your global specialist tribojournal - klueber.com piet maljaars, cluster coordinator at the...

Tribojournal

your global specialist

2012

– A masterpiece in the Oosterschelde estuary– Efficientgenerationofcleancompressedair– High-precisionmachinetooloperation– Analysisservicefortrouble-freeoperation

Tribojournal 1/2012

A masterpiece in the Oosterschelde estuaryLubricationandsealingfunctionsfullyretainedafter25yearsofservice

WorkingwithcleancompressedairNew,fullysyntheticcompressoroilshaveproventheirworthinpractice

Newserviceforoperatorsofwindturbines Bearinggreaseconditionanalysesfortrouble-freeandreliableoperation

Precision,efficiency,sustainabilitySpecialitylubricantsformachinetoolscontributetohigherproductivity andlowerlifecyclecosts Tailor-made,reliableandgoodfortheenvironmentNewsterntubeoilexpandstherangeofreadilybiodegradableoilsforthemaritime and offshore industry

All-roundlubricantforexcellentwearprotectionKlüberfoodNH194-6000isahigh-performancefluidgreaseforhigherprocessreliability

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We thank the company DECKEL MAHO Seebach GmbH for their kind support and provision of pictures.

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Newwaysofkeeping you informed

Dr. Michael KolkHeadofMarketingandApplicationEngineeringKlüber Lubrication München KG

Dear reader

WhenwepublishedourfirsteditionofTribojournaljustovertenyearsago,addedcustomervaluewastheobjectivewehadinmind,aswithallprod- uctsandservicesweoffer.Thisobjectivehasn‘tchanged.Inthecurrentedition,forexample,youcanfindoutwheretolookforpotentialtoreduceoperatingcosts,howmodernspecialitylubricantscanhelpyouattainenvironmentaltargets,andwhichpioneeringnewproductscanenablemore reliable production processes.

Aswithallourservicesandspecialitylubricants,wewillcontinuetotakenewpathswithourpublications,theTribojournalbeingoneofthem,inresponsetoyoursuggestionsandinordertomeetyourwishes.Wetalkedtoourcustomers,askingthemwhichsourcestheyuseandwhichinfor- mationchannelstheyprefer.Wefoundthatdigitalmediaarepreferredbymanyandthatourwebsiteisbyfarthemostfrequentlyusedsourceforinfor- mationonKlüberLubrication.Sowedecidedtosetupanelectronicinforma-tionserviceinplaceofourtraditional,printedcustomerjournal.

This enables us to – provideyouwithaquickandstraightforwardoverview–it‘suptoyou tochoosethetopicsyou‘reinterestedin

– offeryouaconvenientwayofobtainingin-depthinformationontopics ofyourchoiceandcontactingus

– giveyouexactlytheinformationyouneed Naturally,wewouldbeverypleasedtokeepyouinterestedasakeenreader.Whynotregisterforthenewmediumrightaway? www.klueber.com/en/News/Newsletter/.

IwishyouaninterestingreadofthislasteditionofTribojournal

Dr. Michael Kolk

Tribojournal 1/2012

The main difference to the building of a dam, as had origi- nally been planned, is that the Oosterschelde Estuary has not been turned into an inland body of water by the storm surge barrier and, therefore, the natural tidal action was not cut off. This means that mussels and oyster breeding have survived.

Piet Maljaars:Exactly–andassoonasastormiscomingon,wecancloseeverythingoff.Whenthesealevelrisesmorethan3metresabovetheAmsterdamNAPlevel,whichmeansabovethemeansealeveloftheNorthSea,thenit‘stimetooperatethesluicegates.

Building a storm surge barrier with gates was technically much more demanding than building a dam. Can you ex- plain what makes the barrier so special?

Piet Maljaars:Well,buildingthestormsurgebarrierwasahugechallengeforallcompaniesinvolved.Afterall,itconsistsof62mov-inggatesweighingbetween250and400tonseach.That’senor- mous.Consequently,therequirementspertainingtothehydraulicsystemthatmovesthesegatesareextremelyhigh.Thesameappliestothebearingswhichareanabsolutenecessitytomovethegatesatall.Notleast,alsothelubricanthastowithstandextremeconditionsinsidethebearings.Allthosefactorshadtobetakenintoconsiderationduringtheplanningandbuilding.Therewerenorealempiricalvaluesfromearlierprojects.Soitisevenmoregratifyingthatuptothepresentdayeverythinghasbeenrunningsosmoothly.

Foraquarterofacentury,astormsurgebarrieron the North Sea coast of the Netherlands has beenprotectinglandandpeoplefromthesea–safelyandreliably.Thebuildingisstillregardedamasterpiecenowadaysbecause,withtheplan-ningaswellaswiththebuilding,virtuallyeverystepwasastepintounknownterritory.AgreatexampleofanotableEuropeancooperation.

Shortlybeforethe25thanniversaryofthebarrier‘sinaugurationon4October2011,representativesofthecompaniesinvolvedaswellasrepresenta-tivesoftherelevantauthoritycametogetheragain:PietMaljaars,ClusterCoordinatorattheRijkswater- staat(DutchWaterAuthority),Erik-JanDriessenfromKlüberLubrication,aswellasEllisvandenHout from SKF Netherlands and Peter Schmehr fromSKFGermanysharedfascinatinginsightsonthepastcooperation,thepresentperformanceofthestormsurgebarrierandprospectsforthefuture.

Would you say now, 25 years after its opening, that the storm surge barrier has been an all-around success?

Piet Maljaars:AttheOosterschelde,theDeltawerkenhavein- deedachievedwhattheysteppeduptodoaftertheflooddisasterin1953.Notonlyhasareliableprotectionbeeninstalledforthepeople,whohavebeenabletoliveandworkheresafelyeversince.Anothergoalwastoprotectthefloraandfaunaandmaintaintheecologicalbalance.Mussels,oystersandmanyotheranimalsareheremoreplentifulnowthanever.FortheNetherlands,thestormsurgebarrierisofvitalimportance.Today,thestructureandthesurroundingnaturereserveexistinharmonioussymbiosis.

