Burke Lubricants | Latest Industrial Articles

Best Practice Approach to Switching to Synthetic Lubricants

Mon, 20 May 2013 12:48:34 +0100

Sandra Legay

Global Industrial Products Technical Advisor, ExxonMobil Lubricants & Specialties

With more wind farm operators discovering the numerous benefits of using synthetic lubricants in wind turbines, such as superior component protection and extended oil drain intervals, companies need to make sure they make a successful switch from mineral to synthetic oils to ensure they maximise the benefits. In the following article, Sandra Legay, Global Industrial Products Technical Advisor, ExxonMobil Lubricants & Specialties, shares best practice advice on how to convert successfully to the latest fully-synthetic lubricants.

As the wind sector evolves, operators continue to invest in more advanced, larger turbines, which run at higher speeds to help drive down the cost of electricity generation. At the same time, wind farms are being commissioned in even more remote locations. These two trends have put increased focus on minimising unscheduled downtime.

The associated costs of unscheduled downtime for wind turbines that may stand up to 400 feet high in the air and are situated far out at sea can be significant. As well as the high costs associated with replacement parts and labour, the logistics of reaching offshore wind turbines can run into six-figure amounts, through chartering specialist ships to help carry out the maintenance.

In addition, in some geographies, winter maintenance procedures are not feasible at all due to the associated health and safety risks, which means that affected wind turbines could remain offline indefinitely, bringing significant additional costs.

Why the Switch to Synthetic Lubricants?

New synthetic lubricants are justifiably gaining a reputation for their superior performance over traditional mineral-based oils. Advantages such as enhanced gearbox protection and longer oil drain intervals help to maximise the profitability of a wind turbine generator by increasing turbine availability while minimising costs.

For example, ExxonMobil’s fully synthetic Mobilgear SHC XMP 320 is increasingly used in wind turbine gearboxes as it exceeds the performance of conventional, mineral-based oils by extending the interval between oil changes from 18 months to more than three years. Other performance advantages of fully synthetic oils such Mobilgear SHC XMP 320 include excellent low temperature performance, which is of growing importance given the increasingly harsh environments in which wind turbines operate.

Best Practice Approach to Switchovers

However, the full range of benefits offered by synthetic lubricants can only be realised by implementing a successful switchover from mineral-based oils. There are a plethora of issues to consider when looking to switch from mineral to fully synthetic lubricants such as chemistry compatibility. All lubricants are made up of different formulations and traces of a previous mineral oil may alter the chemistry and thus performance characteristics of the fully synthetic oil introduced into the system. That is why it is crucial that wind turbine operators engage with a lubrication specialist when switching to fully synthetic lubricants.

There are three stages to a best practice switchover:

evaluate the condition of the main gearbox and used oil;
evaluate the impact of used oil contamination on the performance of the new oil; and
select and follow an appropriate oil change procedure.

An evaluation of the condition of the main gearbox and used oil should include a visual inspection of the gearbox and system components to assess the level of deposits and contamination. This assessment will influence the recommended oil change procedure.

Oil compatibility is fundamental to the successful introduction of the new synthetic oil. To assess the compatibility of the old and new oil, samples of both oils should be mixed and analysed. ExxonMobil, for example, has undertaken rigorous tests to assess the compatibility of Mobilgear SHC XMP 320 against used oil chemistries including mineral-based, ester-based and semi-synthetic. Different ratios of Mobilgear SHC XMP 320 have been mixed with typical old oil chemistries and stored at elevated temperatures for over two weeks to assess the compatibility of the oils.

At the end of the test, the oils were evaluated for the following properties: viscosity, viscosity index, appearance, filterability, foaming tendency and stability and gear scuffing protection. Undertaking this level of analysis enables ExxonMobil engineers to recommend the best oil change procedure to customers switching to the latest synthetic lubricants.

Based on the evaluation of the condition of the main gearbox and compatibility of the oils, the following oil change procedures are recommended (see Table 1).

Oil Change Procedures

Oil Drain

The oil drain should be carried out immediately after the equipment is shutdown. This will typically allow more oil to leave the system of its own accord due to the oil being less viscous at operating temperature. In addition, it is vital to drain all external lines from the oil pump and drain oil coolers as well as change-out all removable filters and clean filter housings. Without a thorough drain procedure, over five per cent of residual oil could still remain within the gearbox, which can have a significant impact on the performance of the new oil.

Flush and Drain

After a thorough gearbox drain, operators should add the required quantity of flush oil according to the gearbox manual or supplier’s recommendation for minimum volume for circulation (typically 60 per cent of a full oil change). The oil should then be circulated at a high-level pumping speed for between two and four hours until its temperatures reaches 60 °C/140 °F. Meanwhile, the oil filters should be monitored and replaced if plugging occurs and all filter housing should be kept clean. The circulation cycle should continue until any filter plugging is eliminated.

Clean and Drain

If excessive levels of deposits or contamination are detected, use of cleaning agent and/or mechanical cleaning approach may be required. Great care is required when using cleaning agents because effective gearbox cleaning agents are generally not compatible with gear lubricants. For example, contamination of fresh gear oil with cleaning agents could impact air release performance, possibly leading to excessive foaming.

If cleaning agents are used, several precautionary measures should be taken to help reduce the chances of contamination: removal of oil if necessary to prevent overfill, add cleaning agent to the in-service gear oil,1 circulate as needed and drain thoroughly.

Fill

Finally, the system can be charged with the wind turbine gear oil, using original equipment manufacturer (OEM) recommended filter media oil to achieve the oil cleanliness level. At the same time, a sample should be taken to establish a benchmark for future oil analysis.

Oil and Equipment Condition Monitoring

Once the new lubricant has been introduced to the system, it should be supported by routine, scheduled maintenance of the gearbox and oil circulation system, including oil analysis. Routine oil analysis is one of the most widely used proactive maintenance strategies for wind turbines and employs a test slate that is designed to evaluate the condition of the in-service lubricant and equipment. First, it will help indicate if the switchover has been successful. Over time, gathering an analysis of a timeline of data provides insight to turbine performance trends and operational issues. If incorporated into a preventative care programme, maintenance professionals can extend the lives of both the gearbox and gear oil by detecting and acting on early warning signs such as oil contamination, cleanliness levels or increasing wear metals. To obtain the greatest benefit from oil analysis, it is preferable to conduct it every six months, working closely with an expert lubricant manufacturer.

ExxonMobil’s state-of-the-art Signum Oil Analysis programme is an effective tool for understanding an oil’s ongoing condition. When samples are taken from relevant equipment areas at scheduled intervals, it acts as a diagnostic service that highlights critical indicators in used oil based on leading equipment builder specifications, international standards and supported by detailed condition assessment.

The technically advanced oil-analysis programme includes proprietary capabilities that are available online for operators’ convenience as well as comprehensive reporting. From here, the expert service can identify problems, potential causes and recommend solutions before any unscheduled downtime occurs.

Taking Wind Turbine Productivity to New Heights

Mobilgear SHC XMP 320, with its balanced formulation, exceeds the performance of conventional, mineral-based oils by extending the interval between oil changes from 18 months to three years or more. The fully synthetic gear oil is used in over 30,000 wind turbine gearboxes worldwide, approved by the majority of the top twelve global wind turbine manufacturers and the initial fill choice of many key wind turbine manufacturers.

As well as the gearbox, wind farm operators should look to incorporate high performance oils and greases across the entire wind turbine including the main, pitch and yaw bearings. Mobil SHC Grease 460 WT is proving a compelling choice of synthetic grease for the lubrication of main, pitch and yaw bearings due to its excellent low and high temperature performance, structural stability even in the presence of water, excellent false brinelling and wear protection and rust and corrosion inhibition. It allows consolidation of main, pitch and yaw bearing greases into one product, minimising the risk of re-lubrication with the wrong product and without introducing unnecessary operational risks.

The Benefits of Making a Successful Switch

Taking care and undertaking the appropriate oil change procedure will minimise negative impacts of used wind turbine gear oil on the performance of the new oil. Successfully switching to fully synthetic lubricants will help wind turbine operators to improve profitability by extending oil drain periods, maximising oil filter change intervals and minimising unscheduled downtime.

Mobilgear SHC XMP 320 Delivers Annual Savings of US $ 176,000 for West Virginia-based Wind Farm

A West Virginia-based wind farm operating 44 NEG MICON 1.5 MW wind turbines installed Mobilgear SHC XMP 320 as the initial fill gear oil in its turbines’ Flender gearboxes.

The oil switchover was undertaken to address the significant lubrication challenges of operations in a four-seasons climate, with rain, snow and temperatures ranging from -10 to 100 °F annually.

The wind farm’s maintenance team has worked closely with the local ExxonMobil engineer to ensure optimum lubricant performance and help achieve maximum equipment reliability. ExxonMobil’s Signum Oil Analysis enabled operators to monitor both the lubricant and equipment condition and establish proper lubricant drain intervals based on oil analysis findings. As a result, Mobilgear SHC XMP 320 has performed consistently well for an average of six years.

The wind farm has been able to extend oil drain intervals to twice that of industry averages and maintain excellent gear condition. These performance benefits have delivered an annual total cost of ownership savings of US$ 176,000 from the reduction of oil-related maintenance expenses associated with reduced oil changes, increased component life and increased wind turbine availability.

Further Information

For further information about ExxonMobil’s range of products or other Mobil-branded lubricants and services, please contact Burke Lubricants:

E: sales@oil.ie

T: 01-4988999 / 0404-20333 / 051-870995

Web: http://www.oil.ie/

Click HERE to purchase SHC XMP 320

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Vanquish Varnish to Improve Gas-Turbine Reliability

Fri, 26 Apr 2013 10:29:02 +0100

By James Hannon, ExxonMobil Lubricants & Specialties Co, and Andrea Wardlow, ExxonMobil Research & Engineering Co

Gas turbine owner/operators know that varnish can have a significant adverse impact on engine performance. However, there had been little formal research conducted on the problem until recently.

According to an ExxonMobil Lubricants & Specialties survey of 192 US powerplants with a combined total of 626 gas turbines, approximately 40% of those generating facilities reported current or historical varnish issues within six years of oil service life.

Electric power industry sources estimate today’s cost of a utility trip or no-start to be as high as $100,000 per event. This is expected to increase dramatically as turbines are dispatched to support renewable energy generation. In refineries, the economic impact of a turbine trip or no-start can be measured in millions of dollars per event.

Varnish is mistakenly perceived as an unavoidable problem. However, the selection of oil specifically formulated to minimise the impact of varnish in conjunction with improved maintenance strategies, can extend the oil service life for GT’s. If the key to minimizing varnish problems is selecting the right turbine oil formulation, then critical to identifying the best formulation lies in testing under real-world operating conditions, followed by state-of-the-art field tests of the oil in service.

What is varnish?

Varnish is a catch all term for deposits (Fig 1), either in the form of sludge of varnish. Here, varnish refers to both sludge and varnish unless otherwise specified.

Sludge is a soft, pliable, organic residue that can be easily removed by wiping, while varnish is a hard, oil-insoluble organic residue difficult to remove by wiping. Varnish and sludge are formed in different ways after an oil’s additive components and/or base stock decay.

Turbines with common control- and bearing-oil reservoirs are far more susceptible to unit trips or no-starts related to varnish that turbines with segregated reservoirs. In common-reservoir systems, which are those that rely on a single reservoir and oil to meet bearing and hydraulic needs, the same turbine oil that is used to carry the bearing load at elevated temperatures must also flow through three-micron-tolerance servo valves.

The turbine oil, which is supplied to these servo valves via external tubing, often is not circulating during unit shut down and will be coo. As the oils cool, insoluble products of oxidation can come out of solution and subsequently foul the hydraulic elements. These cooler, low-flow, tight tolerance areas are the most prone to varnish problems.

By comparison, steam- and gas-turbine journal and thrust bearing clearances are around 200 microns. Mild varnish can build on journal and thrust bearings with little or no impact on bearing temperatures or shaft rotation. Unit trips or no-starts attributed to varnish rarely, if ever, are reported. For these reasons, varnish prevention and detection is focused on turbines with a common control- and turbine-oil reservoir.

Example: The GE frame 7FA gas turbine has a 6400-gal oil reservoir that supplies the turbine and generator bearings, seal oil, and system hydraulics at a full flow rate of 700 gpm. Flow to the hydraulics, supplied through secondary booster pumps, represents less than 1% of the total system flow. However, it only takes a small amount of varnish to cause hydraulic filter fouling or servo valve in turbine bearings or high pressure hydraulics and result in adiabatic compression, which can elevate local oil temperature and promote varnish formation. In addition, inferior air release impairs system hydraulics. Excessive surface level foaming can accelerate oxidation and cause operational issues – such as the inability to measure lubricant levels correctly, or cause reservoir overflow from vents.

An oil with poor filterability will foul filters faster than an oil with good filterability. Consequence of the latter is more frequent filter changes. Rust and corrosion also can contribute to oxidation and the formation of contaminant-based varnish. Finally, wear on high-pressure hydraulics and on the gears of the accessory gearbox, generator reduction gear or turning gear can be a source of varnish formation. Metal particles act as an oxidation catalyst.

The concept of a balances formulation is best understood as an optimisation process. The most important attribute of a low varnish/sludge oil is deposit control.

Advanced testing

Test rig research is superior to glassware testing. The Valve Varnish Rig Test (VVRT) for example simulates real world service and varnish formulation, and consequences like servo-valve movements to simulate startup and shutdown.

Voltage measurements are made during valve extension and retraction. Voltage signals are compared with response time, overshoot and undershoot. High varnish forming oils show stick slip friction and valve hunting at fewer operating hours than low varnish forming oil. Test-rig components also are physically examined for signs of varnish and turbine-oil degradation.

Rig testing goes beyond industry standards such as ASTM D2272, “Standard Test Method for Oxidation Stability of Steam Turbine Oils by Rotating Pressure Vessel,” or ATMS D943, “Standard Test Method for Oxidation Characteristics of Inhibited Mineral Oils.” Candidate turbine oils should, at a minimum, exceed OEM and new-oil acceptance standards, but additional field-simulated rig testing may offer the best indication of success.

In-service testing

Once the appropriate lubricant is selected, in-service performance must be monitored through a proactive oil analysis program. Generally, sampling and testing should be done at least quarterly, more frequently as the oil condition degrades. Trending results gives maintenance personnel valuable insights into the condition of the oil, the condition of the equipment and the remaining service life of both.

Today’s common oil analysis testing methods – including ASTM D2272, total acid number (TAN) increase (ASTM D664), and ISO Cleanliness Code 4406 – do not accurately predict varnish. A superior approach is based on a combination of ultra centrifuge (UC), membrane patch colorimetry (MPC) and remaining useful life evaluation routine (RULER) based on linear sweep voltammetry tests. All are gaining credibility and acceptance on the industry.

Action plans based on these tests should be application- and oil-specific. Application- specific plans recognise that gas turbines with combined hydraulic and bearing reservoirs are more varnish sensitive than a steam turbine with separate hydraulics. Oil-specific action plans refer to the unique chemistry of each turbine oil. Action plans for varnish-prediction test results may be unique to each oil chemistry. More field correlation work is required.

`the test results may require the use of different interpretative methods, depending on the presence of various additive components, your lube-oil supplier can provide details on these relatively new but successful industry approaches.

Briefly, UC is a varnish prediction test. A test tube of oil is spun at 17,500 rpm at ambient temperature for 30minutes. The tubes are visually examined for residue and given a rating of between one and eight, with one being the cleanest. UC scores continue to correlate well with field varnish observations.

MPC identifies the contamination level in used oil related to oil degradation and potential varnish development. This test entails pulling an oil sample with a vacuum pump through a membrane nitro-cellulose patch. The resulting stain on the patch is numerically rated, based on the increased absorbency of specific visible light waves.

The RULER test identifies levels of antioxidants, typically phenols and/or amines. In-service oil antioxidant levels are compared to those for new oil. As antioxidants age, the can volatize or convert to new species that have antioxidant properties, called intermediates. The intermediates can be measured by RULER but may require additional analysis and processing. In gas-turbine operation, phenols typically will deplete first because of temperature, followed by amines.

Action codes based on these varnish prediction techniques should be validated by actual visual component inspections because oil-specific chemistry and equipment applications will vary. During shutdown, the servo valve and last chance filters should be inspected for signs of varnish. With the servo valve removed, the spool valve and pencil filter can be pulled for inspection. Note that if the spool valve is removed it should be properly reconditions prior to replacement because the spool land surface may be damaged during inspection.

The original article can be found here

THE PERFECT BLEND

Thu, 25 Apr 2013 13:56:11 +0100

How well-balanced gearbox lubrication is key to wind turbine profitability

Turbine availability is one of the key parameters of a successful wind farm operation as it directly increases productivity, which leads to higher profitability. Consequently, engineers and operation and maintenance managers need to seek ways to maximise the availability of their wind turbines. Lubrication technology plays an important role in achieving greater turbine reliability.That’s why choosing the correct lubricants, alongside a preventative maintenance programme, are fundamental to running a successful wind farm operation.

Maximising performance

While conventional mineral oils can provide a certain level of lubrication and protection, a wind turbine’s availability may be improved by selecting the most appropriate synthetic lubricant for each application of a wind turbine, especially wind turbine gearboxes operating in challenging conditions. Synthetic polyalphaolefin (PAO)-based lubricants are formulated with special additives to further enhance the operational properties of advanced wind turbine gear oils. Numerous benefits, including enhanced gearbox protection and longer oil drain intervals, help to maximise the profitability of a wind turbine by improving performance and reducing maintenance costs. One PAO-based lubricant that is helping to provide optimal protection for wind turbine gearboxes is Mobilgear SHC™ XMP 320 that is used in over 40,000 wind turbine main gearboxes worldwide.

