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

IKEC Deploys Lube Program to Avoid $2 Million in Annual Losses

A recent study of the motor and pump repairs at IKEC’s Clifty Creek generating station revealed that approximately $2 million dollars was being lost annually due to improper lubrication. This has led to dramatic changes, including Noria training and a greater emphasis on lubrication to ensure the health and reliability of the plant’s equipment.

Improved Lubrication Practices Stop Machine Failures at TEP

As part of its Lubrication Program Development (LPD), Noria’s team of consultants devised a plan of attack to put the Tucson Electric Power (TEP) generating station in Springerville, Arizona, on the path to lubrication excellence. The plant now sees far fewer equipment problems due to insufficient or improper lubrication, and its lubrication-related machine failures have been reduced dramatically.

Better Lubrication Management Boosts Gerber’s Asset Availability

The Gerber production plant in Fort Smith, Arkansas, hired Noria to implement a new approach for maintaining oil levels and extracting oil samples from critical gearboxes. Noria’s training courses and learning materials also helped the facility change how it managed lubrication, which has resulted in increased equipment life cycles and reduced downtime.

Lubrication Program Enables Simmons Feed to Cut Downtime by 50 Percent

The Simmons Feed Ingredients plant in Southwest City, Missouri, brought in Noria consultants to develop a roadmap for lubrication excellence. After implementing Noria’s Lubrication Program Development and training, the facility was able to achieve cleaner oil, prevent machine failures, avoid lost production and save up to $1 million a year.

Lubrication Training Leads to Success at Kimberly-Clark Mill in Fullerton, California

Noria’s machinery lubrication training enabled Kimberly-Clark’s Fullerton Mill to achieve significant increases in machine reliability. With Noria’s help, the mill’s lubricant consumption has been reduced dramatically and oil losses have dropped by 30 percent. Machine delays have also decreased, and the mill now experiences fewer equipment breakdowns.

For the Sinclair Wyoming Refinery, machinery lubrication was a trouble spot until Noria helped put it in the spotlight.

Noria’s onsite training and Lubrication Program Development helped transform the Sinclair Wyoming Refinery into an industry leader for machinery lubrication. With guidance from Noria, the refinery was able to shift to a proactive maintenance approach and adopt best practices, significantly impacting its operations and bottom line.

When OG&E needed best practices for lubrication,
Noria had the best solution: LPD.

Oklahoma Gas and Electric (OG&E) retained Noria to implement its Lubrication Program Development (LPD) at one of the seven power plants OG&E operates throughout Oklahoma. Noria helped OG&E transform the plant’s lubrication procedures on all critical assets. Now machinery breaks down less often, and maintenance issues are better anticipated.

Manufacturer Transforms Lubrication Program

A 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 Plant

Numerous 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 Failures

A 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 Processing

Noria 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 Lubrication

A 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 Failures

Numerous 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 Machinery

A 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 Selection

A 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 System

A 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 Development

A 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 STP

Noria 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 Grease

Polyol 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 Supplier

A 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.

Food Processor Resolves Chain Lube Reliability Issues

A large meat processor was experiencing chronic chain failures on a belt used to convey food through an oven. Many different lubricants and lubrication methods were previously attempted by plant personnel to improve reliability without success. With Noria’s involvement, a detailed tribological study was performed to identify the root cause of the failures. It was determined that the primary culprit related to the daily sanitation process. This process stripped the chain of critical lubricant protection at extremely hot temperatures and high loading. The solution was to use a specialty lubricant designed specifically for this application that could withstand the severe conditions from the sanitation cycle.