A masterpiece in the Oosterschelde estuaryLubricationandsealingfunctionsfullyretained after25yearsofservice


How many times have the gates had to be closed for safety reasons over the past 25 years?

Piet Maljaars: Wehavehadtoclosethegates26times.24timesbecauseofastormsurge,andtwicebecauseithadrainedsomuch.ByclosingthegatesandpumpingoutthewaterfromthepoldersintotheOosterschelde,thewaterlevelbehindthebarriercanbeheldlowartificially.

What exactly happens in the event of an emergency? Do the gates close automatically?

Piet Maljaars:Therearetwooperatingmodes.Thefirstisthemanualone.That’swhatweprefer,because,intheend,aftertakingallaspectsintoaccount,mancanstillmakethebestdeci- sions.Thenthereisthefullyautomaticmodedesignedfortheeventthatno-onecangettothecontrolcentreintime.Thewholebarriercanbeclosedinjustoneandahalfhours–withoutanypowerfromtheelectricitygrid.Thismeanswecanoperatethegatesinatotallyself-sufficientwayintheeventofanemergency.Andtomakesurethateverythingrunssmoothlyintheeventofanemergency,wecarryoutacompletetestrunfourtimesayear.

Weather forceasts have become more accurate over the years. Are their data useful for you, and how do you use them for your warning system?

Piet Maljaars:Rijkswaterstaathasitsownmeteorologicalser- vices.Expertsareconstantlyobservingandanalysingthetechni- caldata.Themomenttheyhavegoodreasontofearthatthewaterwillrise2.75metresabovetheAmsterdamlevel,theystartmakingtheircalculations.Thentheteamhastodecidewhethertoclosetheslidesornot.ButthedirectorofthewaterauthorityhereinZeelandalwaysgetsthelastword.

How vital was the input of the companies that were given the opportunity to demonstrate their capabilities here – such as Klüber Lubrication, the German lubrication specialist, and SKF, the Swedish rolling bearing manufacturer – to the success of the project?

Piet Maljaars:Ofcourse,theplanningwasdoneonmanydiffer- entlevels,includingthepoliticalone.Personally,Ihaven’tbeenonboardforsolong,soIcan‘tcommentonitfrommyownex- perience.Forme,itisanextraordinarilygoodsignthatthepro- fessionalcooperationandthegoodpersonalrelationshipbetweenus and the companies still continue up to the present day.

Ellis Jan van den Hout:Suchclosecooperationissomethingoutoftheordinaryalsoforus.Hereonsite,forexample,westillgetinvolvedinthemaintenancework.Rijkswaterstaat,SKF,KlüberLubricationandmanyothersworkhandinhand.AgreatexampleofgoodEuropeancooperation.Specialeffortshadtobemadeforthisspecialprojectandtherehadtobeahugedegreeofcommitmenttowardsthecontractingauthorityonthepartofthecompanies.Ifwehadn‘tgivenlongguaranteeperiods,wecouldn‘thavedoneanybusiness.Theopennesseveryoneevincedtowardseachotherledtosynergiesthatnoonewouldhavethoughtpossiblebeforehand.Theenthusiasmwithwhichevery- oneparticipatedinthedevelopmentofthisbigandtotallynewachievementwasnoticeable.Know-howfromindustry,authori-tiesandthedifferentinterestgroupsallcametogetherhere.

So everyone had to enter unknown territory and actually get involved with a unique project.

Piet Maljaars:Thatwasexactlywhatmadeitsospecial,sounique.

PietMaljaars,Dutch Water Authority

EllisJanvanderHout,SKF Netherlands

Erik-JanDriessen,KlüberLubricationBelgium

PeterSchmehr,SKFGermany

Tribojournal 1/2012

Erik-Jan Driessen:Thecorrosionprotectionwascrucial.Istillknowfromthepast–IhavebeenworkingforKlüberLubricationformorethan20yearsnow–thatwehavealwaysattachedgreatimportancetofulfillingbothfunctions:sealingandlubricating.Naturally,bearingscanneverbedesignedtobecompletelysealediftheyaretowork.Afterall,theyhavetobefreetomove.Sothelubricanthastotakeoverasealingfunctionaswell.

How did you go about choosing the grease, and how come you decided to go for the German provider?

Peter Schmehr: Extensiveandprotractedexaminationsofthecomponentswerenecessary.Wehadtogainafirst-handunder- standingofthecontactofthegreasewiththeothercomponents.Forexample,howwouldtheslidingmaterialandthesteelgowitheachother,likewisethesealthatwouldenclosethebearinglater?

Everysinglecomponenthadtobecompatiblewiththegrease.Afteralltheteststherewerejustfourtypesofgreaseleftthatwetheninvestigatedmoreclosely.TheKlüberproductattainedthebestresults.SowesuggestedKlüberLubricationastherightpartner.Infurthertests,atSKFandalsoatKlüber,wevalidatedonceagainthebesttypeoflubricant.

Erik-Jan Driessen:Keepingthebalancebetweentherequire-mentsofprotectingandlubricatingwasthemostdifficulttask,butwemanagedit.Theprotectivefunctionhadtokeepgoingformany,manyyearsandthelubricationfunctionhadtobeavailablewheneverneeded.

And what, in your opinion, were the biggest challenges?

Piet Maljaars: The compression of the seabed so that the piles couldbefirmlyanchoredwasonething.Then,ofcourse,wehadtodealwiththespecificlocalcircumstances,suchasthechang- ingofthetides.Andthesizeoftheprojectrequiredthedeliveryofgiganticvolumesofconcrete.Thebeststeelbearingswereneededforthegatesaswellasaspecialitylubricantthatwasabletofulfilitslubricationpurposereliablyandonalong-termbasisandthatwas,furthermore,capableofpreventingcorrosionbytheseawater.Andthen,ofcourse,therewasalsotheprecisionwithwhicheverythinghadtobeperformed.Thegateshadtobefittedtoveryfinetolerances.Intheend,itwasallthelittledetailstogetherthatresultedintheimpressiveoverallresult.Andtheverybestthingisthat25yearsafteritsopening,thewholethingstillworkswiththesameprecisionasonthefirstday.