The importance of balanced formulation

In developing superior lubricants, a balanced formulation is crucial to the overall benefits it can offer to wind turbine operators. In order to develop advanced lubricants, they must demonstrate high performance in all of the properties desired by the lubricant. A well-balanced lubricant should have no weak link in the chain. Leading lubricant companies take several approaches in developing their latest synthetic lubricants. ExxonMobil, for example, uses a scientifically engineered ‘balanced formulation approach’ that leverages technology and application expertise. Lubricants developed based on a balanced formulation deliver high levels of performance across all critical areas for each application – such as oxidative stability, component wear and corrosion protection, filterability, shear stability and extreme temperature performance. This approach to lubrication development is supported by close contact between ExxonMobil and key original equipment manufacturers (OEMs) to ensure that lubricants provide exceptional performance with rapidly evolving application designs and operations. As part of the research and development programme for Mobilgear SHC XMP 320, ExxonMobil undertook a series of standard tests to assess the ‘overall’ performance of the product against other synthetic gear oils available in the marketplace. The results below highlight the performance of Mobilgear SHC XMP 320 compared to other lubricants in the markets.

Maintaining the perfect blend

However, with these latest balanced lubricants it’s important that companies do not spoil the blend. Some companies may recommend adding special additives to ‘enhance’ one of the desired properties of a lubricant. These are likely to affect the balanced formulation of a lubricant, impacting on its all-round performance. Modifying a lubricant which has been bespoke formulated especially for conditions encountered by wind turbines is not recommended. It is advised to contact the wind turbine builder, gearbox manufacturer and /or lubricant supplier to enquire about approval status before incorporating any of these types of additives.

Changing lubricants

Different lubricants are not always compatible. Compatibility needs to be checked in advance of any oil change, with the assistance of the lubricant supplier who will carry out compatibility tests. If the lubricants are compatible, the used system oil can simply be drained – although it is best practice to also carry out a flushing procedure. If the lubricants are incompatible or if the used oil analysis shows deposits, additional action such as cleaning and flushing may be required. It is not uncommon for the same type or brand of lubricant to be used throughout the life of a wind turbine. However, once a wind turbine is out-of-warranty, the wind farm operator or owner should review the performance of the lubricant. For instance, filters may be blinding and require changing too often. It would be prudent though to only consider high-performance lubricants which have been approved by the wind turbine builder or gearbox manufacturer, or lubricants which are proven in the field.

Benefits of best practice

With some governments looking at reducing subsidies, it’s important that wind turbine operators continue in their mission to improve productivity and profitability. By working closely with cutting-edge lubricant companies, such as ExxonMobil, wind turbine operators can benefit from their application expertise and a range of high performance lubricants which can impact positively on wind turbine availability.

Source: Wind & Wave Connect

UNLOCKING OPERATIONAL PRODUCTIVITY IN 40,000 WIND TURBINES WORLDWIDE

Mon, 15 Apr 2013 10:37:42 +0100

Windfarm operators constantly look for innovative ways of boosting productivity and reducing operational costs to increase competitiveness with traditional power sources. To achieve this, the industry is looking to drive energy efficiency as well as minimise the risk of unscheduled downtime and maintenance costs. As a result, more operators are relying on highly effective next-generation lubricants that can improve equipment reliability and extend oil drain intervals. Additionally, challenging weather conditions in cold, remote locations create additional complexities – so lubricants that are formulated to perform in these environments are also proving to be an essential part of modern turbine operations. This growing trend has been noted by leading lubricant manufacturer, ExxonMobil, whose advanced lubricants are being used in 40,000 wind turbines worldwide.

PROVEN PERFORMANCE

A US-based energy company realised significant performance and cost benefits by switching to ExxonMobil’s gearbox oil, Mobilgear SHC XMP 320. The mountaineer wind site operates forty-four turbines with a 66-megawatt (MW) output. The Flender Model PEAS 43090.5 gearboxes (60 gallon capacity) within the 44 NEG Micon1.5MW turbines were filled with Mobilgear SHC XMP 320 gear oil in 2002.

EXTREME CONDITIONS

These gear boxes operate in an extreme four-season climate with temperatures ranging from -25°C in winter up to +40°C in summer. The operations, therefore, require a lubricant that could perform in tough applications across a wide temperature range, whilst also providing protection against micropitting and gearbox deposits.

HARD COST SAVINGS

As a result, the operator has reported hard cost savings of US $176,000 over seven years of service. This was largely achieved by extending oil drain intervals to twice the industry average for wind turbine gear boxes, saving $4,000 per turbine in reduced oil change maintenance costs. As part of its Signum oil condition monitoring programme, findings from the used oil analysis also showed excellent gear box cleanliness and better overall gear condition than expected, thereby helping to manage costs.

40,000 GEARBOXES WORLDWIDE

Due to results like this, Mobilgear SHC XMP 320 is now used to protect 40,000 gearboxes of wind turbines worldwide and is the initial-fill gear oil of choice for many of the world’s top wind turbine builders. In addition to its ability to maximise equipment performance and durability, the ability to extend the interval between oil changes from 18 months to three years or more can potentially make a big impact on reducing costs and difficult maintenance logistics. For example, this helps operators avoid the expense associated with replacement parts, labour and chartering specialist vessels to carry out the maintenance of offshore wind turbines.

UK’S GROWING WIND POWER INDUSTRY

Closer to home, the latest additions to the company’s global customer base are three North Sea-based wind farms – Alpha Ventus, Borkum West and Thornton Bank, which demonstrates how these specialist lubricants are being relied upon by the UK’s growing wind power industry.

GETTING WARMED UP

To complement the improved functionality of gearbox operations, Mobil SHC 500 hydraulic oils have been proven to offer energy efficiency benefits in hydraulic equipment. Compared to standard mineral hydraulic oils, Mobil SHC 500 can help to reduce hydraulic system energy consumption by up to 6.2 percent. This series was engineered to help protect hydraulic equipment operating in extremely cold conditions in offshore wind farms such as the North Sea or in remote onshore locations. At low temperatures Mobil SHC 500 is four times thinner than similar viscosity grade conventional mineral hydraulic oils, allowing it to circulate around the hydraulic system faster at start up, ensuring the lubricant is in place to protect machine components. Although wind farms are unlikely to be exposed to such extreme arctic temperatures, the extent of the lubricant’s cold temperature performance demonstrates that operating within UK weather conditions and wind chill factors can be easily met.

COLLECTIVE RESULTS

When combined with application expertise such as ExxonMobil’s Signum Oil Analysis Programme, which monitors the performance and health of the oil and components on an ongoing basis, the considered application of advanced lubricants to different components of wind turbines can achieve significant results.

Please visit www.oil.ie/products/industrial

Source: Wind Energy Network, Feb / March 2013

Proven performance for power plants Making power plant turbines fly

Tue, 02 Apr 2013 13:20:45 +0100

Increase equipment reliability

Lower operating costs

Extend machine life

With the wide range of advanced lubricants and expertise from Mobil, more productivity = more output = more profit.

Increase your plant’s productivity through enhanced reliability and uptime, with the help of Mobil industrial lubricants. Formulated to help you get the most out of your equipment, these high-performance lubricants are backed by over 100 years of industry experience and expertise in lubrication. And engineered not simply to make your operation run — but help it fly.

Supported by unsurpassed industry expertise.

Our highly experienced engineers work closely with customers and leading equipment builders for unique insights into their new technology and lubrication requirements. These insights then help guide our product development process. This gives our research scientists and lubricant formulators the ability to build leading-edge lubricants for the most demanding peak power, gas compression, or captive power applications from the ground up — making them highly effective in the equipment they lubricate. Our knowledgeable Field Engineering Services (FES) team can offer you professional advice on sound lubrication practices, proper lubricant selection, equipment troubleshooting, and other lubrication services that will help you run your plantlonger and in top condition.

Backed by extensive builder approvals and proven field performance.

Thoroughly tested before they are commercialized, Mobil industrial lubricants and greases are well supported by equipment builder approvals. For example, the new Mobil DTE 700 Series surpasses 19 industry and equipment builder specifications for gas and steam turbine oils. And the Mobil DTE 800 Series, our top-of-the-line turbine oils, has delivered significant savings for customers through extended oil life.

Get peak performance from a global leader in synthetic technology and advanced turbine oils.

Mobil Industrial Lubricants offers a wide range of specially formulated high-performance synthetic lubricants for your critical equipment needs, as well as premium turbinelubricants developed to protect your investment.

These include*:

Mobil SHC 800 Series synthetic oils for land-based gas turbines

Mobil DTE 800 Series high-performance oils for gas, steam, and combined-cycleturbines

Mobil DTE 700 Series mineral oils for steam turbines and non-geared gas turbines

Mobil Raru SHC 1020 Series synthetic oils for booster pumps and air compressors

Mobilith SHC Series synthetic greases for demanding and high-temperature applications

Mobil SHC 600 Series synthetic circulating oils for pumps and other high-temperature applications

Mobil Pyrotec HFD 46 synthetic hydraulic fire-resistant governor oil for turbines

Mobil Jet Oil II synthetic turbine oil for stationary aero-derivative gas turbines

Engineered to perform even in demanding conditions — including high temperature, heavy load, and water contamination — these lubricants and greases will help keep your power plants operating in top form.

*Since equipment and operating conditions vary, please refer to the equipment builder manual for final lubrication recommendations.

How we help keep your gas and steam turbine power plant running better – longer.

Proven performance is the foundation of Mobil-branded products – each one formulated to offer outstanding equipment protection and long oil life. These are just a few of our high-performance series for your operation.

Turbine

- Turbine Reservoir: Mobil SHC 800, Mobil DTE 800, Mobil DTE 700

- Generator Bearings: Mobil SHC 800, Mobil DTE 800, Mobil DTE 700

- EHC System: Mobil DTE 800, Mobil DTE700, Mobil Pyrotec HFD 46 (fire-resistant applications.)

Gas Compressors

- Compressors: Mobil SHC 600

Steam Loop / Feed Water Pumps

- Pumps: Mobil DTE 700, Mobil SHC 600

- ElectricMotors: Mobil SHC 600, Mobil Polyrex EM, Mobil DTE 700, Mobile DTE Oil Named, Mobilith SHC

Cooling Towers

- GearDrives: Mobil SHC 600

- Electric Motors: Mobil Polyrex EM

Backup Generators / Fire Water pumps

- Diesel Engines: Mobil Delvac 1300 Super

- Electric Motors: Mobil Polyrex EM

Air Compressors

- Compressors: Mobil Rarus SHC 1020 (screw), Mobil Rarus 800 (reciprocating)

Miscellaneous

- Forced Draft (FD) Fans: Mobil SHC 600

- Induced Draft (ID) Fans: Mobil SHC 600

A state-of-the-art used-oil analysis program

To help you monitor lubricant and equipment condition and increase equipment reliability, Mobil Industrial Lubricants offers an oil analysis program specifically tailored to monitor critical indicators in used oil based on leading equipment builder specifications and international standards. This program is backed by our FES team who can train your personnel to run an effective used-oil analysis program and interpret analysis results.

Our innovative Turbine Commissioning Program makes your job easier

This comprehensive service helps you prepare your turbine lubrication system and turbine oil for start-up, ensuring timely and reliable operation. To help you meet equipment builder requirements and to begin a comprehensive lubrication program at your new installation, we can offer product recommendations, turbine lubrication system and oil preparation, and additional post-commissioning integrated lubrication services.

So team up with Mobil Industrial Lubricants for continually advancing, standard-setting products and services. And take advantage of our leading-edge lubricant technology and unmatched global expertise to help you unleash the productivity of your operation.

For more information about ExxonMobil’s range of products and services for the primary metals sectors, please visit www.oil.ie/products/industrial

A New High Performance Gas Turbine Oil

Fri, 22 Mar 2013 08:24:55 +0000

ExxonMobil Lubricants & Specialties has introduced the Mobil DTE™ 932 GT, scientifically engineered gas turbine oil that can help oil and gas operators to increase productivity by reducing unscheduled downtime and supporting their safety and environmental care objectives. Engineered to enhance the performance of frame size combustion gas turbines with a common hydraulic and bearing oil reservoir, Mobil DTE 932 GT can help provide trouble-free service in gas turbines, which is crucial given the oil and gas industry’s reliance on turbine reliability. Gas turbines play a fundamental role in liquefied natural gas (LNG) production with many LNG plants using gas turbines to drive compressors that cool and liquefy gas for transportation. Keeping gas turbines running effectively is key to maximising plant productivity and reducing unscheduled downtime.

One challenge to maintaining effective gas turbine performance is controlling the formation of varnish, a catchall terms for deposits found in gas turbine operations.

“Varnish can have a significant detrimental impact on gas turbine operation, but Mobil DTE 932 GT offers the potential for greatly reduced varnish formation,” says Yan Côté, global business development advisor, ExxonMobil Lubricants & Specialties. “Other performance benefits of Mobil DTE 932 GT include exceptional high temperature performance, outstanding deposit control and excellent foam control and air release.”

Across a wide range of testing procedures, Mobil DTE 932 GT was shown to deliver critical performance benefits that can help enhance turbine performance and durability. As a result, Mobil DTE 923 GT meets or exceeds the standards for General Electric frame 3, 5, 6, 7 and 9 turbines.

In addition to Mobil DTE 923 GT, ExxonMobil offers many high-performance lubricants for the oil and gas industry, including:

-Mobil SHC™ 600 Series – A family of high-performance synthetic circulating and gear oils that can deliver a service life up to six times longer than competitive mineral oil based gear and bearing lubricants. The oils also demonstrate outstanding low temperature fluidity to enable start up and operation at low temperatures, and excellent resistance to rust and corrosion. Mobil SHC 600 Series oils also exhibit energy savings of up to 3.6 percent compared with conventional oils.

-Mobil SHC™ Pegasus Series – Natural gas engine oils which help to reduce fuel consumption by up to 1.5 percent and have the potential to increase oil drain intervals up to more than 16,000 hours – four to eight times that of standard gas engine oil.

-Mobil SHC™ Polyrex Series – Advanced synthetic greases that can help protect equipment from wet environments by delivering a combination of low and high temperature performance, excellent water resistance and balanced wear protection.

Alongside its high quality lubricants, ExxonMobil offers its proprietary online oil analysis service, Signum Oil AnalysisSM. Signum enables operators to proactively monitor the condition of lubricants and address conditions, which have the potential to lead to unscheduled downtime and increased costs.

For more information about Mobil SHC-branded synthetic lubricants or any other Mobil-branded products and services, please visit http://www.oil.ie/products/industrial/

Food Grade Lubricants with ISO 22000

Thu, 14 Mar 2013 06:49:26 +0000

Certification is one of the most stringent for manufacturers in the food-processing sector

ExxonMobil Lubricants & Petroleum Specialties Company, a division of ExxonMobil Corporation, recently announced that it is the first lubricant provider to garner ISO 22000:2005 certification for facilities that manufacture NSF H1-registered lubricants.

This accreditation is for facilities that produce ExxonMobil’s popular Mobil SHC Cibus Series of high-performance NSF H1 registered food machinery lubricants. The ISO 22000 certification is one of the most stringent and comprehensive food and beverage safety standards. Established by the International Organisation of Standardisation, ISO 22000 is a food safety management system with a set of specified requirements that ensure a company’s ability to control food safety at every step of the manufacturing process.

“ExxonMobil is committed to the highest standards of manufacturing hygiene and safety, and we are proud to again lead our peers in the lubricant industry by becoming the first company to produce in facilities which have achieved ISO 22000 certification,” said Yan Côté, global business development advisor, ExxonMobil Lubricants & Petroleum Specialties Company. “In addition to protecting product integrity during manufacturing, Mobil SHC Cibus lubricants can help companies improve the energy-efficiency and productivity of their operations.”

Ideal for a wide range of applications, such as food, beverages and pharmaceutical processing, and animal feed manufacturing, Mobil SHC Cibus lubricants are suitable under Halal and kosher dietary law and are designed to be gluten-, nut-, and wheat- free. They are formulated to deliver excellent wear and rust protection, long-term oxidation stability and can help food and beverage processors realize valuable

sustainability-related benefits.

For instance, in extensive laboratory and field-testing, Mobil SHC Cibus demonstrated the ability to deliver energy efficiency savings of up to three percent* in gear oil application when compared to conventional, mineral-based oils. In proprietary rig testing, Mobil SHC Cibus Series synthetic lubricants also demonstrated their ability to last up to two times longer than comparable mineral oils, allowing for extended drain intervals, depending on the severity of the application.

Source : Food & Marketing Technology Magazine - 01/12/2012

The ISO 22000 international standard specifies the requirements for a food safety management system that involves the following elements:

- interactive communication

- system management

- prerequisite programs

- HACCP principles

Critical reviews of the above elements have been conducted by many scientists. Communication along the food chain is essential to ensure that all relevant food safety hazards are identified and adequately controlled at each step within the food chain. This implies communication between organizations both upstream and downstream in the food chain. Communication with customers and supplies about identified hazards and control measures will assist in clarifying customer and supplier requirements.

Recognition of the organization's role and position within the food chain is essential to ensure effective interactive communication throughout the chain in order to deliver safe food products to the final consumer.

The most effective food safety systems are established, operated and updated within the framework of a structured management system and incorporated into the overall management activities of the organization. This provides maximum benefit for the organization and interested parties. ISO 22000 has been aligned with ISO 9001 in order to enhance the compatibility of the two standards.

ISO 22000 can be applied independently of other management system standards or integrated with existing management system requirements.

ISO 22000 integrates the principles of the Hazard Analysis and Critical Control Point (HACCP) system and application steps developed by the Codex Alimentarius Commission. By means of auditable requirements, it combines the HACCP plan with prerequisite programmes. Hazard analysis is the key to an effective food safety management system, since conducting a hazard analysis assists in organizing the knowledge required to establish an effective combination of control measures. ISO 22000 requires that all hazards that may be reasonably expected to occur in the food chain, including hazards that may be associated with the type of process and facilities used, are identified and assessed. Thus it provides the means to determine and document why certain identified hazards need to be controlled by a particular organization and why others need not.

During hazard analysis, the organization determines the strategy to be used to ensure hazard control by combining the prerequisite programmes and the HACCP plan.

ISO is developing additional standards that are related to ISO 22000. These standards will be known as the ISO 22000 family of standards. At the present time, the following standards will make up the ISO 22000 family of standards:

ISO 22000 - Food safety management systems - Requirements for any organization in the food chain.

