plants together), an engineered turbine oil specification was written and approved based on the collective input of all participants. With this specification, candidate lubricants and associated technical data from interested suppliers were reviewed and studied in detail. Supplier representatives were interviewed. References were checked. Independent lab studies including compatibility analysis of leading candidate oils were performed. After considering technical and application evaluations, the utility was able to make an informed decision on turbine oil selection.