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Lee’s Summit, Missouri (800) 246-7689 Jerry Enyeart

Lee’s Summit, Missouri (800) 246-7689 Jerry Enyeart. Who Is Progressive Maintenance Technologies?. PMT is an engineering and technical services company that specializes in plant reliability and maintenance improvement programs. Our Mission.

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Lee’s Summit, Missouri (800) 246-7689 Jerry Enyeart

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  1. Lee’s Summit, Missouri (800) 246-7689 Jerry Enyeart

  2. Who Is Progressive Maintenance Technologies? PMT is an engineering and technical services company that specializes in plant reliability and maintenance improvement programs

  3. Our Mission To assist companies in moving from a Cost Centered maintenance operation to a Profit Centered maintenance operation

  4. A Step In The Right DirectionInvolves Lubrication Management “You Cannot Maintain Or Manage Equipment Without Maintaining And Managing Lubricants”

  5. What Is Lubrication Management Evaluation Process: • Review manufacturers lubrication recommendations/specifications • Evaluate each piece of equipment for both existing specifications and recommended performance specifications • Establish generic lubrication specifications based on equipment performance requirements • Establish lubrication PM program • Consolidate plant lubrication chemistries • Review equipment for proper filtration and breather applications • Establish oil analysis and contamination control program for applicable pieces of equipment • Evaluate storage and handling • Trouble shooting

  6. Lubrication Management Helps Prevent Issues Like These

  7. Lubrication Knowledge Is Important • Understand Equipment Performance requirements • Understand Performance Characteristics Of Lubricants • Put them together

  8. Easier Said Than Done OEM Recommendations Are Either Wrong, Inadequate Or Outdated

  9. Ashless Anti-wear Additives • Are hydrolytically stable and resist degradation caused by water • Are ashless and therefore reduce deposits caused by additives • Provide protection against coast down wear and permit use in gas turbines • Make consolidation of lubricants easier • Turbine Oils • Hydraulic Oils (AW & R&O) • AGMA • AGMA EP (Meets FZG Specifications) • Compressor Oils • Meets “Non-Detergent” Recommendations

  10. New Generation Turbine Oils

  11. New Raw Materials and Manufacturing Techniques Provide Additional Performance • Group II basestocks • Ashless anti-wear additive package • R & O only packages

  12. Group II Basestocks • Have inherently better oxidation resistance • Have better viscosity indexes • Have lower sulfur content

  13. Synergistic Anti-oxidant Blends • Provide initial PVOT (RBOT) values for new turbine oils which are four to five times higher than older turbine oils or Group I turbine oils • Resists degradation – service life can easily quadruple compared to older turbine oils

  14. Requires high cleanliness standards • Bulk loads should be manufactured and delivered at ISO 15/13/11 cleanliness levels • Dirty oil oxidizes more easily and produces more wear

  15. USAGE • These chemistries are being field tested and have demonstrated excellent performance in both steam and gas turbines • Field data confirms that oxidation based degradation of the oil is significantly slower than older generation oils.

  16. Lubrication Concerns • Oil companies have made drastic formulation changes over the last 10 years • Oil historically used in hydro units no longer available • Additive technologies may be incompatible • Sludge formation when new oil added • Operational difficulties

  17. Oil Analysis Concerns • Oil samples seldom show wear debris prior to failures • Bulk oil sample looks good , but sludge formation occurs • Unreliable or different sampling methods exist • No current method to ensure compatibility of new oil on top of old oil • Lack central database for trends and condition based maintenance

  18. Lubricant Formulation Background 10 Year Change Over Group I Base Oil to Group II and Higher Base oil

  19. Foam Inhibitor Additives

  20. Foam & Air Entrainment THRUST BEARING OIL POT SAMPLE PORTS GUIDE BEARINGS Polydimethylpolysiloxane (SILICONE) Suspended Solublized Acrylate Copolymers ( ACRYLATE)

  21. US ARMY CORP OF ENGINEERS OIL AND SLUDGE Caused when Group II added to Group I Oil

  22. Hydrodynamic Lubrication Regime Can be interrupted by Deposits Result of Cavitation Result of degradation or incompatibility Source: Kingsbury

  23. Deposit and Sludge Formation Four Possible Reasons • Group II base oils do not hold varnish precursors in suspension as old generation group I base oils. These insolubles may form deposits. • The antioxidant precipitate as they are preferentially oxides causing the varnish. • The new generation antifoam additives have less effective short time domain air release characteristics and these small air bubble are adiabatically compressed causing the varnish • Cross-Contamination with Hydraulic Oil (AW)

  24. Routine Lube Oil TestingTurbine Bearings and Governors • Metals Straight Run • Digested Metals (filtered) • Acidity • Viscosity @ 40oC • Filter Residue (filterable solids) • Water in ppm (parts-per-million) • ISO Particle Count

  25. Varnish Potential Testing • Routine Test Package (Previous Slide) • ASTM D2272 RPVOT for Oxidation Time • ASTM D2272 Sludge Forming Tendency • Voltammeter (RULER) ASTM D6971 • Infrared Analysis Filterable Solids RULER New Oil has high RULER Values Phenolic Peak

  26. Compatibility Testing • Mixing / Blending • Heating (aging) Cooling (aging) • Visual Compatibility HL-1193 • Acidity ASTM D974 • Viscosity @ 40C ASTM D445 • Filterable Solids Pentane HL 1116 • Aniline Point ASTM D611 • ASTM Color ASTM D1500 • Foaming Characteristics ASTM D8921 • Air Release Properties ASTM D34272 • Water Separability ASTM D1401 • Rust Prevention ASTM D665 • Copper Corrosion ASTM D130 • RPVOTASTM D2272 • Sludge Forming Tendency ASTM D2272 (Modified)

  27. As a predictive tool, oil analysis provides equipment and lubricant condition information identifying potential failures. • Alignment • Balancing • Vibration Analysis • Infrared Thermography • Ultrasound Detection • Motor Analysis • Oil Analysis

  28. Fluid monitoring using particle count technology to control cleanliness levels, eliminating contamination as a factor in equipment failure. • Alignment • Balancing • Vibration Analysis • Infrared Thermography • Ultrasound Detection • Motor Analysis • Oil Analysis • Contamination Control

  29. Benefits • Reduced maintenance costs • Increased output through reduction of down-time (increased up-time) • Greater safety and environmental protection • Increased product quality • Longer operating life of expensive equipment • Significant energy savings

  30. An Effective Reliability Program Looks Like This

  31. Visit our Web Site! • Corporate Overview • Cost Benefits • Innovative Solutions • Information Center • News & Press • Employment Opportunities • Training Center www.progressivemaintenance.com

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