ISO 22001 - Guidelines on the application of ISO 9001:2000 for the food and drink industry (replaces: ISO 15161:2001).

ISO/TS 22002- Prerequisite programmes on food safety—Part 1: Food manufacturing

ISO TS 22003 - Food safety management systems for bodies providing audit and certification of food safety management systems.

ISO TS 22004 - Food safety management systems - Guidance on the application of ISO 22000:2005.

ISO 22005 - Traceability in the feed and food chain - General principles and basic requirements for system design and implementation.

ISO 22006 - Quality management systems - Guidance on the application of ISO 9002:2000 for crop production.

ISO 22000 is also used in the Food Safety Systems Certification (FSSC) Scheme FS22000. FS22000 is a Global Food Safety Initiative (GFSI) approved scheme

Source : Wikipedia

Oil Analysis Monitoring - The lifeblood of Wind Turbines

Tue, 12 Mar 2013 06:37:32 +0000

As maximising operational productivity and cost-efficiency become ever more critical to the sustained growth and competitiveness of wind-generated energy, turbine operators are increasingly looking at new ways to realize efficiencies.

This has driven more operators to recognize the benefits of switching to user higher performance oils and greases within the turbines. Combining this with a regular and robust oil analysis programme can increase opportunities to extend oil drain intervals, protect against component wear and prevent downtime even further.

Oil analysis

Oil analysis is one of the most valuable maintenance programmes that turbine operators can implement. As health professionals often utilize blood samples to help determine our body condition, gear oil or hydraulic oil analysis supported by expert interpretation and advice, can also be utilized to help determine the condition of the components the oil is in contact with.

Concurrently, the analysis and interpretation can maximize the application of high quality lubricants and identify early warning signs of contamination to help take greater control over managing downtime and extending equipment life.

In order for wind farm operators and equipment engineers to improve productivity and potentially increase profitability through oil and equipment monitoring there are a number of elements to be considered.

Start off with the basics

There is a certain protocol that should be followed to help ensure the accuracy of oil analysis results. First, maintenance professionals should always use a clean, dry container to draw oil samples. Any contamination that is in the container before the oil sample is collected could result in an inaccurate result. Most oil analysis companies will provide suitable and new bottles for the samples to be collected.

Ideally, samples should be drawn when equipment is at its normal operating temperature, provided it is safe and the oil system is being circulated. If, however, this is not feasible, the oil sample needs to be take as soon as possible after the turbine is shut down (within 30 minutes.)

Maintenance records

To identify the most appropriate sample point, it is imperative to consult with your oil analysis provider and machine manufacturer for application-specific advice. Once the location has been identified, it should be noted in the maintenance records so samples can always be taken from the same place. This will ensure that results from the analysis of sequential oil samples can be compared and trended to provide accurate insight into equipment and lubrication condition.

Dedicated sample points

Oil samples should always be taken in the same manner and from the same sampling point. Dedicated sample points situated prior to the filter are best though other sample points may also be acceptable including using a thief pump to take a sample from a sump or reservoir using a new tubing of similarly measured length. Consistency is paramount.

Oil samples should always be take n before equipment is drained. If the oil has been drained, samples taken and then deemed acceptable for continued use, there is no way the hydraulic oil or lubricant should be reused for applications such as hydraulics or gearboxes. Also, do not take an oil sample immediately after oil changes or after a large amount of make-up oil has recently been added.

Sampling frequencies

Sampling frequencies are usually set by the Original Equipment Manufacturer (OEM) which are typically six monthly for wind turbine gearbox oils and annually for hydraulic oils. The more frequent oil samples are taken then the more likelihood there is of detecting any equipment or fluid issues but the practicalities of sampling clearly need to be considered.

Consideration should be given to taking hydraulic oil samples at the same time as taking gearbox oil samples since the additional analysis costs are relatively small compared to the additional cost of taking the hydraulic oil sample and the relatively high cost should an issue be missed for a further six months before the system is analyzed again. More frequent sampling is also highly recommended if there are abnormal levels of wear or contaminant elements, if vibration readings are increased or if there is an unexpected increase in operating temperatures.

Seek out partners with application expertise and OEM relationships

Selecting an oil analysis partner that has application-specific expertise and strong relationships with original equipment manufacturers (OEM) is extremely valuable. OEMs establish proprietary control limits based on the equipment model, lubricants used, applications and operating environments.

When compared against oil analysis results, these predetermined safeguards can help maintenance professionals make the best-informed decision about the condition of the lubricant equipment.

Online efficiency

Just because you participate in an oil analysis programme does not mean that you are going to be inundated with paper reports. The digital age is helping maintenance professionals clean up the clutter in their offices while also successfully managing their oil analysis programme.

Most oil analysis companies also have some level of online functionality so it’s important to evaluate oil analysis partners based on how these offerings can help expedite the administrative components of an oil analysis programme. Tasks such as managing/updating equipment registration, printing completed labels for sampling bottles, ordering additional sampling kits and confirming delivery of samples can be greatly simplified through online tools from leading oil analysis providers.

Online programmes can also arm maintenance professionals with the proper tools to make more informed decisions about oil and equipment stability. For example, ExxonMobil, a global leader in the field of oil analysis, offers its proprietary Signum oil analysis programme. Maintenance professionals can access the Signum website, and/or be sent expert oil analysis assessments that identifies potential issues, list possible causes and recommends corrective actions.

These files are formatted so they can be easily shared with colleagues. ExxonMobil’s Signum website is also equipped with a knowledge library so maintenance professionals have the resources to gain more information about specific equipment issues.

Long-term success

By following the recommendations detailed above, wind turbine operators can benefit from optimised equipment performance, streamlined production and minimised maintenance. Selecting an oil analysis provider that has application specific expertise, intimate relationships with OEMs and a comprehensive online oil analysis offering will help maintenance professionals achieve their company’s production goals as well as their own.

Robert Pears

ExxonMobil Lubricants & Specialties

www.oil.ie/products/industrial/

Source: Wind Energy Network

Steel Plant increases productivity by switching to high performance lubricants

Mon, 11 Mar 2013 11:34:01 +0000

- Mobil Vacuoline has enabled Russian steel manufacturer to reduce downtime and save up to $222,000 USD over two years.

- Bearing failures at a steel mill eliminated following the introduction of Mobilgrease XHP 461.

- Mobil-branded industrial greases and oils have the potential to help steel operators achieve a competitive edge.

Mobil Vacuoline 100 and Mobilgrease XHP 461, part of ExxonMobil’s comprehensive range of products for primary metal companies have helped two Russian steel mills to increase productivity, reduce unscheduled downtime and, by default, promote significant financial benefits.

One Russian steel producer reported issue with its SKET 350 rolling mill, with bearing failures and unscheduled downtime occurring as a result of the lubricant in use. The poor water separation capability of the lubricant was causing the bearings in the rolling mill to rust and fail.

Following a recommendation from ExxonMobil engineers, the metallurgical plant switched to Mobil Vacuoline 133 to protect the bearing in its SKET rolling mill 33. This high performance circulating system oil contains high quality base stock and additives the resist emulsion and sludge, contributing to cleaner systems and filters, as well as helping solid contaminants separate for easy cleaning by centrifuge, filtration or settling.

Following the introduction of Mobil Vacuoline, the bearing life was significantly improved with the resulting savings in maintenance and replacements of bearings, helping to generate cost saving of approximately $222,000 USD.

Alongside its range of high performance industrial oils, Mobil-branded greases have also helped to increase productivity and reduce unscheduled downtime. For example, a hot sheet steel rolling mill in Russia was experiencing problems with bearing failure in the roller bearings cages of its work rolls 2000.

Following an investigation by ExxonMobil engineers, the identified the bearing failures were occurring due to significant water washout of the grease in use, which was leading to corrosion attacking the bearings due to the lubricant being unable to sufficiently protect the bearings.

To address the problem, ExxonMobil recommended switching to Mobilgrease XHP 461 due to the product’s superior resistance to water washout, excellent rust and corrosion protection and good thermal stability. Following the switch over, lubricant-related bearing failures were eliminated and other benefits such as lower grease consumption were reported, helping cost control.

“With major international sporting events on the horizon, the demand for primary metals in Russia has soared and local manufacturing facilities are constantly looking at ways to boost productivity,” commented Kirill Chervyakov, Industrial Marketing Advisor – EAME, ExxonMobil Lubricants and Petroleum Specialities Company, a division of ExxonMobil Corporation. “By switching to high performance Mobil Industrial Lubricants, operators can look to boost plant output and significantly reduce maintenance costs.”

For more information about ExxonMobil’s range of products and services for the primary metals sectors, please visit w ww.oil.ie/products/industrial

Source: Process Industry News - 07/01/2013

Mobil SHC 500 Series - Supreme performance synthetic hydraulic oils

Mon, 11 Mar 2013 10:21:59 +0000

Mobil SHC 500 hydraulic oils can help reduce equipment energy consumption by up to 6.2%*

- Exhibits excellent low and high temperature performance.

- Delivers outstanding oxidation stability and innovative ‘keep-clean’ properties.

- Mobil SHC 500 can help to extend both oil and equipment life in a wide range of applications.

LONDON, 13 December 2012 – Mobil SHC 500 series of hydraulic oils have been proven to offer greater energy efficiency benefits in hydraulic equipment than standard mineral hydraulic oils. Compared to standard mineral hydraulic oils, Mobil SHC 500 can help to reduce hydraulic system energy consumption by up to 6.2 percent*, and as a result will display the company’s proprietary “Energy Efficiency” logo on packaging. Improved hydraulic efficiency benefits can translate to increased machine productivity and/or reduced fuel consumption.

The Mobil SHC 500 series was developed in conjunction major OEMs to meet stringent requirements of demanding hydraulic systems and to help manufacturers improve safety, productivity and sustainability performance across a variety of applications. The range of supreme-performance hydraulic oils formulated from synthesized, wax-free, hydrocarbon base fluids combined with a carefully engineered super-stabilized additive system. These high-quality, wide-temperature, shear-stable hydraulic oils offer manufacturers the benefit of controlled low-temperature pumpability properties with maximum anti-wear protection for high-pressure vane, piston and gear pumps.

The increased hydraulic efficiency, system cleanliness and durability offered by the Mobil SHC 500 Series can help manufacturers extend oil drain intervals and optimum equipment protection decreasing both machine maintenance and product disposal costs. Additionally, the increased hydraulic efficiency potential of Mobil SHC 500 can reduce overall CO2 emissions, helping to lower the environmental impact of operations.

The Mobil SHC 500 Series is designed to perform in extreme environments, providing excellent low and high temperature performance along with an extra margin of equipment protection beyond capabilities of comparable mineral oil-based products.

Andrea Jacobsen, Industrial Marketing, Europe, Africa and Middle East, Exxon Mobil Lubricants and Petroleum Specialties Company says, “Raising operating costs and ever increasing regulatory requirements are two of the main challenges facing organizations across a wide range of manufacturing and processing industries. By significantly extending oil drain intervals and helping reduce energy consumption, Mobil SHC 500 can help companies optimize productivity and improve profitability. The annual fuel savings alone can sometimes be more that the yearly cost of the hydraulic oil.”

The benefits offered by the Mobil SHC series are further proof of how Mobil Industrial Lubricants’ application expertise and portfolio of synthetic products can help manufacturers worldwide minimize unscheduled downtime and increase productivity.

For more information about Mobil SHC branded synthetic lubricants, or any other Mobil-branded products and services, visit http://www.oil.ie/products/industrial/

Source: Process and Control today - 17/12/12

Heat Transfer Lubricants for Potato Processors: A Cut Above the Rest

Thu, 07 Feb 2013 00:00:00 +0000

In the highly competitive food industry safety is of paramount importance, which is why potato products manufacturers across EAME are increasingly switching their operations to NSF H1-registered lubricants to minimise the risk of contamination, protect their brand reputation and avoid costly product recalls. However, in the quest for heightened food safety, industry members do not wish to sacrifice product quality and operational efficiency. In the following article Rainer Lange, Mobil SHC Brand Advisor for EAME, ExxonMobil Lubricants & Petroleum Specialties Company, looks into how the latest food grade lubricants can help potato plant operators increase their productivity, gain competitive edge and reduce unscheduled downtime.

Industry challenges

The versatile nature of potato lends itself to a variety of food applications including crisps, snacks, frozen products, powder and other processed potato foods – each of which have their own individual processing challenges. Some processes involve equipment operating at high temperatures, which puts processing and sorting equipment under additional stress to perform and can lead to increased unscheduled downtime and operating costs. Therefore, lubricants need to be able to perform in these tough conditions. In the highly competitive food industry, manufacturers rely on their ability to ensure the product completes its journey from farm to fork without losing its visual appeal, texture and flavour. Advanced lubrication used in food processing, can maximise productivity whilst eliminating the risk of food contamination from lubricating oils and greases.

In a typical potato processing plant, a variety of lubricants including greases, heat transfer fluids as well as hydraulic, compressor, gear and chain oils are used to help a production line operate effectively. In the food manufacturing sector, where production equipment is typically run for extended periods of time and under extreme conditions, any unscheduled or scheduled downtime can have a significant financial impact on a business. For this reason, lubricants used in baked goods processing must be able to keep equipment runningsmoothly for longer and to prevent wear, degradation and unnecessary repairs - even under these challenging conditions.

Chipping away at unscheduled downtime

ExxonMobil’s SHC Cibus Series are designed to help increase productivity and reduce unscheduled downtime. For example, Mobil SHC Cibus 32 HT is a synthetic NSF H1 and HT-1-registered heat transfer oil that has become the product of choice for many potato chip manufacturers across Germany. This high performance oil is part of the Mobil SHC Cibus series, designed to help enhance equipment efficiency and maximise productivity across food and beverage processing companies worldwide.

Mobil SHC Cibus 32 HT is recommended for closed heating and cooling systems in a wide range of food processing applications where a NSF H1 and HT-1 registered food machinery lubricant is required. It has been designed to have good heat transfer properties such as specific heat and high thermal conductivity that help provide rapid heat dissipation that can lead to increased efficiency of the whole system. The lubricant also demonstrates good fluidity at low temperatures leading to easier start-up at cold ambient temperatures.

The heat transfer oil has a proven track-record in the field. For example, one German potato chip manufacturer turned to ExxonMobil and Mobil SHC Cibus 32 HT when its heat transfer system was due an oil change. Following a Hazard Analysis Critical Control Points (HACCP) analysis conducted alongside ExxonMobil, a NSF H1 lubricant was recommended since contamination of foodstuffs by the heat transfer oil could not be excluded.

Based on the customer’s specific operating conditions and system design, which required a heat transfer oil to operate effectively at temperatures close to 300°C as well as complying with NSF H1 lubricant standards, ExxonMobil recommended the use of Mobil SHC Cibus 32 HT*. ExxonMobil supported the oil change by flushing the 40,000-litre system within just 72 hours using a special cleaning agent. The system has been running trouble free since switching to Mobil SHC Cibus 32 HT. Other potato chip manufacturers in Germany have also experienced the benefits of switching to this high performance NSF HT-1 registered heat transfer oil.

Food-grade lubricants

While productivity is important, safety is paramount and manufacturers choose to protect their products and operations by using NSF H1 registered lubricants that comply with Title 21 CFR 178.3570 of the Food and Drug Administration (FDA). ExxonMobil’s flagship food- grade range, Mobil SHC Cibus Series, are formulated to nut, wheat and gluten free standards and suitable under Halal and Kosher dietary law. This means the lubricants can be used globally, catering for a variety of cultural and health-related food processing requirements.

Enhancing energy efficiency

In addition to lubricants delivering safety and performance benefits, they can also help improve energy efficiency in food machining. Mobil SHC Cibus range is ideal for the full spectrum of hydraulic, gear, bearing, circulation system and heat transfer applications in potato processing. The premium-performance synthetic lubricants offer enhanced safety and productivity benefits alongside energy efficiency potential when compared to conventional mineral-based oils. Moreover, the flagship range has the potential to help food and beverage companies achieve energy efficiency savings of up to 3.6 percent for gear oil applications. The Mobil SHC Cibus Series for gear oil applications, is the latest ExxonMobil product to earn the official designation of an “Energy Efficient” industrial lubricant and will feature the company’s proprietary logo on the packaging*.

Grease lightening

As well as high performance oils, ExxonMobil also offers leading technology greases that can help protect food processing equipment and contribute to problem-free operation. Unlike mineral alternatives, Mobil-branded greases offer enhanced equipment reliability and performance even in severe operating conditions, including very high and low temperatures, presence of water contamination, heavy or shock loads and variable speeds.

NSF H1 food-grade registered Mobil SHC Polyrex Series of greases for example, were specifically designed using advanced Polyurea technology to provide long lasting protection for equipment that operates in extreme conditions, such as potato ovens. Due to the excellent high-temperature performance, Mobil SHC Polyrex range is suitable for use up to 160°C (320°F). Frequent re-greasing intervals support lubrication with peaks at 170°C (338°F). Plus, the product series offer notable stability and resistance to water washout that helps maintain effective lubrication that can lead to increased bearing life and reduced corrosion-related failures.

Fully comprehensive portfolio

To develop these high performance lubricants, ExxonMobil works closely with equipment manufacturers to ensure the company’s R&D efforts are aligned with the potato processing industry’s needs, offering commercially viable solutions to the specific operating challenges. By using reliable food-grade lubricants that deliver outstanding performance, withstanding the rigours of severe operating conditions and high temperatures, manufacturers can deliver high capacity yields, high quality products, simplify maintenance and extend equipment life span.

In a potato processing plant, equipment that varies from a conveyor to a slicer, all require adequate lubrication. Mobil Industrial Lubricant’s range of NSF H1 lubricants help to keep manufacturing plants running efficiently and give the industry producers the peace of mind to go to market with safe and high quality products.

Mobil, Mobil SHC Cibus and the energy efficiency design are trademarks of Exxon Mobil Corporation or one of its subsidiaries.