One element is of special importance: the lubricant that is used for the bearings of the gates has not had to be exchanged until today. The requirements were very high and it was a big challenge to find the perfect solution.

Ellis Jan van den Hout:Thelubricationcapacityofthegreasewasascrucialasitsresistancetowater.Thebearingshavetobeprotectedinthebestpossibleway,butprotectionfromcorrosionalsohastobeensured.Saltwaterisextremelyaggressive.Ifany- thinghasahighlydestructiveinfluenceonthelubrication,it‘ssaltwater.Sothebestprecautionisabsolutelyessential.

Thestormsurgebarrierprotectspeopleaswellasplantsandanimals-aperfectsymbiosisofnatureandtechnology

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Ithasalwaysbeenourdefinedgoaltofindpreciselytherightsolutionforthecustomer.Inthiscase,oneofthebigchallengeswastowarrantaservicelifeoftenyears.Alubricantthatwouldhavetobereplacedafterfiveyearswouldhaveincurredmuchhigheroverallcoststhantheextracostofourlubricant.Thepro- cessofexchangingthelubricantaloneisverypricey–andthatdoesn‘tevenincludethecostofthegrease.

So, Klüber’s specialty lubricant should not be considered a typical C-component but an actual design element?

Erik-Jan Driessen:Exactly.Evenwith14,000kilogramsoflubricanttheone-timecostofpurchaseisn’tthecriticalfactorbuttheadditionalvaluefortheoperatingcompanyoverthewholeoperatingperiod.Imean,wecannotjustpumpouttheoldgreaseandpumpinthenewone.Everythingwouldhavetobecom- pletelydismantled.Thecostswouldprobablybeimmense.Butatthemomenttherearenosignsthatanyexchangemightbenecessary. So the decision for Klüber Lubrication in terms of a long-terminvestmentprotectionhasprovedtoberight!

The lubrication at the Oosterschelde storm surge barrier is subject to regular sampling. Can you describe this process?

Erik-Jan Driessen: The free movement of the cardan suspen-sionsismeasuredeveryyear,andonceeveryfiveyearstheamountofgreaseischecked.Greasesampleshavebeentakenfromthebearingsandanalysedinthelaboratorythreetimessofar–with-out any cause for complaint.

The lubricant is simply too good.

Erik-Jan Driessen:IntheOosterscheldestormsurgebarrierprojecteverythingjustworkedoutreallywell.Thiscannotsimplybeexplainedbythewell-engineeredtechnologyoftheindividualcomponents.Icanonlyrepeat:everythingwenttogetherperfectlyandwasperfectlycoordinated,too.

Has the lubricant been improved in the meantime? Or is the product offered today still the same as it was 25 years ago?

Erik-Jan Driessen:Both.Theproductthatwasusedbackthenstillexists.Butofcoursealotofnewproductshavebeendevel- opedinthemeantime.Thepermanentlyincreasingrequirementsfromthedifferentindustriesrequirespecialtylubricantswithahighfunctionalandeconomicaleffectiveness.Therefore,atKlüberLubrication,weattachutmostimportancetoinnovation.

The Oosterschelde storm surge barrier became a prestige project for the companies involved. Is it still the same today? Are those who were and still are involved still proud to say: We were part of it?

Piet Maljaars:Yes,theOosterscheldestormsurgebarrierisanexcellenttestimonial.ThevastnumberofcompanybrochureswithpicturesoftheDeltawerkenisproofofthis.

Erik-Jan Driessen:ForKlüberLubricationIcansay:weareproudthatwegottobeinvolved.Anachievementandaresultthatcarriesweight.

Peter Schmehr:AlsoforSKF,itwasandstillisahighlyprestigiousproject.

Finally a personal question: 4 October is the 25th anniver-sary of the storm surge barrier – is it a special date for you?

Piet Maljaars:TheOosterscheldestormsurgebarrierwasapioneeringproject25yearsago.Becauseofthatitisstillsome- thingspecialtoday.Soattheanniversarytheinternationalnet- workforprotectivewaterweirsgatheredhereforaseminar.Apartfromthat,4Octoberwasaworkingdayjustlikeanyother.

Thebarrierconsistsof62movinggates,whichcanbelockedeithermanuallyor automatically

Tribojournal 1/2012

Workingwithcleancompressedair New,fullysyntheticcompressoroilshaveproven theirworthinpractice

Twokeyfactorsplayamajorroleincompressedairgeneration:highavailabilityofcleancompressedairandcompressedairgenerationatreasonablecost.Newly-developedsyntheticcompressoroilshaveproventheirworthinpractice.Longoillife- time,highefficiencyandaverylowoilcontentinthecompressedaircombinetoreduceoperatingcosts considerably.

Compressedairisthefourthenergyutilityafterelectricity,gasandwater.Fewproductionlinesintheworldwouldrunwithoutit.Themajorityofcompressedairisprovidedbyoil-injectedscrewcompressorsandthecompressoroilsplayamajorroleingener- atingcleancompressedairinanenergy-efficientway.Theyaccountfor less than one percent of the cost of compressor operation; however,therightoilhelpssaveaconsiderablepartofthetotalcost.Theoilhasthreekeyfunctions:Firstitensuresthattherotorsandrotorbearingsinthecompressorarelubricated,secondit dissipates the heat of the compression process and third it formsasealingfilmatthesealedgebetweentherotorandthecompressorcasing.

Forefficientandtrouble-freeproduction,anoilwithlongservicelifeandgoodtemperaturebehaviourwithlowresidualcontentinthecompressedairisrequired.However,thereareconsiderabledifferencesbetweentheperformancesofdifferentcompressoroils.Awell-formulatedsyntheticproducthasconsiderableadvan- tagesovermineraloil-basedproductsandstandsoutinparti- cularforoptimumoxidationprotection,goodadhesionandlowresidueformation.Thenewly-developedsyntheticoilsoftheKlüberSummitSHseriesandtheNSFH1-registeredKlüberSummit FG series made by Klüber Lubrication stand out because oftheirconsiderablyincreasedperformancecomparedtocon- ventional compressor oils.

