Q & A

"My lube supplier is recommending that I begin using high performance products to extend my reservoir change cycles. Does this work?"

This approach can work for some equipment. However, the issue of sump management still needs to be addressed. If you want to extend change cycles, you need to know when the oil needs attention. A calendar cannot give you this insight. You, or your supplier, should still set up an analysis program and begin tracking the lubricant products and machinery.

If this is how the supplier intends to validate the extension, and if the supplier has a well-developed plan complete with formulas to improve monetary value - then the approach may have merit. However, if the supplier wants your faith in his product that you can make the extension without any further input, then question the approach very carefully.

Success Stories

Scott Mizell at Weyerhaeuser Flint River Operations implemented an aggressive contamination control and on-site oil analysis program. A baseline of the machines' cleanliness levels revealed hydraulic machines and lubricated machines were operating at ISO 19/17 and 22/19 respectively.

Four primary sources of this contamination were targeted: new oil, built-in during manufacture or repair, ingested from the environment and internally generated. Multiple changes were made including the addition of desiccant breathers on reservoirs and new oil storage tanks, off-line filtration and portable filter carts were employed, random cleanliness checks at rebuild shops, and sealed, small volume containers were used for make-up.

Routine oil analysis such as particle counting, moisture testing, viscometry and some microscopic analysis, is performed onsite. More extensive testing like elemental spectroscopy, acid number, etc., however, is reserved for an outside laboratory.

Since implementing this program, downtime has been reduced by 90 percent and repair costs have been reduced 74 percent. When a dollar in maintenance costs is avoided, that money goes directly to the operating profit line because there is no cost of goods sold associated with the improved revenue. That makes the repair cost reductions especially important to overall profitability. Because cost reductions and production improvements occur simultaneously, proactive maintenance pays both coming and going at Flint River.

Do you have a Success Story you want to share with Lube-Tips readers? Send your story to webmaster@noria.com.

Today's Tip

• Store tubes of greases vertically, not on their sides. This will minimize the amount of oil loss from bleeding, keeping the containers and storage area in better condition.

Each tip published will earn the sender $10. Send your tips to webmaster@noria.com or fax to 918-746-0925.

Book Bits

From the book "Wear Debris Analysis":

Spectrometric Identification

An important ‘tool’ used by analysts world-wide in determining material composition is spectrometric analysis. The spectrometric examination of particles usually requires much more expensive laboratory equipment. The glossary of terms [in Chapter 6] describes a number of these analyzers, but generally what is achieved is a listing of the elements within the particle, or the compounds present. Where proportions are also determined actual metal alloys can be identified, and hence the most likely origin of wear particles. Where compounds are suggested then the presence of additives as well as debris may be decided. Those spectrometers which require the particle to be burnt will only work where the mass of the particle is sufficiently small. This means that the size limit associated with each spectrometer must be adhered to, otherwise totally misleading results will be achieved (8 microns, or less, may be the maximum particle size to be detected).

The basic idea of spectrometry is to cause the elements in a sample substance – in our case, the debris particle – to become excited and give away their presence! The excitation may arise from X-rays or high temperatures (up to 10,000 K), and the detection of the elemental wavelength could be by a photographic monochromator or ion detectors.

For more information about the book "Wear Debris Analysis" go to:

http://www.noria.com/secure/product_detail.asp?catalogid=38

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Lube-Tips is published by Noria Corporation. Oil Analysis and Lubrication Experts