*In closed systems, maximum bulk operating temperatures are 280°C with maximum skin temperatures of 295°C. Maximum operating temperatures are dependent on the duration of exposure to higher temperatures which can vary due to a range of operational factors. Operators should always consult the original equipment manufacturer to confirm.

** The energy efficiency design is a trademark of Exxon Mobil Corporation. Energy efficiency relates solely to the fluid performance when compared to conventional (mineral) reference oils of the same viscosity grade in circulating and gear applications. The technology used allows up to 3.6 percent efficiency compared to the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operating conditions and applications.

EXXONMOBIL HELPS WIND TURBINE OPERATORS TO GENERATE SUCCESS

Thu, 31 Jan 2013 07:32:25 +0000

ExxonMobil has been at the forefront of developments in the wind energy sector for over 30 years, championing thought-leadership and best practice from the advent of the industry to its current burgeoning growth. The company understands the challenges Equipment Builder engineers and wind farm operators face. Their superior lubrication products and services can help to cost-effectively maximise wind turbine productivity by improving equipment performance and reducing the need for maintenance.

PROVEN IN THE WIND SECTOR

Mobil Industrial Lubricants, a flagship brand of ExxonMobil Lubricants & Specialties has firmly established its reputation within the global wind energy sector for its accomplishments in research and development (R&D), close collaboration with the industry decision-makers and excellence of service. From its onset, their innovative wind lubricant technology and application expertise have been supporting this growing industry by reducing both maintenance requirements and operational costs. The Mobil-branded fully-synthetic lubricants are specifically formulated to overcome difficult operating conditions associated with offshore and onshore wind farms.

ENGINEER-FRIENDLY TECHNOLOGY

ExxonMobil’s global network of application engineers work from the initial design stage with turbine builders and other key component manufacturers to ensure the appropriate lubricant choice, depending on specific operating conditions. To develop its range of high quality lubricants, the company’s lubricant technologies undergo vigorous laboratory and rig testing before field trials commence.

Their fully synthetic lubricants and technical expertise has a proven track record of operating effectively in some of the most demanding applications. This includes the largest turbine models that are designed to feed energy to extensive power grids, with rotors up to 400 feet in diameter, churning up to six megawatts of electricity. As wind turbines are often situated in remote environments, either onshore or far out to sea, there is no such thing as a simple oil change or routine maintenance. Given these increasingly challenging operational conditions, ExxonMobil recognises that maximising equipment performance and durability is one of the most essential requirements for success.

PIONEERING INNOVATION AND PROBLEM-SOLVING

In the mid-1990s the wind energy sector encountered a challenge of traditional oils causing microscopic pits, ultimately shortening the life of the gear components. In collaboration with a major gearbox manufacturer, in 1998 ExxonMobil delivered a synthetic solution to the problem – Mobilgear SHC XMP, the company’s first synthetic gear oil for wind turbines.

Today, Mobilgear SHC XMP 320 remains the initial-fill gear oil of choice for the majority of the world’s top wind turbine builders and is now being used to protect more than 30,000 wind turbine gearboxes worldwide. It is an excellent lubricant for gearboxes used in wind turbines because it exceeds the performance of conventional, mineral-based oils, with benefits including extending the interval between oil changes from 18 months to three years or more.

FULLY INTEGRATED PORTFOLIO

ExxonMobil’s offer goes beyond its portfolio of cutting-edge products to address lubrication holistically. Its application-based counsel and technical guidance enable customers to make informed decisions about lubricant selection and performance. For example, to help operators navigate the broad portfolio of Mobil-branded oils and greases, ExxonMobil created Looble, a user- friendly, online industrial lubricant selector that provides targeted product recommendations with performance ratings based upon users’ specific industries, applications and equipment.

PRO-ACTIVE APPROACH TO MAINTENANCE

In addition, to help wind farm operators maximise productivity and extend oil drain intervals, ExxonMobil recommends incorporating an oil and equipment condition monitoring programme, as part of a pro-active approach to maintenance. ExxonMobil’s SIGNUM service was designed to help address any potential lubricant and equipment issues before any unscheduled downtime occurs. To obtain the greatest benefit from oil analysis, it is imperative to work closely with an expert lubricant manufacturer and participate in oil analysis typically every six months.

BEST PRACTICE IN ACTION – AN EXAMPLE

ExxonMobil Lubricants and Petroleum Specialties, a division of Exxon Mobil Corporation, has expanded its lubricant supply and service contract with E.ON, one of the UK’s leading integrated power and gas companies.

After successfully introducing a range of Mobil Industrial Lubricants into E.ON’s Combined Heat and Power (CHP), Combined Cycle Gas Turbine (CCGT) and coal-fired power stations, saving the company in excess of £1.4 million, ExxonMobil is now also focussed on optimising the lubrication performance of E.ON’s extensive wind farm operations across the UK.

“Over the last five years ExxonMobil has delivered a lot of value to our business,” said Chris Smith, Contract Performance Manager at E.ON Climate & Renewables. “It’s not just the range of high quality lubricants they provide, it’s the consultative approach they take to proactively identify cost saving and business improvement opportunities. Given the success the team has achieved to date, which has already gained them the E.ON Sustainability Award, we’re looking forward to working together to identify and deliver improvements to our wind farm operations.”

As wind grows as the most popular source of alternative energy, ExxonMobil continues to work closely with wind turbine companies to help advanced lubrication unlock greater operational efficiencies and reliability, supporting wind’s overall relevance as a viable fuel source.

ExxonMobil

Mobil SHC Cibus has saved 1,400 Euros as well as additional production losses.

Tue, 29 Jan 2013 00:00:00 +0000

Irish Pride Bakeries

Ballinrobe, Co. Mayo, Ireland

Background

The major food retailers supplied by Irish Pride require NSF H1 food machinery lubricants to be used in the production areas, both above and below the production line.

Irish Pride has a number of moderate duty and severe duty gearboxes used in production. In addition they have four sump-Iubricated Slicers. A large variety of lubricants were stocked both standard and NSF H1 food machinery lubricants. Max Tonge, Area Manager for Burke Lubricants was called in to determine whether the number of products held could be reduced and service intervals increased.

Recommendations and Solutions

It was decided that changing the lubricants used in the main production gearboxes and sumps to the Mobil SHC Cibus Series would be the best option, This would reduce the number of lubricants held, and in turn the risk of lost production through contamination was reduced.

Additionally the Mobil SHC Cibus range has allowed Irish Pride Bakeries to extend their oil change intervals by up to three times the service life resulting in reduced production down- time for oil changes, and directly saving annually on lubricant purchases.

The main benefits of using Mobil SHC Cibus Series for Irish Pride Bakeries are:

*NSF H1 registered lubricants suitable for food machinery used throughout production

*Formulated to be gluten, nut and wheat-free giving enhanced compliance for food manufacturing.

*Potential for up to 3% overall energy efficiency improvement

*Extension of service intervals by up to 3 times

*Can be used in moderate and severe duty applications - suitable for all of Irish Bakery`s gearbox requirements

*Reduced inventory- reduces the variety of lubes in the plant-reducing purchasing costs and reduces the risk of the wrong lubricants being used.

For more information on Mobil Industrial Lubricants, please contact Burke Lubricants, your local Mobil industrial lubricants distributor on +353 (404) 20333, sales@oil.ie or visit www.oi.ie

Mobil SHC Cibus Production Facilities Earn Food Safety Management Certification

Thu, 24 Jan 2013 00:00:00 +0000

Date: 27 November 2012

Type: Regulatory News

Source: Food Ingredients First

Sector: General Company & Ingredient Information

Summary: Facilities Producing Mobil SHC Cibus Food Grade Lubricants Have Earned ISO 22000 Certifications. Mobil SHC Cibus is the first lubricant range produced in ISO 22000:2005 certified facilities. Certification is one of the most stringent for manufacturers in the food processing sector. Mobil SHC Cibus also offer operators energy efficiency benefits of up to 3 percent

27 Nov 2012 --- ExxonMobil Lubricants & Petroleum Specialties Company, a division of ExxonMobil Corporation, today announced that it is the first lubricant provider to garner ISO 22000:2005 certification for facilities that manufacture NSF H1-registered lubricants. This accreditation is for facilities that produce ExxonMobil’s popular Mobil SHC Cibus Series of high-performance NSF H1 registered food machinery lubricants.

The ISO 22000 certification is one of the most stringent and comprehensive food and beverage safety standards. Established by the International Organization of Standardization, ISO 22000 is a food safety management system with a set of specified requirements that ensure a company’s ability to control food safety at every step of the

manufacturing process.

“ExxonMobil is committed to the highest standards of manufacturing hygiene and safety, and we are proud to again lead our peers in the lubricant industry by becoming the first company to produce in facilities which have achieved ISO 22000 certification,” said Yan Côté, global business development advisor, ExxonMobil Lubricants & Petroleum Specialties Company. “In addition to protecting product integrity during manufacturing, Mobil SHC Cibus lubricants can help companies improve the energy efficiency and productivity of their operations.”

Ideal for a wide range of applications, such as food, beverage and pharmaceutical processing, and animal feed manufacturing, Mobil SHC Cibus lubricants are suitable under Halal and Kosher dietary law and are designed to be gluten-, nut- and wheat-free.

They are formulated to deliver excellent wear and rust protection, long-term oxidation stability and can help food and beverage processors realize valuable sustainability-related benefits.

For instance, in extensive laboratory and field testing, Mobil SHC Cibus demonstrated the ability to deliver energy efficiency savings of up to 3 percent in gear oil applications when compared to conventional, mineral-based oils.

In proprietary rig testing, Mobil SHC Cibus Series synthetic lubricants also demonstrated their ability to last up to two times longer than comparable mineral oils, allowing for extended drain intervals, depending on the severity of the application.

Mobilgrind Series

Thu, 17 Jan 2013 00:00:00 +0000

Honing and grinding fluids for precision machining

Benefit from Mobilgrind Series advanced technology.

Mobilgrind Series is the latest high performance Mobil branded neat cutting oil — designed to help maximize machine tool availability and improve working conditions during precision grinding, honing and EDM operations. These advanced lubricants, based on high quality base oils and high performance additive systems, aim to improve machining economics and boost productivity. What’s more, Mobilgrind Series products are chlorine-free, which can help make disposal easier and reduce disposal costs.

Outstanding surface finish during machining.

Designed to help reduce loading of the grinding wheels and help reduce abrasive consumption, Mobilgrind Series offers outstanding surface finish in a range of applications. This helps reduce regrinding costs and helps boost productivity. Mobilgrind Series products can be used in individual machine tools or in centralized systems.

Low color and odor for better working conditions.

Mobilgrind Series fluids have a mild odor and low volatility to help improve working conditions in the machine shop, and they remain clear and transparent for long term visibility of the tool and workpiece. Some Mobilgrind Series fluids use high purity, specially refined base oils as their major component. Lower evaporation and misting, less drag out, and a longer working life compared with previous generation technology are some of the major benefits to machine shop managers.

High Performance Benefits

Balanced, highly effective additive pack

Designed to help maximize productivity rates, extend grinding wheel life, and improve dimensional accuracy.

Reduces grinding wheels loading

Helps increase machine tool availability and reduces abrasive costs.

Suitable for multiple applications

Supports reduced inventory and prevents misapplications.

Chlorine-free

Meets latest environmental standards, helping to reduce disposal costs.

Mobilgrind Series — Summary

Source: ExxonMobil Research & Engineering

For more information on these and other Mobil industrial lubricants and services, please contact Burke Lubricants.

Mobil, Mobilgrind, and the Pegasus design are trademarks of Exxon Mobil Corporation or one of its subsidiaries.In this document, the terms ExxonMobil and Mobil are used for convenience only and may refer to Exxon Mobil Corporation or one of its affiliates. Nothing in this material is intended to override the corporate separateness of local entities. Not all products are available in all markets.

Mobilmet Series

Tue, 15 Jan 2013 00:00:00 +0000

Neat cutting oils for precision machining

Lift productivity with our cutting oil technology. Mobilmet Series neat cutting oils are innovative, technically advanced metalworking fluids designed to meet the performance targets of today’s metalworking industry and equipment builders. These state-of-the-art lubricants, based on high quality base oils and advanced performance additive systems, are formulated to meet the latest health and safety guidelines, and have been developed to help improve machining economics and increase productivity.

Excellent machining performance for long tool life and outstanding surface finish. Mobilmet Series has been developed to offer outstanding machining performance in tough operating conditions. From deep-hole drilling to gear cutting and broaching to milling and tapping — on a range of alloy and carbon steels, and nonferrous metals such as copper-based alloys — high-performance Mobilmet Series spans a multitude of applications and offers outstanding tool life and surface finish to help reduce tool regrinding and component rejects.

Versatile and wide application range. Mobilmet Series offers a wide application range to help facilitate product rationalization programs at customer sites. Both Mobilmet 420 Series and Mobilmet 440 Series can be used in low-severity machine tool lubrication systems. Mobilmet Series can be used equally in individual machine tools or in centralized systems.

Conscious of the workplace — and the environment. Mobilmet Series fluids are designed to have a low odor, which, combined with good antimist technology, helps to improve the conditions when machine doors are opened, even after high speed machining operations. What’s more, Mobilmet Series products are chlorine-free, helping to simplify environmental disposal and be more cost-effective.

High Performance Benefits

Outstanding machining performance

Helps save costs on tool regrinding as well as contributes to less component rejects.

Low odor and misting

Helps improve workplace environment.

Suitable for multiple applications

Helps reduce inventory and misapplications.

Chlorine-free

Meets latest environmental standards, helping to reduce disposal costs.

Mobilmet Series — Summary

Source: ExxonMobil Research & Engineering

For more information on these and other Mobil industrial lubricants and services, please contact Burke Lubricants.

Mobil, Mobilmet, and the Pegasus design are trademarks of Exxon Mobil Corporation or one of its subsidiaries.In this document, the terms ExxonMobil and Mobil are used for

convenience only and may refer to Exxon Mobil Corporation or one of its affiliates. Nothing in this material is intended to override the corporate separateness of local entities.

Not all products are available in all markets.

Mobil DTE 10 Excel series

Thu, 10 Jan 2013 00:00:00 +0000

PROOF OF PERFORMANCE

Energy savings of 3.7% on average

Used in injection molding machines for manufacturing molded plastic parts in the automotive industry

Volkswagen AG

Wolfsburg, Germany

Situation and goal

In the manufacture of plastic molded parts, the automotive industry uses injection molding machines from Krauss Maffei among others. Injection molding machines use hydraulics for generating clamping force, moving the injection unit, ejecting the molded part, etc. In order to lower the total energy demand of the system, reduce leakage oil and increase oil service life, the search was on for a hydraulic oil that was better suited and thus able to replace the mineral-based hydraulic oil HLP-D 46 that had been used so far.

Recommendation and solution

Initially, the use of Mobil DTE 10 Excel 46 series, a high-performance hydraulic oil according to ISO VG 46, was recommended. The structure of this mineral-based lubricant fosters the reduction of power losses in the hydraulic system, resulting in a measurable decrease in energy uptake. The very good viscosity/temperature behavior of the Mobil DTE 10 Excel series allows selecting a lower viscosity grade. This benefits the start-up behavior in systems retrofitted with variable pump drives in the low-temperature range, avoiding the need for expending additional energy for pre-warming the oil. Thus in future, using Mobil DTE 10 Excel 32 for all systems will be recommended.

Result and advantage

Measuring the energy uptake before and after the switch to Mobil DTE 10 Excel 46 resulted in energy savings of 3.7% on average. Power consumption was measured under identical production conditions. Material used and material throughput per hour were identical. In addition to the advantages of extended oil change intervals and system service life due to strong wear protection, this will result in energy savings of at least 330,000 kWh / year (based on 6,000 operating hours p.a.) for the 22 systems operated at the site.

It may be assumed that total CO2 reductions will be about 200,000 kg p.a.*

* CO2 reduction was calculated based on an immissions factor of 0.605 kg per kWh of power consumed (source: WWF)

For additional information on Mobil SHC and other Mobil lubricants, please go to www.mobilindustrial.com or contact our Technical Helpdesk at TechDeskEurope@exxonmobil.com.

The Mobil Delvac and ExxonMobil logotypes are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries. The term “ExxonMobil” is used for convenience only and could refer to Exxon Mobil Corporation or one of its affiliates as the case may be. Other logotypes and trademarks are the property of the respective owners.

Mobilcut Series

Tue, 08 Jan 2013 00:00:00 +0000

Soluble cutting fluids for precision machining

Aim to increase productivity with advanced soluble technology.

Mobilcut Series water soluble cutting fluids are designed to help offer long service life, have low maintenance requirements and be suitable for a wide range of materials and operations. Offering the right balance between cooling and lubricity, Mobilcut Series aims to deliver excellent tool life and surface finish, which help reduce tool regrinding and component rejects. Formulated to meet the latest health and safety guidelines, the products are particularly suitable for modern machine shop managers aiming to improve productivity and reduce machine downtime.

Low maintenance and easy use help lift machining productivity.

Offering a long service life, Mobilcut Series helps generate less waste and improve machine tool availability —especially at critical times. The products are easy to mix and monitor, offering low maintenance costs and showing outstanding residual corrosion protection without undesirable residues. Low foaming tendencies, even under high pressure conditions, help provide trouble free operation for modern machining operations.

Multipurpose for optimized inventory.

Mobilcut Series has been developed to offer outstanding machining performance in tough operating conditions. Its wide application range means the number of products you need can be reduced, leading to product optimization, easier inventory management, and higher product turnaround. From boring, milling, and tapping on a range of alloy and carbon steels to drilling, reaming, and grinding on low carbon and alloy steels and nonferrous metals, Mobilcut Series can be used equally in individual machine tools or in centralized systems.

Compatibility with other Mobil lubricants can mean greater efficiency.

Mobilcut Series soluble oils are designed to be compatible with Mobil Vactra Oil Numbered Series slideway oils and Mobil DTE Series hydraulic oils, providing a suite of products to help keep your machine tools running at maximum efficiency.

High Performance Benefits

Excellent rust and corrosion protection

Aids long-term protection of machine tools and component parts, reducing rejections and rework.