Benefitsofsyntheticcompressoroils

Specialoxidation-resistantcompressoroilsensurereducedmaintenancecosts,highercompressoravailability,reducedtotalcostforoil,oilfiltersandoilseparatorsaswellasreduceddis- posalcosts.Furthermore,therightcompressoroilincreasescompressorperformancewiththesamepowerinputowingtoitshighlubricitybaseoilcombinedwiththeoptimumadditivepack- age.Duringthecompressionprocess,thisproductwillavoiddecomposition,oxidationandresidueformationoftheoil.

Thereareseveralfactorswhichhaveaneffectontheoilinthecompressor:highpressure,continualintakeoffreshair,hightemperatures,considerableshearingforces,particleintrusionand atmospheric humidity.


Allthesefactorscauseageingoftheoil,whichshowsmostlyasoxidation.Attemperaturesbetween90°Cand100°Cormoreandundercontinualoxygenintake,organicacidsproducedbyoxidationquicklydecomposetheoil,i.e.theoilagesrapidly.Theconcentrationofsuchacidsisexpressedbytheso-calledneu- tralisationnumber.Thelowerthisvalue,thelowertheextentofoxidation.KlüberSummitproductsensurealowneutralisationnumberthroughcarefullyselectedhigh-qualityadditives.

Condensateproducedbyairhumidityisanotherfactorleadingtohighmaintenancecostsasitmustbeprocessedpriortodisposaltothesewagesystem.Unsuitableoilsorlow-qualityadditivesleadtoemulsificationofthecondensates,makingitimpossibletoseparateoilandwaterinanormalseparator,requiringmore- expensivecondensateseparators,increasingcost.Particularlyinthefood-processingandpharmaceuticalindustries,theoilcon- tentinthecompressedairmustbeaslowaspossibleandcom- pressoroilsmustberegisteredasNSFH1,forexampletheKlüber Summit FG series.

Savingrealmoney

AleadingsausagemanufacturerwashavingtroublewithhisNSFH1compressoroils.Oilservicelifeoflessthan1,000hourscausedhighmaintenancecostsandfrequentdowntime.Follow- ingpreciseanalyses,KlüberLubricationrecommendedon-linecleaningofthecompressorswithKlüberSummitVarnasolvandchangeovertoaKlüberSummitFGoil.Aftercleaning,thecom- pressorcouldbeoperatedupto15Kelvincoolerthanbefore.Additionally,thecoolernolongerrequiredanannualstripandclean.Theoperatinghoursincreasedtomorethan4,000andmaintenancecostsweredecreasedconsiderablywhiletheoilpricewascomparable.

KlüberSummitFGoilswereespeciallydevelopedforcompres-sorsinthefood-processingandpharmaceuticalindustrieswherecompressedaircanhavecontactwiththeendproductduringtheproductionprocess.WithNSFH1registrationandcertifica-tionaccordingtoISO21469,theseoilssupportmanufacturingplantsintheircompliancewithdemandinghygienerequirements.KlüberSummitFGoilsshowverygoodresistancetooxidation,whichmeansthatthepresenceofoxidationresiduesorlacquerin the compressor is minimised.

Oilchangeintervalscanbeextended,e.g.upto5,000operatinghoursinoil-injectedscrew-typecompressors.Besidesreducedmaintenanceandoperatingcosts,thisenableshigheropera-tional reliability.

Anotherexampleisamanufacturerofparticleboards.Compressoroilchangeswererequiredafter2,000operatinghours. KlüberLubricationrecommendedchangingtoaKlüberSummitSHseriesoil.After8,000operatinghours,usedoilanalysisintheKlüberLubricationlaboratoriesrevealedthatadditivedegradationintheoilhadstarted,howevertheoilwouldnothavetobechangedforanother2,000hours.Hence,theoilservicelifeisfivetimeslongerthanwiththepreviously-usedcompressoroil.Summingthetotalcostsforoilchange,disposal,oilfilters,oilseparatorsandmaintenance,thepremiumproductturnsouttobethemostcost-efficientone.

Oil service life in compressors used by a manufacturer of particle boards could bequadrupled

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Thetotalcostcalculationintheaboveexamplerevealsconsider-ablecostsavings.Morecompressedaircanbeproducedwiththesameenergyconsumption(improvedspecificperformance).

KlüberSummitSHoilswereespeciallydevelopedforthelubrica- tionofheavily-loadedaircompressorswithprojectedoilchangeintervalsofupto10,000operatinghours(undernormaloperatingconditions).Theyareneutraltowardsmostelastomersealsusedin air compressors. Special inhibitors keep compressors clean ontheinsidetoavoidcleaningcostsandunplannedcompressordowntime.

Easycompressorcleaning

Mineraloil-basedcompressoroilscancausevarnishandcarbonbuild-up,especiallyinoil-injectedscrewcompressorsandrotaryvanecompressors,whichsettleintheentireoilcircuit.Inhydraulicsystems,mineraloilscancauseglueingofvalvesonhotsurfaces,resultinginhighenergyconsumption,cloggedoilductsandfiltersandhighmaintenancecostsanddowntime.

KlüberSummitVarnasolvmadebyKlüberLubricationisahighlyeffectivecleaningconcentratebasedonesteroilwithcleaningadditives.Itissubstitutedinaconcentrationof10%totheoilfilling60hourspriortothenextoilchangeandrunnormally.Thecleaningconcentratedissolvesresiduesonthesurfaceswhilethecompressorisinoperationandensuresthattheyremaindis- solvedintheoiltobeflushedoutattheoilchange.Thismethodismuchmoreeffectivethanflushingthecompressorwithnormalcompressor oil.

