Up Time Magazine - February/March 2009 - (Page 33) previous improvements, the potential for material conservation, reduced lubricant consumption, will already have been achieved. Three highly visible targets for lubricant consumption improvements include: Compressor Lubricant Usage – Reciprocating cylinder and sliding vane cylinder feed rates are often significantly above OEM suggested values. The excess causes varnish buildup on heat exchangers and coats pipes and air components with excessive oil residue. Synthetic lubricants can be used to optimize the throughput and reduce the risk of varnish accumulation. Hydraulic and Circulation System Leakage – Hydraulic system designers collectively agree that the majority, perhaps as much as 80%, of hydraulic system leakage is controllable, and much of it is a consequence of poor hydraulic fluid contamination control. Those ‘difficult to identify’ leaks can be found using fluorescent dye and black light technique. Retrofitting hydraulic circuits with leak resistant fittings, and instructing general maintenance mechanics and pipefitters on the proper installation and use of these fittings adds to the long term value of a leak control initiative. Open Gear Lubricant Application – American Gear Manufacturers Association (AMGA) standard 9005-EO2 provides specific guidance on the required volume of open gear feed per minute of operation for several gear sizes and speeds. Measuring the current feed, and judging the potential for reductions in feed is initially a simple mathematical exercise. Judging the adequacy of the feed rate at various steps in the reduction cycle may require the assistance of the lubricant supplier, or a knowledgeable technical consultant. critical production machines. Mike Johnson is the founder of Advanced Machine Reliability Resources Inc., a firm that provides precision lubrication program development, consulting and training. He has written and presented numerous technical papers at symposia and conferences throughout North America about how to use machine lubrication to drive machine reliability. Mike is happily married, plays and coaches soccer, and has 3 young children that consume his remaining time and attention. He can be reached at mjohnson@amrri.com or 615-771-6030. References 1 - “Interview with Luminary Professor H. Peter Jost – The Man Who Gave Birth to the Word ‘Tribology’”. Fitch, J. Machinery Lubrication Magazine, Jan., 2006. 2 - “Lubrication for Industry, 2nd Edition”, page13. Bannister, K. Industrial Press. 2007 3 - L. Rudnik and R. Shubkin, “Synthetic Lubricants and High Performance Functional Fluids, 2nd Edition”, page 88. Marcel Dekker Publisher. Summary Precision lubrication practices support machine reliability interests, produce best use cost, and improve labor efficiency. Electrical energy consumption can be reduced through the use of high performance lubricants and a careful measurement plan. Human energy consumption can also be reduced through careful evaluation and improvement of machine lubrication requirements, including the application of high performance lubricants for The Manufacturing Game® www.mfg-game.com (281) 812-4148 The Original Game ThaT promoTes and susTains reliability We battle “bugs” everyday. Let us show you how to eliminate defects and Begin the Road to Continuous www.uptimemagazine.com Improvement 33 http://www.mfg-game.com http://www.uptimemagazine.com
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