Suitable for multiple applications

Helps reduce inventory and misapplications.

Increased machining performance

Helps decrease tooling changes and regrinds while maintaining excellent surface finish.

Chlorine-free

Meets latest environmental standards, helping to reduce disposal costs.

Mobilcut Series — Summary

Product Line

Recommended Concentrations

Mobilcut Series products are provided as a concentrate and must be mixed with water before use. Typical concentration ranges are provided in the table below. For additional recommendations, consult the technical help desk or your local ExxonMobil representative.

Soluble Fluids Care and Maintenance Advice

• Add the concentrate to the water — not water to concentrate. Use freshly mixed product only.

• Monitor and record coolant concentrations and conditions regularly, and take the necessary corrective measures in a timely manner.

• Keep systems clean by avoiding adding contaminants.

• Remove tramp oil frequently.

• Ensure that all leaks of hydraulic oil, gear oils, and other machine-tool

lubricants are attended to immediately.

• Keep coolant concentration at recommended level allowing for slideway/ hydraulic oil contamination.

• Do not use water from infected sources, such as fire hose, borehole, header tank, etc.

• Do not put clean coolant into dirty machines. Use system cleaner and follow the specified cleaning procedure carefully.

• Do not leave machines full of coolant standing idle for long periods, particularly when contaminated with tramp oil.

• Do not prepare products in dirty or galvanized containers.

• Do not top off with water. Always use diluted emulsion.

Application Guide

For more information on these and other Mobil industrial lubricants and services, please contact the Technical Helpdesk on TechDeskEurope@exxonmobil.com or visit our website at www.mobilindustrial.com

Mobil, Mobilcut, Vactra, DTE, and the Pegasus design are trademarks of Exxon Mobil Corporation or one of its subsidiaries.In this document, the terms

ExxonMobil and Mobil are used for convenience only and may refer to Exxon Mobil Corporation or one of its affiliates. Nothing in this material is intended to override the corporate separateness of local entities.

Savings of 100,000 Euros in electric motors with Mobilith SHC grease

Thu, 03 Jan 2013 00:00:00 +0000

Paper company

Germany

Situation

Motors were for years lubricated using grease compliant with DIN KP2N-20. The result was oil ingress into the winding space due to excessive oil deposits.

Recommendation

Use grease compliant with DIN-KP3N-20. DIN-KP3N-20 is the preferred OEM recommendation. Motors are generally supplied with this grease. Cage creep was identified by vibration measurements. Bearing damages resulted in a total cost of € 250,000.

Solution

Use of Mobilith SHC 100.

Impact

Base oil: ISO VG 100 - High speeds

Synthetic base oil - Low starting torque, low torque, high and low operating temperatures, no cage creep

Lithium complex soap - Low oil deposits, long lubrication intervals

Additives - For boundary lubrication. High sliding friction in bearing with rims.Wear protection given by additives

Benefit

No bearing damage, no oil-stained windings. Reduction in maintenance costs by approx. € 100,000 /y.

For more information on Mobil Industrial Lubricants and services, call Burke Lubricants or the ExxonMobil technical help line at +420 221 456 426.

Also contact us by e-mail through TechDeskEurope@exxonmobil.com or visit www.mobilindustrial.com

Mobil, additional trademarks, and the Pegasus design are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries. POP 2009-18

This proof of performance is based on the experience of a single customer. Actual results can vary depending upon the type of equipment used and its maintenance, operating conditions and environment, and any prior lubricant used.

Linear Robots

Wed, 02 Jan 2013 00:00:00 +0000

Change of grease type

Mobilux EP 004 - Mobilith SHC 007.

Machinery / Equipment Linear robot linear guides, shafts, racks and pinions

Austria

Situation

Lubrication of linear guides, vertical shafts, racks and pinions with Vogel-SKF central lubricating system – grease Mobilux EP 004, operating speed 5 m/sec, position tolerances 0.05 mm. Wear on rack and pinion, system and component contamination by grease being thrown out and by dripping.

Recommendation

Use of Mobilith SHC 007 in the central lubricating system – adjustment of lubrication intervals – lubrication quantity per linear guide cycle 0.03 cm³, rack 0.06 cm³.

Impact

No wear observed on rack and pinion, lubricating interval extended, reduction in grease use, no contamination of the machine and components. Change all linear robot series to Mobilith SHC 007, as well as OEM filling in production and lubrication recommendations for operators.

Benefit

Grease consumption reduced by 80%, lower maintenance costs, no wear observed, higher machine availability, no system and component contamination caused by grease.

For more information on Mobil Industrial Lubricants and services, call Burke Lubricants or the ExxonMobil technical help line at +420 221 456 426. Also contact us by e-mail through TechDeskEurope@exxonmobil.com or visit www.mobilindustrial.com

Mobil, additional trademarks, and the Pegasus design are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries.

POP 2009-17

Mobil SHC Polyrex 462 saves 40,000 Euros /y in sugar mill

Fri, 28 Dec 2012 00:00:00 +0000

Rotary valves of vacuum evaporators

Sugar Company

Germany

Situation

High temperature (130°C - 160°C) in rotary valves.

High wear and low lifetime of plates, drums and rotors.

No NSF-certificated grease in use, but contamination is possible.

Recommendation

Change to NSF-certificated Mobil SHC Polyrex 462.

Impact

With NSF-certificated product, legal requirements were met.

Reduction of the wear.

No change in grease consistency, no hardening or bleeding.

Excellent sealing effect against dust.

Reduction of the grease top-up amount.

Benefit

Savings about € 40,000/year.

Lifetime increase of plates, drums and rotors about 6 years.

Reduction of overall grease consumption.

Mobil, additional trademarks, and the Pegasus design are registered trademarks of Exxon Mobil Corporation or one of its subsidiaries. POP 2008-03 This proof of performance is based on the experience of a single customer. Actual results can vary depending upon the type of equipment used and its maintenance, operating conditions and environment, and any prior lubricant used.

Mobilith SHC 220 Helps a Mexican Building Materials Manufacturer Extend Roller Bearing Life, Generating More Than USD 24,500 in Annual Savings

Thu, 27 Dec 2012 00:00:00 +0000

Fuller Pump Bearings

Building Materials Manufacturer

Nuevo León, Mexico

Situation

A Mexican building materials manufacturer operates a set of Fuller pumps. The pumps are expected to operate in extreme conditions, and over the span of just 15 months, an elevated operating temperature of 120°C (248°F) led to the costly replacement of 62 roller bearings. The manufacturer asked ExxonMobil to recommend a lubricant capable of providing protection in extreme temperatures, thus reducing equipment downtime, cutting extraneous maintenance costs and curbing grease consumption.

Recommendation

ExxonMobil engineers recommended switching to Mobilith SHC 220 grease. Formulated with a wax-free synthetic base fluid and lithium complex thickener, Mobilith SHC 220 grease is specifically designed for application in extreme temperatures—both hot and cold. Engineers also proposed implementing a regreasing interval schedule.

Result

Seven months after transitioning to Mobilith SHC 220 grease, maintenance personnel had only replaced 10 roller bearings. The manufacturer also successfully reduced grease consumption and labor costs, while eliminating the need for external fan cooling. In total, the switch to Mobilith SHC 220 accounted for approximately USD $24,790 in annual savings.

The product performance of Mobilith SHC 220, alongside the application expertise provided by local ExxonMobil engineering support, is helping to improve customer productivity potential.

Mobilith SHC 220 grease helps this building materials manufacturer reduce equipment downtime, grease consumption and labor costs, generating annual savings of USD $24,790.

For more information on Mobil SHC and other Mobil Industrial Lubricants and services, call Burke Lubricants or visit www.mobilindustrial.com.

All trademarks used herein are trademarks or registered trademarks of Exxon Mobil Corporation or one of its subsidiaries unless indicated otherwise. POP 2009-013

This Proof of Performance is based on the experience of a single customer. Actual results can vary depending upon the type of equipment used and its maintenance, operating conditions and environment, and any prior lubricant used.

Advanced Lubrication

Thu, 20 Dec 2012 00:00:00 +0000

Instead of using a 'sprinter' oil which may be able to perform well in one area, companies that want to be successful in the long run have come to use versatile 'decathlete' synthetic oils, which can offer both productivity and efficiency benefits.

At every major track and field event, the 100 metres sprint is usually the most spectacular competition, since it determines the fastest man in the world. However, exactly 100 years ago, King Gustav V of Sweden realised that the real athletic champion is to be found somewhere else.

At the Stockholm Summer Olympics in 1912 he told Jim Thorpe, winner of the decathlon: "You, sir, are the world's greatest athlete". What King Gustav V recognised was Thorpe's achievement in being the most versatile athlete of all - after having achieved the best result in all ten disciplines combined. What is true in the world of sports also applies to industrial lubricants.

Increasing global competition and maintaining an edge on competitors are paramount concerns in today's global manufacturing marketplace. Yet being ahead of competitors on a sustainable and enduring basis is a complex challenge. Rather than focussing exclusively on the maximum output of production machinery, being successful today means taking into account the whole lifetime of a machine. Total Cost of Ownership (TCO) is the term commonly used in this respect.

Companies must deal with the maintenance challenges that are often associated with today's industrial machinery, seeking new ways to enhance their overall energy efficiency, reduce energy costs, increase productivity and remain committed to sustainable practices.

Successful machine builders as well as operators increasingly view preventive and predictive maintenance as investments to help ensure long-term success, and choosing the correct lubricants is the most fundamental component of a successful, preventative maintenance programme. The increasing recognition that conventional, mineral-based lubricants are limited in their capabilities means operators are evaluating and improving equipment performance and reliability with the use of high-performance, synthetic lubricants and related support services.

Synthetic lubricants - decathletes for industrial machinery

Instead of using a 'sprinter' oil, which may be able to perform well in one area, companies that want to be successful in the long run have come to use 'decathlete' synthetic oils. By definition, 'decathlete' oils are lubricants which excel in all critical areas of lubrication and can consequently offer both productivity and energy efficiency benefits.

For example, the Mobil SHC brand of high performance lubricants meets 'decathlete' performance status, thanks to ExxonMobil's Balanced Formulation Approach to lubricant development. This approach selects advanced technology base stocks and carefully designed additive packages to complement the excellent lubrication properties of base fluids to develop lubricants with decathlete qualities, achieving a high level of performance that extends across all critical areas of lubrication including:

wear protection
oxidative stability
viscosity index and shear stability
air and water tolerance
rust and corrosion control
filterability
extreme temperature performance
seal compatibility.

Synthetic gear, circulating and bearing oils

The next generation of Mobil SHC 600 high-performance synthetic gear, circulating and bearing oils, is the latest product launched by ExxonMobil that includes a balanced formulation designed to help optimise 'overall' performance.

As part of the research and development programme for the product, ExxonMobil undertook a series of standard tests to assess the 'overall' performance of the next generation Mobil SHC 600 Series against other synthetic gear oils available in the marketplace. While Mobil SHC 600 oils delivered exceptional performance across all critical areas, other oils had mixed results as depicted in the spider diagrams below.

Performance in the Field

The balanced formulation of Mobil SHC 600 oils has recently led to Smurfit Kappa, one of the world's leading producers of paper-based packaging, achieving an impressive reduction in energy consumption. The company has reported a gearbox energy efficiency saving of approximately 6.5 percent, following a field trial using the new Mobil SHC 600 Series.

Significant other benefits brought about by the lubricants include outstanding low temperature fluidity to enable start up and operation at low temperatures, and excellent resistance to rusting and corrosion for enhanced equipment protection.

It's not just Mobil SHC 600 which delivers a competitive edge to industrial companies. Plastic pipe manufacturer Ostendorf used the Mobil SHC Gear Series, a fully-synthetic industrial gear oil, and improved the energy efficiency of an extruder by an average of 3.3 percent while extending oil drain intervals (compared to the existing lubricant being used, a competitor's mineral ISO 220 gear oil). Furthermore, the average extruder gearbox temperature was reduced by 5°C, helping to reduce unscheduled downtime and component wear, and in turn improving performance.

The Mobil SHC Gear Series demonstrates excellent water-handling properties, enhanced resistance to micropitting fatigue, improved seal compatibility and outstanding shear stability.

Conclusion

In order to remain competitive in the market, manufacturing companies can no longer afford to use lubricants which do not optimise the performance of their business. Since maintenance and energy costs have become key elements to economic success, smart industrial players have come to use synthetic oils and greases that provide multiple performance benefits, which include extending the lifetime of their machinery. Or, in other words: they rely on the 'decathletes', not the 'sprinters'.

Smurfit Kappa Reports Significant Energy Efficiency Benefits with Mobil SHC 600

Tue, 18 Dec 2012 00:00:00 +0000

Mobil SHC 632 achieves up to 6.5 percent energy efficiency improvement in an industrial gearbox

Energy efficiency benefits of Mobil SHC 600 help to support Smurfit Kappa’s sustainability objectives
The Mobil SHC 600 Series can help to reduce equipment operating temperatures, helping to extend component life
Mobil SHC 600 Series oils can deliver a service life up to six times longer than conventional mineral oils

Smurfit Kappa, one the world’s leading producers of paper-based packaging, has reported a gearbox energy efficiency saving of approximately 6.5 percent following a field trial using the new Mobil SHC 600 Series. These high-performance synthetic gear circulating and bearing oils have been engineered to help pulp and paper companies increase productivity, reduce costs and deliver sustainability-related benefits.

As part of Smurfit Kappa’s on-going commitment to improving the productivity and sustainability of its operations, the business recently undertook a field trial to monitor the performance of the new Mobil SHC 600 Series. ExxonMobil engineers visited Smurfit Kappa’s plant in Snodland, Kent, and ran Mobil SHC 632 against the mineral-based oil already used in a Santasalo 2S56 double reduction gearbox in the 2nd press drive on its PM7. ExxonMobil engineers recorded temperature and power usage data from the gearbox with both the previous oil and the new Mobil SHC 600 Series over a six month period. The gearbox was operated at a constant load throughout this reference period.

The introduction of the new Mobil SHC 600 Series achieved significant results compared to the previous lubricant. For example, the lower traction coefficient and superior viscometrics of the fluid enabled the customer to report an average energy efficient saving up to 6.5 percent. In addition, an operating temperature drop of 8.40C was also realised, which can help to prolong the life of both the oil and equipment.

Rainer Lange, Mobil SHC Brand Advisor for Europe, Africa and Middle East, ExxonMobil Lubricants and Petroleum Specialties Company said, “As the pulp and paper industry continues to face challenging market conditions with high competition and rising costs, Mobil SHC 600 Series lubricants are expertly formulated to help large scale industrial operators like Smurfit Kappa meet their application-specific goals and provide valuable sustainability-related benefits, such as enhanced energy efficiency, extended oil drain intervals and prolonged equipment life.”

In addition to potential energy efficiency benefits, the enhanced Mobil SHC 600 Series oils can deliver a service life up to six times longer than competitive mineral oil based gear and bearing lubricants. Further benefits of the Mobil SHC 600 Series include outstanding low temperature fluidity which enable start up and operations at low temperatures and excellent resistance to rusting and corrosion for equipment protection. The multi-purpose potential of Mobil SHC 600 Series oils can enable companies to reduce their overall lubricant inventory, delivering additional cost-savings and storage benefits.

For more information about Mobil SHC branded synthetic lubricants, such as Mobil SHC 600, or any other Mobil-branded products and services, visit mobilindustrial.com.

Grease Fittings with Pressure Relief

Thu, 29 Nov 2012 00:00:00 +0000

There are millions of pieces of industrial equipment in operation today that are lubricated with grease.Many of these applications are in very tough service and non-ideal environments, which makes regreasing a challenging part of the maintenance activities. Using spring-loaded grease fittings helps prevent overpressurisation of the bearing housing and protect bearings with shields from being damaged. Pressure-relief fittings can also reduce the time it takes to complete the regreasing activity.

Shut-Off Grease Fittings

These fittings prevent overpressurisation of the bearing chamber and shield during grease injection. While a typical grease gun can put out as much as 10,000 psi, this fitting provides pressure-specific shut-off at the greasing inlet. When a predefined shut-off pressure (typically 20 psi) is exceeded, the grease will not be allowed to flow into the bearing chamber. When pressure falls below the shut-off pressure, the grease flow will resume. The typical design includes a 60-degree angle and a 1/8-inch PTF male pipe thread for pressure relief.

Pressure-Relief Vent Fitting

This fitting works as a pressure-relief valve at the grease plug (or outlet). When the design pressure (typically 1 to 5 psi) is exceeded, the valve will open and vent off grease. When the pressure is relieved, the valve will close to form a seal like a normal grease plug. In doing so, this device provides the additional advantage of eliminating the run-in that is required after regreasing (typically 15 to 30 minutes).

The Benefits

Pressure-relief fitting are available in a variety of quantities and sizes from various suppliers including Alemite, Lincoln, and McMaster-Carr (check the manufacturers’ websites for the supply source nearest to you).

While pressure-relief fittings are inexpensive (often less than one dollar apiece) and can easily be replaced during the next scheduled regreasing, without them the operation of the equipment is affected. Their use can result in a number of benefits:

Improved bearing reliability through elimination of failures from overpressurisation of the bearing shield (i.e., motor bearings)
Reduced regreasing time
Improved lubricant quality through reduced high-pressure churning
Contaminants should be reduced through adequate flushing

If you’re in doubt or want to know more about ExxonMobil greases, contact Burke Lubricants for assistance.

Mobil Glygoyle 220 saves 360,000 pounds per year for CAB Plant Hire

Thu, 01 Nov 2012 00:00:00 +0000

CAB Plant Hire

Newtonards, Co. Down, Northern Ireland

Situation

CAB plant hire employ four Wirtihen soil stabilisers for off road building, stabilising land for road building and building foundation work. The work places tremendous loads on the machine components, which ultimately lead to frequent gearbox failures that needed to be regularly replaced at the cost of £50,000 per unit. These failures also contributed towards signigicant downtime and increased labour costs required for servicing.