TheoperatorcaneasilydetermineifandwhenanoilchangeisnecessarywiththeKlüberSummitTANKit,whichusesthebreak- downacidsintheoiltoindicatebycolourtheextentofoxidationoftheusedoil.Alternatively,KlüberLubricationcanmakeafullusedoilanalysistodetermineanycontaminationandwearin the unit.

Conclusion

Practicalexamplesshowthatchangeovertofullysyntheticcom- pressor oils made by Klüber Lubrication can be made very easily. Oilservicelifecanbeconsiderablyextendedandcompressorperformance increased to save costs and valuable resources.

Core statements:– Modern compressor oils help save money– Morecompressedairwiththesameenergyconsumption

IfandwhenanoilchangeisrequiredcanbeeasilydeterminedbymeansoftheKlüberSummitTANKit

Robert Corna

SalesManagerCompressors

Klüber Lubrication Deutschland KG

[email protected]


Availabilityiskeytotheoperationofwindturbinesasunplanneddowntimeresultingfromcomponentwearcanbeverycostly.Repairsorbearingexchangearetobeundertakenonlyintimesofplanneddowntimeandshouldbepreventedwheneverpossi- ble. Lubricant analysis can provide helpful information. While used oilanalysisisalreadystandardforgearoils,KlüberLubrication‘sanalysisserviceisnowalsoavailableforlubricantsingenerators,bladesandmainbearingsofwindturbines.The”GreaseConditionAnalysis(GCA)“serviceisnowavailableaspartofKlüberMonitor.

Bearinggreaseconditionanalysesbymeansofstandardisedmethodsonaregularbasisprovideinformationonthecurrentconditionofthegrease.Basedonanalysisresults,thefailure riskofexpensivecomponentsorsystemscanbereducedanduseful life be increased. Grease condition analysis is not only recommendedforstandardconditionmonitoring,butalsopriortochangingovertoanotherbearinggrease.

”KlüberLubricationconsidersthisoffertobeanelementofsus- tainablecustomercare“,saysAri-PekkaHolm,ManagerBusinessUnitWindEnergyatKlüberLubrication.”Ourresponsibilitydoesnotendafterhavingsoldabearinggrease.”

Ournewgreaseconditionanalysisserviceinformsoperatorsonthestatusquoandgivesasignofwarningwheneversomethingiswrong.“

Grease condition analyses made in Klüber Lubrication laborato-riesprovideinformationonseveralaspectsofagrease‘scurrentcondition,includinggeneralgreasecondition,behaviouroftheadditives,oxidation,wearparticles,mixingwithforeignmatterandoxidationandtheextenttowhicholdandnewlubricantaremixedafterchangeovers.Asamplingkitwithdetaileddescriptionis available from Klüber Lubrication.

TheexpertsfromKlüberLubricationwillbeprovidingastraight-forward,clearreportontheresultscontainingrecommendationsonhowtoproceed.GreaseconditionanalysisisavailableforselectedlubricatinggreasesfromKlüberLubrication.

NewserviceforoperatorsofwindturbinesBearinggreaseconditionanalysesfortrouble-freeandreliableoperation

Dipl.-Ing. Alexander Dörner

Service Developer

Klüber Lubrication München KG

[email protected]

Tribojournal 1/2012

Machinetoolstodayshouldbecapableofincreasingtheoverallproductivityofacompanythroughmaxim- isedmachiningspeedsandfeedsandtheassociatedreduction of cycle times. Both the manufacturers and operatorsofmachinetoolsexpectsafeoperationandhighprocessreliabilityaswellasincreasedmachineavailability.Furthermore,thedynamic,globalconsid-erationofcostshasbecomeincreasinglyimportant:conceptssuchaslifecyclecosting(LCC)ortotalcostofownership(TCO)takeintoaccountnotonlythepurchasepriceofamachine,butalsoalladditionalcostsarisingduringitsoperationalservicelifetime.Theseincludenotonlyrecurringexpensesforserviceandmaintenance,spareparts,compressedair,energydemand,lubricantsandtools,butalsopotentialcon- sequentialcoststhatmayarisefromtheoperationofthemachineaswellaseventualdisposalcosts.

Besidestheeconomicaspects,greatemphasisistodayplacedonenvironmentalissues,i.e.theobjec-tive that machine tool operation should pose as little anenvironmentalhazardaspossible.Theglobalavailability of products needed for machine operation istodaygenerallyexpected,asiseffectiveserviceandsupport,tobedeliveredeitherbyqualifiedstaffvisitingtheplant,orbymeansofremotemaintenance.

Lubricantswithoptimisedfrictioncoefficientscanhelpincreaseenergyefficiency

Empiricalstudiesshowthatasmuchas70to85ofamachinetool‘slifecyclecostsisalreadydeterminedduringthedevelopmentstage. Synthetic lubricants can help to minimise these costsbyextendingcostlyrelubricationandoilchangeintervals,orevenbyenablinglifetimelubrication.Atthesametime,theseproducts can improve machine performance.

Precision,efficiency,sustainabilitySpeciality lubricants for machine tools contribute tohigherproductivityandlowerlifecyclecosts


Itpaystoconsiderlubrication atthemachinedesignstage

Empiricalstudiesshowthatasmuchas70to85ofamachine‘slifecyclecostisalreadydeterminedduringitsdesignstage.1)Itisatthispointthatlubricants,whichareoftenoverlookedduetotheirpresumedminorrole,areinfactofextremeimportance:Syntheticspecialitylubricantshaveinmanycasesproventoextendre- lubricationandoilchangeintervals.Quiteoften,theycan even enable lifetime lubrication in an application. Atthesametime,specialitylubricantscanenhancemachineperformanceintermsofimprovedprecision,extendedproductionoutputorreducedrejectrate.KlüberLubricationprovidesawiderangeofhighlyeffective,high-qualityspecialitylubricantsforallmachinetoolapplications.Havingbeendevelopedincloseco- operationwithmanufacturersofmachinetoolsandtheircomponents,thesespecialgreasesandoilsareusedforinitialfillbytheOriginalEquipmentManufacturers(OEMs) and also recommended in lubrication charts provided to the operators.