Recommendation

Burke lubricants engineers worked along with CAB personnel to understand the key suffering points of the equipment, and subsequently recommended the replacement of a competitive gearbox lubricant with Mobil Glygole 220, synthetic gearbox oil. Mobil Glygole 220 offers high thermal and oxidatice stability as well as excellent antiwear protection, providing outsanding gear protection under severe load factor situations.

Result

In the two years since employing Mobil Glygole 220, CAB plant hire have experienced no further gearbox failures.

With previous failure rates at an average of one gearbox per year, per machine, coupled with downtime and labout costs this constitutes as saving of £90,000 per year, per machine.

Total savings to the customer are up to £360,000 / year.

Mobil Delvac XHP LE 10W-40 saves 300,000 pounds per year for CAB Plant Hire

Tue, 16 Oct 2012 09:33:01 +0100

CAB Plant Hire

Newtonards, Co. Down, Northern Ireland

Situation

CAB plant hire employ four Wirtihen soil stabilisers for off road building, stabilising land for road building and building foundation work. The stabilisers are driven by V12 Mercedes engines. The engine main bearings were experiencing rapid wear, causing the engine to seize. On each occasion the engine would need to be stripped down and rebuilt or replaced, an operation that costs £75,000 for parts, labour and downtime.

Recommendation

On investigation by Burke lubricants engineers and CAB personnel it was found tha the worn bearings were suffering from oil starcation, which was the lead cause of the engine seizures. It was apparent that the current, comeptitive 15W-40 diesel engine oil was not providing sufficient wear protection on start-up to provide suggicient protection to the entire engine.

The recommendation was made to replace with Mobil Delvac XHP LE 10W-40 synthetic dieser engine oil, which displays excellent low temperature pumpability and start up wear protection, to provide increased protection during initial operation

Result

Since employing Mobil Delvas XHP LE 10w/40 synthetic CAB plant hire have experienced no further engine failures.

Further advantages are the potential for enhanced oil drain, longer engine life and increased shear stability.

Total savings to the customer are up to £300,000 / year.

Mobil SHC Pegasus Q&A

Tue, 04 Sep 2012 01:00:00 +0100

Throughout the world, increasing competition and the rising demand for reliable energy supplies are putting significant strains on companies in the power generation sector. That is why companies in the industry are today more than ever seeking new ways to stay ahead of the competition and maximize their productivity.

Below, Kathleen H. Tellier, Products Research and Technology, ExxonMobil Research and Engineering, gives insights into the latest trends impacting the power generation sector, such as, advancements in equipment design and the increasing value companies are putting on the use of high performance synthetic lubricants. An Advanced Engineering Associate with 20 years experience in the ExxonMobil Research and Engineering team, Kathy is the lead gas engine oil formulator for Mobil SHC Pegasus and the entire Pegasus product line.

1. Over the past decade, the power generation industry has undergone some significant changes, most notably, the steady rise in global energy demand. What do you see as the key challenges faced by gas engine operators today?

Tellier: There are several key challenges impacting companies in the power generation sector. Most notably, as you said, the demand for energy continues to grow nearly everywhere around the world. As a result, how companies are going to meet these new demands and how they will do so in the face of ever-increasing competition are the issues that are of critical importance to them.

As the industry strives meet the growing demand for reliable energy supplies, you are likely to continue to see several key trends, including:

A rise in the number of installed gas engines;
An increase in the use of combined heat and power (CHP), landfill and Biogas;
The installation of new gas transmission pipelines; and,
A growth in methane coal bed applications.

2. How do you anticipate these changes and trends will impact lubricant suppliers?

Tellier: Every day, Mobil Industrial Lubricants' family of premium oils and maintenance solutions help enable successful companies within the energy sector to boost their productivity, enhance the performance and life of their equipment, increase profitability and reduce downtime.

For these companies, machine reliability is crucial - and any unplanned stoppages for breakdowns and early oil changes, for example, become critical factors that significantly impact operating costs and ultimately productivity. Today, companies in the power generation sector are operating turbines and natural gas engine systems that feature extremely sophisticated and advanced technology.

Overall, trends in engine design have yielded systems that typically deliver increased power output through higher compression ratios, coupled with an increasing focus on emissions - reducing the amount of oil available in the engine. These smaller, more powerful units put new levels of strains on gas engine lubricants. To operate at peak efficiency, they require high performance lubricants that deliver exceptional protection even under the most demanding conditions, such as extreme temperatures, load conditions and higher operating pressures.

As machine designs have become more advanced, we have seen even greater demand for lubricants that deliver enhanced efficiency over extended periods of time, enabling reductions in engine downtime and labour costs associated with oil changes. We anticipate this trend will continue.

All of these developments make the use of a high performance natural gas engine oil integral to achieving improved productivity and profitability, and explain why we work so closely with OEMs and installers to develop next generation lubricants solutions.

3. How is ExxonMobil helping its customers in the power generation sector stay ahead of the competition?

Tellier: At ExxonMobil, our ultimate goal is to improve our customers' competitiveness by facilitating improved productivity through our commitment to being the technology leader with the highest level of application expertise. As a company, we place an enormous emphasis on ongoing investment in R&D, working side-by-side with the world's leading OEMs to develop the most effective products and maintenance solutions.

This process begins in our Research & Engineering facilities, and is conducted hand-in-hand with leading equipment builders, as well as the users and maintainers of such equipment, to ensure their crucial input at the earliest product-profiling stage. Our latest innovation for the power generation industry - Mobil SHC Pegasus natural gas engine oil - is a perfect example of this symbiotic process, which saw us conduct a number of field, lab and OEM bench tests with market leading equipment builders.

As the company that pioneered synthetic lubricant technology, ExxonMobil has proven time and again that innovative lubricants can help deliver tangible performance and sustainability-related benefits as well as material economic advantages to industry and consumers. For high performance products, we prefer to utilise individual additive components in combination with the highest quality synthetic basestocks (such as polyalphaolefins) to achieve optimum performance in key areas.

Our tests have shown that advanced synthetic lubricating oils can contribute to increased equipment operating efficiency and engine fuel economy, reduced energy and resource use, lower emissions and cost savings for gas engines when compared to conventional mineral oilsⁱ. Innovations in synthetic-based product formulations also help deliver longer lubricant performance cycles, and help reduce lubricant consumption, used oil volumes and operating expenses. Along with providing premium lubricants, the team behind Mobil Industrial Lubricants offers a wide range of aftermarket services that provide companies with dedicated, hands-on support to better manage their equipment maintenance needs.

4. Tell us more about ExxonMobil’s new Mobil SHC Pegasus product.

Tellier: The launch of our Mobil SHC Pegasus represents a significant milestone in lubrication technology for natural gas engines. Mobil SHC Pegasus is a new generation of high performance, synthetic lubricant expertly formulated to help enhance the performance and protection of natural gas engine systems and their key components.

In a wide range of tests performed in the laboratory and in-the-field during real world operating conditions, results demonstrated how Mobil SHC Pegasus can provide significantly longer oil drain intervals of up to 2-3 times when compared to conventional mineral oilsⁱⁱ. In addition, I believe what your readers would be most interested to learn is that Mobil SHC Pegasus is also one of the world's first energy efficient gas engine oils, capable of offering a fuel efficiency increase of 1.5%ⁱⁱⁱ - exactly the kind of competitive advantage that companies are looking for.

Thanks to its superior properties, Mobil SHC Pegasus may help customers experience less equipment downtime, as well as increased efficiency and engine protection - all with one technology.

5. Given the crucial importance of this area in maximising production efficiency, should plant managers place more emphasis on preventive maintenance or energy saving measures to protect their bottom line?

Tellier: Both preventive maintenance and measures designed for energy saving can have a marked effect on a plant's bottom line and as such, we believe that one should not have to be sacrificed for another.

In a recent survey of European gas engine operators, conducted by Mobil Industrial Lubricants and PennWell, results highlighted the crucial nature of both factors, as well as the link to efficient lubrication. In fact, 41 percent of respondents named engine efficiency as a top concern with regard to lubricants, with improving fuel efficiency representing a continuous financial benefit to a company's bottom line. Meanwhile, on preventive maintenance, over half of respondents^iv felt that maintenance related to gas engine lubrication affected their company's bottom line to a "moderate" or "great" extent.

Therefore, by neglecting investment in preventive maintenance, operators would be conscious of ultimately endangering the preservation of significant assets on the balance sheet.

6. What are the key components of a successful preventative maintenance program?

Tellier: The cornerstone of any successful, preventative maintenance program is the selection and proper application of the correct lubricants and greases. With its range of performance and efficiency benefits, we believe that companies in the power generation sector will soon recognize Mobil SHC Pegasus as the right lubricant for many of their equipment needs.

Beyond selecting the optimum lubricant, having a comprehensive oil analysis program is a vital component to a successful preventative maintenance program. An ideal solution for companies that want to enhance their oil analysis monitoring, but do so in an efficient and cost-effective way, is ExxonMobil's proprietary Signum Oil Analysis Program.

Easy and convenient to use, Signum is a state-of-the art online oil analysis program specifically tailored to monitor critical indicators in used oil, based on leading equipment builder specifications and international standards. We know the oil by design and know what to expect in the analysis, so using Signum ensures the right laboratory staff are looking at your oil, from your engine, at the right time.

ⁱExxonMobil’s own conventional mineral oils.
ⁱⁱExxonMobil’s own conventional mineral oils.
ⁱⁱⁱThe fuel efficiency of Mobil SHC Pegasus relates solely to the fluid performance when compared to ExxonMobil's standard SAE 40 natural gas engine oils. The technology used allows up to a 1.5% increase in fuel efficiency compared to Mobil Pegasus 1005 and 805 series when tested in standard natural gas engine applications under controlled conditions. Efficiency improvements will vary based on operating conditions. The energy efficiency claim for this product is based on test results on the use of the fluid conducted in accordance with all applicable industry standards and protocols.
^iv52.7%. The survey was conducted by PennEnergy.com through a partnership with Mobil Industrial Lubricants, November-December 2009.

Mobil Pegasus and the world's largest biogas plant

Thu, 30 Aug 2012 01:00:00 +0100

Mobil Pegasus gas engine oils help keep the world’s largest biogas plant running smoothly, as customers testify in this video case study.

The high-performance range of lubricants plays a key role at the Klarsee BioEnergie Park in Penkun, Germany. The park is at the cutting edge of bioenergy, processing 1,000 tons of corn a day from local farms to power over 40,000 households.

ExxonMobil teamed up with engine manufacturer GE Jenbacher to ensure the plant’s forty 500kW gas engines can perform at their peak with minimum downtime. The ExxonMobil team identified specialist Mobil Pegasus lubricants to protect each component from wear and corrosion, as well as providing Signum, used oil analysis, to help the plant to improve its maintenance more efficiently by reducing unscheduled downtime.

The Mobil Pegasus line has been evolving over 40 years to optimise productivity and efficiency across a range of engine technologies including the latest stationary natural gas engines. This video case study is just one example of the range in action.

Leakage Control (HFI)

Thu, 23 Aug 2012 01:00:00 +0100

It can be a constant battle maximizing the availability of your equipment and managing limited manufacturing resources at the same time. Sooner or later, lubricant selection will come under review to determine if a less expensive alternative exists. While higher quality fluids are recognized as having the potential to better protect equipment and deliver an overall lower total cost basis, the final decision often comes down to leakage. Historically, high leakage facilities, such as metalworking facilities and steel mills, end up using minimum cost hydraulic fluids as a result. This is a classic "double whammy" scenario because facilities with high leakage rates ending up paying more on two fronts: oil consumption and reduced equipment life.

However, you can take action now to reduce short-term expenses and gain better maintenance control by establishing a regular routine of tracking consumption on major reservoirs. When you track consumption, you place a value on each system monitored and can then prioritize those machines that give you the greatest return on your investment.

It's not unusual to expect a reduction in lubricant consumption of at least 10 percent by implementing the following steps:

1. Identify Systems To Be Tracked:
Catalog all major hydraulic systems by reservoir capacity, a unique registration number and name of the fluid each system contains. In the process of cataloging, label each system with an identification tag. This first step is crucial as it accurately assesses plant wide capacity and visually marks those systems that are being monitored.

2. Accurately Meter Fluid Usage:
Install a metering device on lube storage tanks to accurately measure actual gallons delivered.

3. Record Delivered Gallons:
Establish a method for lube personnel to record delivered gallons on each fill. Industrial PDAs with bar code scanners can help minimize administrative workload.

4. Calculate Baseline Hydraulic Fluid Index (HFI):
Spend the time to establish a reasonable baseline that can be used to measure actual cost savings. We recommend collecting at least two months of data. HFI calculations would give you a consistent measure of leakage rates independent of capacity, allowing performance tracking as equipment set-up changes. This calculation can be done with individual reservoirs or groups of reservoirs.

HFI = Annual Usage or Total Fluid Used

Reservoir Capacity Total Site Capacity

The average industrial plant has an annualized HFI of about 3:1. The best plants have ratios of 1:1 or less.

5. Summarize Monthly Consumption:
Pinpoint reservoirs with massage leakage problems.

6. Schedule Ultraviolet / Ultrasonic Leak
Inspections: Once a unit is noted as a high user, schedule inspections to identify the source of the leakage. By focusing on the identification and quantification of leakage up front, you help minimize the impact on production until repairs can be scheduled. For more information on leak detection methods, see how ExxonMobil engineers can help you by reading Service Data Sheet "Comprehensive Leak Detection."

7. Continue to Monitor HFI:
Maintain and update documentation as this will be key to your program's success. You may also want to track "% capture", an indicator of lubricant volume used versus volume purchased. This will help ensure that you stay on target and reach your cost savings objectives.

Refs: "Preventing Leaks From Draining Your Bottom Line" by Toby Hlade. The Engineered Difference

The Mobilcut Series

Tue, 03 Jul 2012 01:00:00 +0100

ExxonMobil and McLaren have been technology partners since 1995. Innovations made by Mobil lubricants have improved the McLaren race team’s driving performance, efficiency and reliability. Mobil has given McLaren a competitive edge.

Many Mobil 1 products are used throughout McLaren technology and not just in racing. The recent introduction of ExxonMobil’s Mobilcut Series has made its way into the McLaren machine shop. It offers long service life, good operator acceptability and easy waste management. The high performance fluid guarantees excellent cutting performance, outstanding machine tool lubrication, corrosion protection and reduced maintenance downtime. Watch this video to find out more about the Mobilcut Series.

1564 Euros Annual Saving on the Operation of Three Renner Compressors: Mobil Rarus SHC 1026

Wed, 27 Jun 2012 08:35:07 +0100

Elastometall (Ireland), Manorhamilton, Co. Leitrim

Situation and Objectives

Three Renner Compressors were lubricated with Shell Corena 46. Carry Over and top-up of the lubricant was required at the rate of 2 litres per week for each compressor. In addition, Iacquering of components took place which required stripping down the machine, cleaning the Components and reassembling them.

Recommendations and Solutions

Foaming of the lubricant was evident when inspected - this reduces the effectiveness of the lubricant. The lubricant used in the three compressors was changed to Mobil Rarus SHC 1026 in December 2012 and the benefits were quickly noticed as follows:

Carryover /Loss of lubricant has been substantially reduced far less top up required
Lacquering of components eliminated--no overhaul required-less downtime.
Foaming of lubricant reduced - more effective lubrication.
Operating temperature reduced by 4 degrees centigrade - resulting in energy savings.

Results and Benefits

In addition to the worthwhile savings of €391, achieved over three months using Mobil SHC 1026, other benefits are obtained. The lower coefficient of friction of synthetic hydrocarbon technology results in energy savings; this was shown by lower operating temperature experienced in the Renner compressors.

The excellent thermal and oxidation stability of the SHC range of lubricants enables the optimum lubricant performance over a wide operating temperature range to be obtained. Its ability to resist cooking and deposit formation was evident in the lack of lacquering in the Renner compressors which was a problem with the previous lubricant.

The compressors will continue to be monitored with the objective of achieving further savings over a more extended period.

For more information on Mobil Industrial Lubricants, please contact Burke Lubricants, your local Mobil industrial lubricants distributor on +353 (0) 404 20333, sales@oil.ie or visit www.oil.ie

Burke Lubricants

Milltown Shopping Park

Rathnew, Co Wicklow, Ireland

Tel. +353 (0) 404 20333 Fax +353 (0) 404 69855 Email sales@oil.ie Web www.oil.ie

New Product Selector Tool Makes It Easy To Choose The Right Product

Tue, 26 Jun 2012 01:00:00 +0100

New Industrual Product Selector Tool Looble makes it easy for you to choose the right product

ExxonMobil Lubricants and Petroleum Specialties have introduced Looble, a user-friendly, online industrial-lubricant selector designed to help maintenance professionals make informed lubricant decisions for optimizing equipment performance and minimizing unplanned downtime.

Looble simplifies the lubricant selection process by providing targeted Mobil-branded product recommendations with performance ratings based upon users’ specific industries, applications and equipment.

With just a click of the computer mouse or a touch on most Internet-capable smartphones, Looble enables users to access lubricant recommendations and application guidance based on their specific applications and operating conditions for a wide range of industries; original equipment manufacturers’ recommended lubricants and schematics for numerous types of equipment makes and models; detailed descriptions and five-star performance ratings for each recommended lubricant and printable recommendation reports.

“With the introduction of Looble, maintenance and production professionals now have a readily accessible resource for lubricant and maintenance best practices that can help them optimize equipment performance and ultimately, enhance their companies’ bottom line and gain a global competitive advantage,” said Ian Davidson, Global Industrial Marketing Manager, ExxonMobil Lubricants and Petroleum Specialties Company, a division of Exxon Mobil Corporation. “Looble is powered by our valuable application-specific expertise and unique insights that we have gained during more than a century of working with customers and the world’s leading industrial equipment

manufacturers.”

For more information about Looble, or other Mobil-branded industrial lubricants or value-added services, visit Oil.ie.

Advanced Lubrication - Maximising Wind Farm Productivity with Mobil Industrial Lubricants

Tue, 12 Jun 2012 01:00:00 +0100

To meet the world’s growing demand for energy from renewable sources and to keep the price on wind generated electricity competitive, wind turbines today are running faster, longer and more efficiently than ever before.

This DNet article aims to provide advice to distributors on how your customers operating wind farms can optimise turbine performance and reduce unscheduled downtime by choosing the right lubricant and following best practice maintenance techniques.

Enhancing turbine performance

One thing will always be at the front of customers’ minds whenever they make a purchase decision - maximising productivity. This is particularly true in the wind sector where advanced lubrication and related services are critical for increasing wind turbine availability and reducing unscheduled downtime.

Minimising unscheduled downtime will become even more important in the future given that some of the wind farms currently under construction in Europe are many kilometers offshore. In addition to the high costs related to replacement parts and labour costs, the logistics of reaching wind turbines far out at sea can run into six-figure amounts, including chartering specialist ships to help carry out the maintenance.

The good news is that by selecting advanced oils and greases, and adopting a proactive approach to maintenance, wind farm operators can significantly improve the productivity of their wind farm operations and reduce costs.

High performance synthetic lubricants

For example take the main gearbox, a key component of a wind turbine. To help maximise productivity and reduce unscheduled downtime, the gear oil needs to offer high levels of performance in all the critical areas required to keep a gearbox working efficiently. This includes outstanding oxidative stability and water tolerance, excellent long term filterability as well as superior gear and bearing protection. It is crucial that the gear oil has a carefully balanced formulation to provide all round protection and performance.

As well as the gearbox, wind farm operators should look to incorporate high performance oils and greases across the entire wind turbine including the main, pitch and yaw bearings. Mobil SHC Grease 460WT is a compelling choice of synthetic grease for the lubrication of this application due to its excellent low and high temperature performance, structural stability even in the presence of water, excellent false brinelling and wear protection, and rust and corrosion inhibition. Its deployment allows consolidation of main, pitch and yaw bearing greases into one product, minimising the risk of re-lubrication with the wrong product and without introducing unnecessary operational risks.

Oil and equipment condition monitoring

Use of high performance lubricants should always be supported by routine, scheduled maintenance, including oil analysis. Routine oil analysis is one of the most widely used proactive maintenance strategies for wind turbines and employs a test slate that is designed to evaluate the condition of the in-service lubricant and equipment. Using routine oil analysis such as ExxonMobil’s Signum service, as part of a preventative maintenance programme, maintenance professionals can extend the lives of both the equipment and lubricant by detecting and acting on early warning signs such as oil contamination, cleanliness levels or increasing wear metals.

To obtain the greatest benefit from oil analysis your customers should work closely with an expert lubricant manufacturer and participate in oil analysis typically every six months. Identifying trends in the data will help maintenance professionals make better informed decisions.

That way, where a trend or sudden change in equipment condition is detected, corrective action can be taken which can help to reduce unscheduled downtime. Oil life can also be extended by implementing a programme of changing the lubricant based on its condition rather than on time-based maintenance. Typically, wind turbine manufacturers state gearbox oil change frequencies of 18 months for mineral oils and three years for synthetic lubricants. By employing an oil analysis programme in a condition based maintenance regime, synthetic oil lubricant life can be extended beyond five years.

By introducing technologically advanced synthetic lubricants alongside an effective oil equipment condition monitoring programme, your customers can look to reduce costs and maximise the productivity of wind turbines, including those operating in remote, offshore locations.

For more information about ExxonMobil’s range of products for wind turbines and the Signum oil analysis service, please speak to your local ExxonMobil Distributor Business
Consultant.

Top-tips to help maximise wind turbine performance

Wind farm operators can significantly improve the productivity of their wind farm operations and reduce costs by selecting advanced oils and greases, and adopting a proactive approach to maintenance.
It is critical that lubricants, such as gear oils, have carefully balanced formulations to provide all round protection and performance.
Fully synthetic gear oils can extend oil changes from 18 months to three years or more.
As well as the gearbox, wind farm operators should look to incorporate high performance oils and greases across the entire wind turbine including the main, pitch and yaw bearings.
To identify the best lubricants for use in a wind turbine, visit http://www.mobilindustrial.com/Apps/ILS/default.aspx.
The selection of high performance lubricants should be supported by routine, scheduled maintenance, including oil analysis.
To obtain the greatest benefit from oil analysis, it is imperative to work closely with an expert lubricant manufacturer and participate in oil analysis typically every six months. Identifying trends in the data will help maintenance professionals make better informed decisions.

High performance hydraulic oils for the plastics industry

Fri, 01 Jun 2012 01:00:00 +0100

Due to the competitive nature of the plastics industry, companies are continually looking to maximise productivity while reducing unscheduled downtime and costs. While they only represent a small percentage of the total maintenance spend, customers in this industry will be keen to learn how the latest hydraulic oils have the potential to inject additional productivity and performance into plastic manufacturing operations.

Find out here how they can do just that.

The role of hydraulic oils in plastics
Within the majority of plastic injection moulding applications, hydraulic oils play a fundamental role in the actual production of plastic components as well as helping to reduce unscheduled downtime and extend oil drain intervals.

However, improvements in hydraulic oil technology now mean that plastics manufacturers can select fluids which not only help produce high quality components but also provide outstanding levels of protection, alongside other potential benefits such as increased energy efficiency and decreased cycle times.

Plastic injection moulding operators will be interested to hear that ExxonMobil introduced in 2009 an awardwinning* hydraulic oil which has been proven to help them increase productivity, reduce unscheduled downtime and improve the energy and cycle efficiency of their machinery. Compared to standard hydraulic oils, Mobil DTE 10 Excel can provide up to a six percent improvement in hydraulic system efficiency**, reduce cycle times and triple oil drain intervals.

Next Generation Hydraulic Oils

To help reduce unscheduled downtime, customers are looking for hydraulic coils with good contamination control. Contamination may be generated in the system or may come in from the outside, so a hydraulic oil needs to demonstrate excellent oxidation resistance and filterability to avoid lubrication and component failures, and frequent oil changes. Customers also want a hydraulic oil to prevent pump damage or failures at equipment start-up and while operating at extremely high temperatures.

Laboratory and in-service field demonstrations conducted on a wide range of modern hydraulic systems, demonstrated that Mobil DTE 10 Excel has exceptional oil life, outlasting standard hydraulic oils by up to three times whilst maintaining outstanding hydraulic system cleanliness and component protection.

In addition to excellent protection, it can also be made clear that Mobil DTE 10 Excel can help provide quantifiable increases in hydraulic efficiency compared to standard hydraulic oils. This can translate to reduced power consumption and cycle times, resulting in monetary savings that customers will be keen hear about.

This is achieved through the oil performing at its optimum volumetric and mechanical efficiency level – achieved when the two efficiencies, which are inversely proportional to each other, are in balance. To ensure this level is maintained throughout the day and to avoid late-day sluggishness ('PM fade'), Mobil DTE 10 Excel's high viscosity index ensures the performance of the oil is not impacted by the equipment heating up during the day while in operation.

In controlled laboratory efficiency testing, Mobil DTE 10 Excel was measured to provide up to a six per cent improvement in hydraulic pump efficiency compared to a standard hydraulic fluid, when operating in typical hydraulic applications. The oil's ability to reduce cycle times delivers additional benefits - for example, in plastic injection moulding equipment, a 0.5 second reduction in cycle time can realise up to an 11 per cent increase in productivity.

Field-tested By the Plastics Industry

You can share with customers examples of how Mobil DTE 10 Excel fares in real industry conditions. A company who recently made the switch to Mobil DTE 10 Excel was Häfner & Krullmann, a company based in Leopoldshöhe, Germany, specialising in processing plastics. The company is one of Europe's largest manufacturers of plastic spools ranging from special spools for the silver stripes used in hundred euro notes, to spools produced under clean room conditions for medical applications. It currently has 52 injection moulding machines, varying in size from 50 to 2,000 tonnes.

The company has realised the importance of hydraulic oils in maximising the productivity of its equipment for a number of years and was keen to see what performance benefits could be realised through the introduction of Mobil DTE 10 Excel.

Following a successful test phase involving two machines, the company decided to convert additional machines to Mobil DTE 10 Excel. Since then, five of the company's installations have been filled with the product and for the other machines it has been used for topping up.

Following the introduction and initial monitoring of Mobil DTE 10 Excel, Häfner & Krullmann expect to extend oil drain intervals from 40,000 to around 50-60,000 operating hours and make an energy saving of two–three per cent. The company also expects to double filter life which in itself will deliver significant cost savings.

Analysis to Maintain Performance and Maximise Productivity

In order to maximise the productivity of machinery and reduce costs, distributors can encourage their customers to incorporate an oil and equipment condition monitoring programme alongside the use of a high-quality hydraulic oil. As part of routine maintenance, the 'health' of the hydraulic oil and the hydraulic system itself should be regularly checked. Industry advice is that maintenance professionals perform quarterly oil analyses and annual system inspections.

The oil analysis should include a measurement of fluid viscosity, water content, dissolved metals and particle count to determine how well the system is operating. Examining changes in the oil analysis data over time - also known as 'trending' - is necessary to assess the condition of the hydraulic fluid. By trending oil analysis data, customers can proactively address undesirable conditions before they become problems.

For equipment maintenance professionals looking for an effective oil analysis programme, distributors can direct them to ExxonMobil Lubricants and Specialities' proprietary online Signum oil analysis programme. Signum oil analysis offers engineers immediate access and direct control of their lubricant sampling programme. With a few keystrokes, customers can manage their oil analysis needs enabling them to:

Update equipment registrations and select analysis options based on their equipment or maintenance needs
Track the status of samples at the lab
Direct actions based on analysis results
Share critical results with colleagues in a secure, password protected environment.

Beyond oil analysis, distributors should also recommend that customers carry out regular visual system inspections to check and document the condition of hydraulic systems. Inspection data can be used to establish the optimum time to perform maintenance on critical hydraulic components such as filters, breathers, valves, hoses, heat exchangers and pumps. Comprehensive leak detection should also be performed, especially if excessive hydraulic oil usage is noted during a routine system inspection.

By combining the use of high quality oils and an effective oil and equipment analysis programme, plastic companies can look to achieve a competitive advantage in their operation, maximising productivity and reducing the energy consumption of hydraulic machinery.

For more information about Mobil DTE 10 Excel or other Mobil-branded lubricants, oils and services, please contact your ExxonMobil Distributor Business Consultant.

*Mobil DTE 10 Excel was awarded 2010 “Product of the Year” from a top industry magazine in Poland. In addition, the product achieved a bronze award in the maintenance category for Plant Engineering Magazine's "Product of the Year" Awards in the United States.

**Energy Efficiency of Mobil DTE 10 Excel relates solely to the fluid performance when compared to ExxonMobil Lubricant and Specialities' standard hydraulic fluids. The technology used allows up to six percent increase in hydraulic pump efficiency compared to Mobil DTE 20 series when tested in standard hydraulic applications under controlled conditions. The energy efficiency claim for this product is based on test results on the use of the fluid conducted in accordance with all applicable industry standards and protocols. In case of queries, please consult TechDeskEurope@exxonmobil.com. Results may vary depending on operating conditions.

Mobil SHC Increases Your Productivity

Tue, 29 May 2012 01:00:00 +0100

Mobil SHC 824 is a supreme performance, synthetic turbine oil and meets the needs of severe marine and industrial gas turbines. Productivity increases with the use of Mobil SHC synthetic lubricants and it also provides excellent anti-wear protection.

This video shows the success story of Mobil SHC 824 and how it ran a solar gas turbine for over 90,000 hours, approximately 13 years. Monmouth Energy, in New Jersey, converts methane gas into energy. The running of one of their gas turbines on its original oil is one of Mobil’s success stories.

Next-Generation Mobil SHC 600 Series Lubricants

Thu, 24 May 2012 01:00:00 +0100

Next-Generation Mobil SHC 600 Series Lubricants: Setting a New Standard in Performance Starts with a Balanced Approach

As a company that helped pioneer synthetic lubricant technology, it’s no surprise that ExxonMobil has set a new benchmark for performance with its recently upgraded Mobil SHC 600 Series, a family of synthetic industrial circulating gear oils.

For more than 40 years, Mobil SHC 600 Series lubricants have been synonymous with exceptional performance and equipment protection, with companies in nearly every industrial sector relying on them to help maximize productivity and enhance equipment life.

To expand further on this 40-year legacy of performance, the new Mobil SHC 600 Series lubricants were developed through ExxonMobil’s proprietary balanced formulation approach and feature the highest level of advanced synthetic basefluids and proprietary additive technology.

Through its balanced formulation approach, ExxonMobil develops lubricants that deliver exceptional performance across all critical areas for each application—such as oxidative stability, corrosion control, filterability, shear stability and extreme temperature performance.

The chart below illustrates how ExxonMobil’s balanced formulation approach enables the next generation of Mobil SHC 600 Series lubricants to provide exceptional balanced performance and exceed the capabilities of competing synthetic and conventional mineral-based fluids.

Mobil SHC 600 Series lubricants are fully optimized to help companies increase their productivity and generate valuable sustainability-related benefits, such as extended oil drain intervals, longer equipment life and enhanced energy efficiency.

In fact, Mobil SHC 600 lubricants exhibited energy savings of up to 3.6% compared with conventional oils across a range of statistically validated tests.* Furthermore, compared with conventional, mineral-based lubricants, Mobil SHC 600 Series lubricants can deliver a service life of up to six times longer than conventional oil, which can help reduce maintenance costs, minimize oil waste, and increase productivity.

While many competitors formulate lubricants to deliver exceptional performance in one area, it’s clear that ExxonMobil’s balanced formulation approach offers distinct advantages and can play a key role in maximizing equipment performance, durability, and overall productivity.

The chart shows some competitive synthetic gear oils are formulated specifically to deliver exceptional results in one area but often sacrifice performance in many other areas. Only by selecting an oil that has a balanced formulation can operators look toward maximizing productivity.
(Source: ExxonMobil Research)

* The energy efficiency design is a trademark of Exxon Mobil Corporation. Energy efficiency relates solely to the fluid performance when compared with conventional (mineral) reference oils of the same viscosity grade in circulating and gear applications. The technology used allows up to 3.6% efficiency compared with the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operating conditions and applications.

The Next Generation Lubricants

Tue, 22 May 2012 01:00:00 +0100

Mobil SHC has set the standard for synthetic lubricants for the last 40 years. It is a supreme performance gear and bearing oil and provides equipment protection, problem-free operation and extended oil life. Using Mobil SHC synthetic lubricants increases customer productivity. The upgraded formulation meets the changing demands of the machinery and is recognised for its innovation and outstanding performance.

This video expands on the benefits of using Mobil SHC synthetic lubricants. Watch it to find out more.

Energy Saving Mobil Lubricants

Thu, 12 Apr 2012 01:00:00 +0100

Mobil, the leading innovators in lubrication technology for the past 100 years, have released two new lubricants that allow equipment to work at peak condition and are energy efficient. The new high-performance lubricants are Mobil SHC 600 Series and Mobil SHC Gear.

The previous Mobil lubricant that is similar to these two is the Mobil SHC Pegasus, which is the first energy-efficient and durable gas engine oil. The Mobil SHC 600 Series provides problem-free operation and increases productivity whilst the Mobil SHC Gear is used for optimising equipment and oil life in gearboxes. The Mobil SHC range is recognised for outstanding performance and innovation. These new lubricants symbolise Mobil’s commitment to using advanced technology to provide outstanding lubricant products.

Fire Resistant Fluids in Power Generation

Tue, 10 Apr 2012 01:00:00 +0100

The importance of the fluid selection and maintenance is visible on the Electro Hydraulic Control (EHC) systems that are responsible for governing steam to turbine generators. Fire resistant fluids need to be used when high pressures and temperatures are present as it could lead to dangerous and expensive fires. Phosphate esters are the most commonly used fluid in EHC systems in power turbine control systems and require special maintenance and care, as opposed to mineral oils.

Fire Resistant Fluids
Fire resistant hydraulic fluids are specially formulated lubricants and are more difficult to ignite; these fluids don’t transmit a flame from an ignition source. Fire resistant must not be confused with fire proof as it will ignite under certain conditions. There are several types but can mainly be classified as: oil and water emulsions, water glycols, and anhydrous synthetics.

The International Standards Organisation (ISO) further classifies the fluid as:

HFAE - oil in water emulsions that have no more than 20 percent emulsifying oil
HFAS - synthetic aqueous fluids
HFB - water in oil emulsions that typically contain 60 percent oil
HFC - aqueous solutions of glycol and polyalkylene glycol thickener in water
HFDR - anhydrous fluids that compose of phosphate esters
HFDU - synthetic anhydrous fluids other than phosphate esters, for example polyol esters and polyalkylene glycols

Flammability Evaluation
The fire resistance of fluids is usually measured in three ways:

The ignition of pressurized fluid spray (spray flammability test).
Ignition of a fluid when sprayed on a hot surface (hot surface ignition test).
The ignition of a fluid that has impregnated porous or wick type materials (fluid evaporation test).

Additionally, Factory Mutual developed the Spray Flammability Parameter and European Economic Community developed the ‘stabilized flame heat release’, otherwise known as the ‘Buxton Test’, through the Luxembourg Report. Both of these standards use spray ignition tests and calculations for the heat rate.

Care of EHC Fluids
HDFR fluids (the phosphate esters type) and triaryl phosphates are usually used in EHC systems. These fluids require special care and maintenance. Resistivity, metals, cleanliness, and the content of water, acid, chlorine, and mineral oil need to be monitored for optimum performance.

Phosphate esters are hygroscopic, which means they have the natural affinity to absorb water, but have poor hydrolytic stability, i.e. fluid can degrade in the presence of water. In the presence of water, phosphate esters can undergo hydrolysis reactions which can lead to increasing acidity, system corrosion and/or the erosion of sensitive components. Therefore the water content and Total Acid Number (TAN) need to be closely monitored frequently.