Thisarticledealswithaspecificitemofcuttingmachinetoollubricationinvolvingcriticaloperatingconditionswithdemandingrequirements:thelubricationoflinearguidesinmachinetools.

The lubrication of drive and guidesystems

Moreandmoreoftoday‘smachinetoolscontainlow- frictionlinearguidesratherthanconventionalslidewaystoenablepositioningoftheworkpieceand/ortool.Motionisnormallyachievedviaballscrews.Thelinearguidesaredesignedasflatguidesorprofiledrailsin- corporatingrecirculatingballsorrollers.

Thespecificrequirementstobemetbythese components–whichalsoinfluencetheselection oflubricant–are:– Highprecision– Highreliability– Lowvibration,nostick-slip– Highspeeds– Highaccelerationleadingtohighdynamicloads

Amultitudeofinfluencingparametersplayaroleintheconstructionandoperationofmachinetooldrivesystems:– Typeoflinearguide– Friction bodies and seals/caps– Operatingconditions– Usefullifeofthelubricantandrelubrication– Otherexternalinfluencingfactors

For Klüber Lubrication, “sustainable industrial production” means long-term, holistic thinking.Three examples for this include: reducing unplanned downtime to a minimum, reducing friction even further and cutting lubricant consumption. The effect: lower energy consumption and cost, less CO2 emission, longer maintenance intervals and longer component lifetime. We also aim at continually developing our environmentally-friendly lubricants to pro- tect man and nature, and helping our customers to attain their goals in the fields of environ- mental protection and conserving resources more easily.

Klüber Lubrication: technological innovations for ecologically and economically efficient solutions.

your global specialist

Speciality lubricants for sustainable efficiency.

Tribojournal 1/2012

operatorsiflubricantsarecompatiblewithandresistanttospe- cificmedia.

Oncethe”correct“lubricant,i.e.oneoftherightconsistencyclassandbaseoilviscosity,hasbeenselected,aproperlyper- formedrunning-inprocedurecanhaveadecisiveeffectonlubricationinthelongterm,andhenceontheperformanceoflubricantandcomponent.Forrunning-in,thegreaseshouldbedistributedalongtheguidewayorintheguidebushingbyper- formingseveralfull-lengthstrokes.Subsequentrelubricationisthencompletedwithamaximumof50%oftheinitiallubricationvolume,butpreferablywithsmallervolumesappliedatshorterintervals.

ConclusionItisnotuncommonforlubricants,whicharenormallyconsideredlow-priority”C“components,toassumean”A“functionwithapositive effect on machine tool TCO. To fully utilise the potential providedbyoptimisedlubrication,aglobalapproachisindispen-sableforanysolutiondevelopment:– The lubricant should be considered as a machine element alreadyatthedesignstageofthemachinetool/component.

– Theperformanceofthelubricant,itsapplicationanddosageare taken into account.

– Thechosenlubricantshouldbecompatiblewithotherlubri- cantsandmaterials,e.g.thoseusedfortheseals.

– Thelubricantneedstoberesistanttoanyexternalinfluencesandliquidmedia,suchascoolants.

Withthesepointsinplace,productiontothescheduledplan canbeexpectedwithoutmachinebreakdownorunplanneddowntime.

References:

1)VDIGuideline2884:Purchase,operatingandmaintenanceofproductionequipmentusing

LifeCycleCosting(LCC),December2005

Dipl.-Ing. Stefan Müller

MarketManagerGlassand

Metalworking,Machines,Tools

andInstallations


[email protected]

Consideringthedesignofinternalandexternalseals,cageguides,lubricant reservoirs and lubricant feed lines it it becomes obvious whythelubricantshouldbeconsideredanimportantmachineelementinitsownrightearlyinthemachinedesignstage.

Consideringthesystemasawhole,thehighrequirementstobemetbylinearguidesresultinequallyhighrequirementstobemetbythelubricants:– Goodanticorrosivebehaviouranddemulsifyingabilityenablingresistancetomedia,andespeciallytocoolinglubricants

– Dampeningofvibrationorshocks,whichisimportante.g. forthemachiningofgreycastiron

– Wearprotectionalsoundermicro-movementconditions– Lowfrictionenablingeasystart-up– Additionalsealingpropertieswhenoperatingincontaminated

environment– Goodcompatibilitywithplastics,elastomersandother

lubricants

Different lubricant compositions to meetdifferentrequirements

Dependingontherequirementsofeachindividualapplications,specialitylubricantsofdifferentcompositionareavailable–e.g.lubricantswithdifferentbaseoilviscositiesmatchingdifferentspeedsandloads(seeFig.1).Differentthickenertypesprovidecharacteristicssuchasimprovedadhesiontometalsurfaces,goodresistancetofluidmediaaswellasimprovedgooddampen- ingeffect.

InitialgreasingoflinearguidesisnormallyprovidedbytheOEMfollowingmanufacture.Relubricationisthenperformedbytheoperatorusingcentralisedlubricationsystemsorlubricantdis- pensers(particularlyforsoftgreases).Itisthereforevitalthatthelubricants used for initial lubrication and relubrication be fully compatiblewithoneanother.Wheremanufacturershavenotpro- videdpertinentinformation,severaltestingmethodscanbeusedtodeterminelubricantcompatibility,e.g.thewaterwashouttest,therollstabilitytestortheSNR-FEB2test.Thesetestsalsotell

Fig. 1:Guideforselectingtherequiredbaseoilviscositiesfordifferinglinear speeds

Linear speed

low

<15m/min

vibration<0.5m/s2

increasedwear

highviscosity(100to500mm2/s)

MICROLUBEGL261/262

medium viscosity(approx.100mm2/s)

KlüberplexBEM41-141/34-132

increased friction heat

lowviscosity(25to70mm2/s)

ISOFLEXNBU15/TOPASNB5051

medium

15to60m/min

vibration < 1m/s2

high

>60m/min

vibration < 2m/s2

Fig. 2:Workedpenetrationistestedtodeterminetheeffectacoolinglubricanthasontheperformanceofagrease.TestsperformedwithISOFLEXNBU15showthereishardlyanydifferencebetweentheoriginalusedgreaseandtheusedgreasecontaining2.5%ofcoolinglubricant.

ISOFLEXNBU15 ISOFLEXNBU15+2.5%coolinglubricant

340 340

320 320

300 300

280 280

260 260

240 240

220 220Wor

ked

pen

etra

tion

1/10

mm

Freshgrease Usedgrease

Examination of resistance to media


Dipl.-Ing. Dirk Fabry

MarketManagerMaritimeund

OffshoreIndustries


[email protected]

More and more operators and suppliers of mari-timeandoffshoreequipmentareinvolvedinmini- misingtheirimpactontheenvironment.Theseefforts affect the choice of lubricants used in ships,andmachineryingeneral.Withspecialitylubricantsenablingsustainableandprofitablesolutions,KlüberLubricationsupportsshipown-ers,OEMsandoperatorsinreachingtheirenvi-ronmentalgoalsmoreeasily.

KlüberbioRM2-100,thenewreadilybiodegradablesterntubeoil,isdesignedforthelubricationofpropellerbushesandpropellershaftsealsoffixed-pitchandcontrollable-pitchpropellers.Thesyntheticspecialityoilisnon-toxictomarineorganisms–accord- ingtoOECD201,202and203tests–anditsbiodegradabilityisatleast60percentaccordingtotheOECD301Ftest.Aleadingglobalmanufacturerofpropellershaftsealssubjectedthenewsterntubeoiltoadynamicendurancetestonatestrigfittedwiththeoriginalseals,anditpassedsuccessfully.

Justasthefirstoilofthisseries,KlüberbioRM2-150,thenewoilwithviscosity100facilitatessmoothstart-upofpropellers,evenatverylowtemperatures.WhereasKlüberbioRM2-150isdesignedforapplicationinmoderateandwarmerregionsoftheworld,thenewKlüberbioRM2-100copesreliablywiththecolderclimates.BothKlüberbioRM2oilshavealongservicelifeowingtotheirgoodstabilityagainstoxidation,hydrolysisandtemperatures.KlüberbioRM2oilsaremisciblewithmineraloil-basedsterntubeoilsforeasychangeover.

InthedevelopmentofbothKlüberbioRM2oils,KlüberLubricationcooperatedcloselywithitsaffiliatedcompaniesSIMRITandMerkelFreudenbergFluidtechnik,bothleadingsuppliersofshaftsealsandprofiledsealstothemaritimeindustry.LikeKlüberLubrication,thesetwocompaniesbelongtotheFreudenbergGroup.Together,thethreecompaniesarethereforeinauniquepositiontomatchelastomersandlubricatingoilsforthetaxingrequirementsofpro- pellermanufacturersandshipowners.

Tailor-made,reliableandgoodfortheenvironment Newsterntubeoilexpandstherangeofreadilybiodegradableoils for the maritime and offshore industry

Tribojournal 1/2012

All-roundlubricantforexcellentwearprotection KlüberfoodNH194-6000isahigh-performancefluidgrease forhigherprocessreliability

Ithasbeentraditionallyassumedthatlubricantsapprovedbythefood-processingindustryare notveryefficient.KlüberLubricationclearlyprovesthiswrongwithitsspecialitylubricantsforthefood-processing,cosmetics,pharmaceuticalandanimalfeedsindustries.ItslatestdevelopmentKlüberfoodNH194-6000forexampleprovesoncemorethatNSFH1-registeredlubricantsareveryefficient.

Thedevelopmentofthisnewspecialitylubricantarosefromaspecificrequirement:Acustomerneededafood-gradegreasewithparticularlygoodflowcharacteristicsincentrallubricationsystemsofferinggoodwearprotection.”Ourproductdeveloperscreatedthishighlyefficientfluidgreasefromcarefullyselectedrawmaterials“,saysSabinePetri,ProductManageratKlüberLubricationMünchenKG.KlüberfoodNH194-6000standsout,amongotherthings,foritspermanentlysoftconsistencyavoidingcloggedfeedlinesincentrallubricationsystemsandhenceprovidinghighprocessreliability.

Duetoitsspecialcomposition,KlüberfoodNH194-6000offersanunusualcombinationofperformancecharacteristics.Itpro- tectsagainstweareffectivelydespiteitsverysoftconsistency(NLGI000)andattainsloadstage>12intheFZGscuffingloadtestaccordingtoDINISO14635.Atthesametime,itoffersex- cellentwearandcorrosionprotection.”Thisisexceptional“,saysSabinePetri,”asthechoiceusedtobebetweeneithertheoneortheotherinthepast.Thereismore:ourproductdevelopmentteamroundedtheconceptoffwithgoodwaterresistanceandgoodlow-temperaturecharacteristics.KlüberfoodNH194-6000thereforeefficientlyprotectsmachinesandinstallationsagainstwear,eveniftheyaresubjecttofrequentwaterwashdownorlowtemperatures.”

KlüberfoodNH194-6000canbeusedinthefood-processing,cosmetics,pharmaceuticaloranimalfeedindustriesowingtoitsmanifoldperformancecharacteristicsandNSFH1-registration,e.g.forbearingordip-feedlubricationofgeardrives,wormgearsorchains.Thespecialgreasehasproventobeeffectiveinmilk- processingequipmentwhichissubjecttochilltemperatures,and

infood-packageprintingmachines,forwhichKlüberfoodNH194-6000wasdeveloped.However,thisspecialitylubricantisalsosuitableforapplicationsoutsidethefood-processingindustry:itensuressmoothrunningoflinearguidesanddoorhingesinkitchen furniture.

”KlüberfoodNH194-6000iscurrentlygoingthroughthecertifi- cationprocedureaccordingtoISO21469bytheNSFinstitute,ashaveallH1productsfromKlüberLubrication“,addsHelgaThomas,MarketManagerforthepharmaceuticalandchemicalindustries.”Inspectionprocessescurrentlytakeafewmonths,soweconsidertheNSFISO21469sealforKlüberfoodNH194-6000willbeavailablebythemiddleoftheyear.“


TheISO21469standardiswell-establishedandtheworldof H1lubricantshasbecomeinconceivablewithoutit.However,thequestionarisesofwhetherthe”ISO21469Certified“logocanbeinterpretedasasealofqualityineverycase.

Withaviewtoquality,itisimportanttohaveacompetentcertifi- cationcompanyinspectingtheH1productionprocessesof H1lubricantsupplierswithacomprehensiveandcomprehensibleISO21469certificationprogramme.

Thecertificationprogrammedeter-mines the individual steps to prove impeccable production conditions for H1lubricantsforuseinthefood-pro-cessingandpharmaceuticalindustries.TheindependentNSFinstituteforin- stancerequiresinitscertificationpro- grammeannualauditsofproductionplantsforH1products.Inadditiontoauditsofproductionprocesses,recipedata are inspected for currency and

compliancewithNSFrequirements.TheNSFalsotakessamplesfor chemical analysis.

Incontrasttothat,theISO21469standarditselfisrathergeneral.Therearenosuitableverifiablecriteriaforacertification.There-fore,certificationbasedonthisstandardonpaperaloneisnotsufficientwhenitcomestocomprehensibleandsustainableim- provements of production conditions of H1 lubricants.

Workingwithacompetent,experiencedcertificationcompanythatisacknowledgedworldwidegivestheextraedgeofsecurityandisrecognisableforcustomersatfirstsight.TheNSFawardsaneasilyrecognisable”NSFISO21469Certified“logoforuseonH1lubricantlabels.Itsmajoreffectistoprovideinspectedsecurityforcustomers:thelogostandsforverifiablequalityinspectionsofproduction conditions for H1 lubricants.

Klüber Lubrication deliberately chose the NSF institute for its long-standingexperienceandhighcompetenceinthefieldoffoodanddrinkingwatercertifications.

The European Hygienic Engineering & Design Group (EHEDG) is a consortium of equipment manufacturers, food industries, research institutes as well as public health authorities and was founded in 1989 with the aim to promote hygiene during the processing and packing of food products.

The principal goal of EHEDG is the promotion of safe food by improving hygienic engineering and design in all aspects of food manufacture.

EHEDG actively supports European legislation, which requires that handling, preparation processing and packaging of food is done hygienically using hygienic machinery and in hygienic premises (EC Directive 2006/42/EC for Machinery, EN 1672-2 and EN ISO 14159 Hygiene requirement).

As a member of this organisation, Klüber Lubrication actively supports and contributes to the goals of EHEDG.

KlüberLubricationisnowalso a member of EHEDG

It’sthelittlethingsthatmake all the difference ISO21469certification

Helga Thomas

State-certifiedfoodchemist

MarketManagerPharmaceuticaland

ChemicalIndustries


[email protected]

Tribojournal 1/2012

AutomotiveEngineeringExposition 23–25MayYokohama,Japan

Techtextil 24–26AprilAtlanta,USA

InnoTrans 18 – 21 SeptemberBerlin,Germany

Newspecialoilforcontinuouswood fibrepanelpresses

KlüberLubricationislaunchingthehigh-temperatureoilKlüberthermCH2-260designedforthelubricationofchainsandsteelbeltsincontinuousfibreboardpresses.Thisoilcom- pletesourrangeofspecialhigh-temperatureoils.DuetoitsnewanduniquerawmaterialsKlüberthermCH2-260offersout-standingperformancecharacteristics.Thisspecialoilshowsexcellentresistancetoevaporationevenattemperaturesas highas250°Candmore.Thedesignofthelubricantensuresthatitformsonlyminimalresiduesandensurescontinuallowfrictioninmachines.Thebenefitsavailableinclude:

– Machinesrequirelesscleaningandmaintenance– Oil and current consumption is reduced– Utilisationofproductioncapacitiesisoptimised

Operatorsbenefitfromsignificantenergyandcostsavings and reliable production processes.

Tradeshows,aplacetomeet

Latestdevelopments,services,andexpertslookingforwardtoansweringyourquestions:TaketheopportunitytomeetKlüberLubricationatoneofthemanytradeshowsweareparticipatinginthisyear.Herearesomeoftheplacesforustomeet:

Youwillfindanoverviewofallthetradeshowsweare participatinginunderwww.klueber.com/News/Events.

Expomin 9 – 13 AprilSantiagodeChile,Chile

IndustriAutomation 15–18MayBudapest,Hungary

BIEMH28May–2JuneBilbao,Spain

SMM 4–7SeptemberHamburg,Germany

HusumWindEnergy 18 – 22 SeptemberHusum,Germany

News


Tribojournal

PublisherandCopyrightKlüber Lubrication München KGGeisenhausenerstraße781379München–Deutschlandphone+49(0)89/7876-0Fax+49(0)89/7876-333E-mail:[email protected]/TJ121002

Reprints,totalorinpart,arepermittedonlypriorconsultationwith Klüber Lubrication München KG and if source is indicated and voucher copy isforwarded.

The contents of these articles are based onourgeneralexperienceandknow-ledgeatthetimeofprinting.Theyserve forgeneralinformationonlyandcanbe nosubstituteforexpertconsulting.Wetherefore do not accept liability for any damageresultingfromusinginformationgainedfromthesearticles.Anyinforma-tiongivenonKlüberproductsdoesnotconstituteanassuranceofproductprop-ertiesorofaproduct’ssuitabilityfora particular application. Our competent staffwillbepleasedtosupportyoubyconsultingyouinallmattersregardinglubrication.Ifrequiredandpossiblewewillbepleasedtoprovideasamplefortesting.

Localfirst-instancecourtMunich, GermanyCertificateofregistration46624

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