A high fluid resistivity, or low conductivity, is necessary to avoid electromechanical erosion of the valve spool when using servo valves. Low resistivity is usually found when the fluid becomes acidic through hydrolysis or is contaminated with chlorine compounds. Chlorine contamination can result from the use of chlorinated solvents and can cause servo valve erosion problems.

The mineral oil content needs to be monitored. An excess (more than 0.5 percent) can affect the air and foam release properties whilst higher than 4 percent reduces the fire resistance and oxidation stability. Minimizing particulate contamination is vital when fire tolerance servo valves are used. Servo valves are sensitive to abrasive wear and erosion from particulates and can lead to the loss of system sensitivity and control. Particulate contamination could also impact resistivity of fluid and lead to further erosion of valve components.

Phosphate Ester conditioning
Special conditioning methods need to be followed to maintain a suitable fluid condition. This can usually be achieved with an absorbent solid filter, such as Fuller’s earth, or activated alumina in combination with vacuum dehydrators and standard particulate filters. Fuller’s earth is used to strip acids and chlorides from fluid to maintain a low fluid acid number level (this should be below 0.2 mgKOH/g). Calcium, sodium and magnesium levels should also be monitored. An excess could indicate that the particulate filters need replacing.

Vacuum dehydrators can be used to maintain the low water content and remove entrained air in the fluid. Particulate filters are used to maintain particulate levels in oil. Cleanliness is reported according to the ISO classification (ISO 4406) of fluid. Usually two filters are required to prevent particulates from damaging or blocking the servo valve components.

Fluid Condition Monitoring
A meticulous program is required to maintain a long problem-free operation. The suggested schedule of a fluid analysis test is as follows:

Viscosity at 40ºC – ASTM D445
Water Content – ASTM D6304
Mineral Oil Content
Flash Point – ASTM D2155
Auto-ignition Temperature – ASTM D2155
TAN – ASTM D664
Volume Resistivity – ASTM D1169
Cleanliness
Foaming Tendency – ASTM D892
Air Release Properties – ASTM D3427
Metals – ASTM D5185

The TAN, water content, particle contamination and volume resistivity need to be monitored monthly. The other properties can be monitored on a quarterly or semi-annual basis.

Material Compatibility
Special conditions regarding material compatibility need to be taken. Phosphate esters will soften some paints and therefore epoxy based paints should be used. It’s also not compatible with standard nitrile rubber seals and specialised seal materials should then be used. Care should also be taken when mixing different phosphate ester from different suppliers.

References

“Current Standards for Certification of Fire Resistant Hydraulic Fluids Used in General Industrial Applications”, Fluid Power Journal Jan/Feb 2006 pp. 30-36.
“Managing the Health of Fire Resistant Steam Turbine Electro hydraulic (EHC) EHC Control Oils”, Machinery Lubrication 2006
Reolube Turbofluids Guide to their maintenance and use, Great Lakes Chemical Corporation Publication

Mobil SHC Cibus Series Oils Help Reduce the Energy Consumption of Food and Beverage Operations

Thu, 05 Apr 2012 01:00:00 +0100

Premits Improve Energy Savings, Deliver Optimum Equipment Protection and Enhance Safety Initiatives

• Lab tests document energy efficiency benefits up to 3.6 percent*
• Customers experience energy efficiency benefits up to 4.3 percent
• Mobil SHC Cibus Series oils are NSF H1 registered

COLOGNE, GERMANY (28 March 2012) – ExxonMobil Lubricants and Petroleum Specialties Company, a division of Exxon Mobil Corporation, today announced that its range of NSF H1 registered Mobil SHC Cibus Series oils have the potential to help food and beverage companies achieve energy efficiency savings of up to 3.6 percent for gear oil applications*.

Ideal for the full spectrum of hydraulic, gear, bearing, circulation system and heat transfer applications, Mobil SHC Cibus premium-performance synthetic lubricants offer enhanced safety and productivity benefits alongside energy efficiency potential. Mobil SHC Cibus Series oils are NSF H1 registered lubricants and comply with Title 21 CFR 178.3570 of the Food and Drug Administration (FDA) for lubricants with the potential for incidental food contact and are manufactured in facilities that meet the hygiene requirements of ISO 21469:2006. In addition to being manufactured in equipment where cross contamination is minimised, Mobil SHC Cibus Series lubricants are formulated to nut-, wheat- and gluten free and suitable under Kosher and Halal dietary law.

“Food and beverage processors are uniquely challenged not only with maximising equipment performance and boosting productivity, but also ensuring food safety,” said Rainer Lange, Mobil SHC Brand Advisor – Europe, Africa and Middle East, ExxonMobil Lubricants and Petroleum Specialties Company. “Mobil SHC Cibus Series lubricants are expertly formulated to help food and beverage processors meet their application-specific goals and provide valuable sustainability-related benefits, such as enhanced energy efficiency and extended oil drain intervals.”

Since their introduction, customers across Europe, the United States and Asia have reported extensive benefits from using the oils. A food manufacturer operating in China, reported energy savings of up to 4.3% when it upgraded its six oil-injected dual screw air compressors from mineral lubricants to Mobil SHC Cibus 32. The 4.3% savings claimed, would result in an annual power reduction of 22,170 kWh.

A manufacturer in Germany also reported energy savings of 3.4 percent by switching to Mobil SHC Cibus Series oils. ExxonMobil recommended converting to Mobil SHC Cibus Series lubricants to help address the issue of frequent unscheduled shutdowns as a result of a compressor overheating. After flushing the screw compressor’s lubricant system and replacing with Mobil SHC Cibus 46, the overheating issue was addressed, it was reported oil life doubled and energy savings of 58,000 kWh per year were realised.

The Mobil SHC Cibus Series for gear oil applications, is the latest ExxonMobil product to earn the official designation of an “Energy Efficient” industrial lubricant and will feature the company’s proprietary “Energy Efficiency” logo on packaging.

For more information about Mobil SHC branded synthetic lubricants, such as Mobil SHC Cibus, or any other Mobil-branded products and services, visit mobilindustrial.com.

Mobil, Mobil SHC Cibus and the energy efficiency design are trademarks of Exxon Mobil Corporation or one of its subsidiaries.

* The energy efficiency design is a trademark of Exxon Mobil Corporation. Energy efficiency relates solely to the fluid performance when compared to conventional (mineral) reference oils of the same viscosity grade in circulating and gear applications. The technology used allows up to 3.6 percent efficiency compared to the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operating conditions and applications.

About ExxonMobil Lubricants and Petroleum Specialties Company
ExxonMobil is a leading marketer of finished lubricants, asphalts and specialty products, as well as one of the world's largest suppliers of lubricant base stocks.

About Mobil Industrial Lubricants
The team behind Mobil Industrial Lubricants delivers advanced products to major industrial equipment manufacturers to protect their customers’ engines and machinery, helping to enable peak performance while improving energy efficiency. This dedicated work force focuses on delivering a reliable supply of high-quality lubricants through its strong distribution network while also providing technical application expertise to customers around the world.

IEN EUROPE interviews Burkhard Busse

Tue, 03 Apr 2012 01:00:00 +0100

30 IEN EUROPE N° 9 - September 2011

IEN EUROPE interviews Burkhard Busse

Equipment Builder Engineer at ExxonMobil Lubricants & Specialties, Brussels

Getting Into Gear: Enhanced Productivity through Advanced Gear Lubrication
In an increasingly competitive marketplace, maximising productivity and reducing operating costs has never been more important. Recently, we had the chance to speak to Burkhard Busse, Europe, Africa, Middle East, equipment builder engineer from ExxonMobil Lubricants & Specialties, about how choosing the right gear lubricant can improve operators’ bottom line and help provide companies with a competitive edge.

IEN: How crucial are gears in the day-to-day running of a plant?
Busse: In gear driven operations such as metals or paper mills, processing industries and manufacturing plants, industrial gears play a critical role in maximising productivity and reducing unscheduled downtime. Critical to the successful functioning of most industrial equipment, providing the necessary torque and rotational speed for machinery to operate effectively, the performance of industrial gears are fundamental to the productivity of an operation.

Even a failure of one gearbox can cause an entire production line to ground to a halt, which can be very expensive both in terms of loss of production as well as associated labour costs and replacement parts to get the operation back on-line.

Lubricants are the lifeblood of a gearbox, helping to reduce friction and provide long-lasting protection for the rotating, sliding and moving components of a gearbox. With the associated costs of gear related downtime, we are seeing a shift by manufacturing and processing industries towards high quality synthetic gear oils such as Mobil SHC Gear, which offer superior protection and performance compared to standard mineral-based industrial gear oils.

IEN: How is the design/development of current/future gearboxes impacting the requirements of gear lubricants?
Busse: Over the years, Equipment Builders (EB) have focused on developing new, more compact and efficient gearboxes that are capable of delivering even higher load capacities. Such improvements put additional stress on lubricants in terms of higher operating temperatures, faster speeds and heavier loads. These effects are compounded by the EB’s drive to reduce total life cycle costs for their products, which includes reducing oil volume while extending oil drain intervals.

To ensure lubricants meet the very latest requirements, leading lubricant suppliers such as ExxonMobil work closely with key EBs to ensure that its products are ideally formulated to meet the rapidly evolving gear designs and operation requirements. A good example of this approach in practice is the recently launched Mobil SHC Gear series of high performance fully synthetic gear oils. Mobil SHC Gear oils have been designed in close cooperation with leading EBs to ensure they operate effectively in the latest gearboxes. Based on extensive research and testing, Mobil SHC Gear oils demonstrate excellent wear protection for gears and bearings, enhanced resistance to micropitting fatigue, improved seal compatibility, excellent oxidation stability and outstanding viscosity behaviour in extreme temperature conditions, to ensure the latest industrial gears maximise their full performance potential.

IEN: How do operators select a gear oil which will help to maximise the performance of the gearbox?
Busse: While equipment is under warranty it is important for operators to select lubricants which have been approved/recommended by the EB to ensure the cover is not compromised. However, many EBs set the minimum requirements for an oil to operate in their equipment and companies can achieve signifi cant performance advantages by selecting lubricants which surpass these levels.

By using high performance industrial gear oils, companies can increase productivity and reduce unscheduled downtime by extending oil drain intervals and reducing component wear. In addition, as well as offering superior levels of protection, the latest synthetic gear oils such as Mobil SHC Gear can also help to improve energy efficiency of applications.

To help customers select the right lubricant for their equipment, ExxonMobil recently launched Looble, an online industrial product selector which provides customers with lubricant recommendations and application guidance based on specific applications and operating conditions across a wide range of industries. Included in the selector are a wide range of gears from leading manufacturers.

IEN: What are the performance advantages of a fully synthetic gear oil versus a conventional mineral-based oil?
Busse: Higher operating temperatures, faster or even slower speeds and heavier loads are just some of the challenges facing industrial gears today. While high-performance synthetic lubricants can perform in these conditions, conventional, mineral-based fluids really cannot deliver the same level of protection and operators need to look to upgrade to synthetic lubricants to help minimise unscheduled downtime and maximise performance.

Advantages of switching to synthetic gear oils such as Mobil SHC Gear oils include longer equipment life, excellent resistance to oxidation and protection against wear, extended drain-life, energy efficiency and high-temperature capability.

IEN: How can an advanced gear oil such as Mobil SHC Gear, offer energy efficiency potential as well as maintain superior protection?
Busse: Mobil SHC Gear’s high viscosity index and low traction coefficient combine to provide a significant reduction in energy consumption in many gear drives. In statistically validated laboratory tests and field trials, Mobil SHC Gear oils exhibited energy efficiency of up to 3.6 percent versus conventional oils, delivering considerable cost saving benefits to organisations.

As well as its energy efficiency potential, Mobil SHC Gear has a balanced formulation and has been developed to offer exceptional performance in all the critical areas required to keep a gearbox working efficiently. This includes outstanding gear and bearing protection as well as excellent oxidative stability, seal compatibility, rust and corrosion protection and foam control. Only by selecting oils which have a balanced formulation can operators look towards maximising productivity.

IEN: What advice can you offer to ensure a successful switch from a mineral to synthetic gear oil?
Busse: The recommended steps for switching gear oils depends on the application, the condition of the lubricant and the gearbox and how much time is available. Where possible, we would recommend carrying out a full drain and flush on the equipment. If the oil is not in a good condition, we would recommend flushing the system two-to-three times. The general rule is to get as much of the mineral oil out of the gears as possible before making the switch - that way you will get the maximum performance out of the synthetic lubrication.

IEN: How can engineers monitor the performance of a gearbox and gear oil?
Busse: In order to help maximise gearbox productivity and reduce costs, operators should incorporate an oil and equipment condition monitoring programme alongside the use of high quality gear lubricants. As part of routine maintenance, the “health” of the lubricant and the equipment itself should be regularly checked. Typically, it is advised that maintenance professionals perform quarterly oil analyses and annual system inspections.

The oil analysis should include a measurement of chemical condition, fluid viscosity, water content, particle count and dissolved metals to determine how well the system is operating. Examining changes in the oil analysis data over time, also known as ‘trending’, is necessary to assess the condition of the lubricant. By trending oil analysis data, it is possible to proactively address undesirable conditions before they become problems.

For equipment maintenance professionals who want an effective oil analysis programme, there is ExxonMobil’s proprietary online Signum oil analysis system. Signum oil analysis offers engineers immediate access to and direct control of their lubricant sampling programme.

Beyond oil analysis, visual system inspections should be conducted regularly to check and
document the condition of the gear box. Inspection data can be used to establish the optimum time to perform maintenance on critical components such as the gear teeth. Comprehensive leak detection should also be performed, especially if excessive oil usage is noted during a routine system inspection.

IEN: Mr Busse, thank you very much for the interview.

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Turbine Oil Development

Thu, 22 Mar 2012 00:00:00 +0000

Turbine oils perform under demanding conditions and their performance has a direct impact on the reliability and profitability of a power generation operation. Lubrication failures can lead to unplanned outages, costly downtime and possible equipment damage. It’s difficult to evaluate turbine oil performance in basic laboratory tests.

The requirements of a modern turbine oil are to deal with higher temperatures, provide long service life and to ensure long-term keep-clean performance. Long-term performance can often be provided by developers using a broad suite of accelerated aging tests. The most commonly used accelerated aging test is the RPVOT (Rotary Pressure Vessel Oxidation Test), otherwise known as the ASTM D2272. Although the aging test can determine long-term performance, it wasn’t intended for the performance comparison of different oil formulations.

The ASTM D2272
The test is conducted by placing lubricant, a copper catalyst and water into a pressure vessel that has a pressure gauge. The vessel is then pressurized with oxygen until it reaches 620kpa. It’s then placed in an oil bath at 150ºC and rotated at 100rpm. The result is the time it takes for a pressure drop of 175kpa below maximum pressure to occur. When there is a drop in oxygen pressure it means that oxygen has been consumed by reacting with the oil’s components. The oxidation stability of the lubricant can be determined by the minutes taken to meet the required pressure drop. This test is useful for quality control and in-service oil condition monitoring.

The advantages of using the RPVOT are the fast results and quality comparison. The results are available within minutes whereas months or years are required for other glassware tests, such as the Turbine Oil Stability Test (ASTM D943). The quality comparison can be used on the same product or as an overall analysis program for in-services oils of the same formulation.

The disadvantages are that the RPVOT doesn’t measure the formation of oxidation by-products, test reproducibility is on average 22%, and the test conditions aren’t regular operating conditions. The RPVOT can’t measure oxidation by-products such as lacquers, sludges, varnishes and acids that can cause lubrication and control system failures. The temperatures that the test runs at are higher to accelerate the oxidation process and are often not found in most turbine applications.

The RPVOT shouldn’t be used as the sole test to compare oxidation performance, oil life or deposit resistance of different formulations.

Balanced Turbine Oils Development
Products that have balanced structures that address multiple formulations is ExxonMobil’s goal. Three goals that are of critical importance in turbine oils are: maximize the life of the lubricant; reduce the by-products formed by oxidation; and manage the inevitable oxidation by-products that develop to avoid turbine operation interference.

Multiple oxidation tests, including standard industry tests, are used to develop Mobil turbine oils. Proprietary bench tests are also conducted to ensure that balanced performance is achieved although these tests aren’t completely sufficient in developing the highest quality oils.

The Results of a Dynamic Rig Test
ExxonMobil developed dynamic rig tests that more accurately represent operating conditions than the RPVOT or other glassware tests do. This measures the overall balanced performance of a turbine oil in a system. The key criteria measured in the test are: RPVOT retention; ultra centrifuge rating; and filter and reservoir cleanliness.

RPVOT Retention
The RPVOT value of new oil does not correlate to the longevity of the oil in a system. The value can be used to monitor the depletion of oil antioxidancy over time. The common limiting value of used oil is 25% of the new oil value per ASTM.

Ultra Centrifuge Rating
This rating is designed to measure the concentration and oxidation of by-products and insolubles in the oil. The rate tracking determines the oil tendency to form oxidation by-products that lead to varnish and sludge. The scale of the rating is from 1 to 8, from best performance to worst.

Filter and Reservoir Cleanliness
The ability of the oil to resist a tendency to lay down deposits in lubrication and control systems is measured by the cleanliness of the filter and reservoir during the rig test. Clean performance allows for smooth running and a decrease in unplanned outages.

The key factor is to ensure that the oil maintains the RPVOT value whilst providing a clean operation.

Conclusion
Control of the detrimental oxidation products, and the deposits that may result, is critical to long-term performance of turbine oils. Care needs to be taken when reading the RPVOT results as comparisons for different compositions is not tested. Standard oxidation tests provide an important indication of in-use oxidation performance of turbine oils. It is vital to include product development tests that address formation and control of the by-products of oxidation and aging. ExxonMobil uses standard industry test methods (with other simulated turbine tests) to develop balanced high performance turbine oil.

Compatible and Incompatible Greases

Tue, 13 Mar 2012 00:00:00 +0000

Mixing different grease can sometimes lead to ineffective lubrication which damages components and could lead to equipment failure if not spotted early enough. This occurs due to incompatible chemical or structural interactions between the thickener or additive systems of different greases.

Incompatibility symptoms vary but most will exhibit a change in consistency. The symptoms will be more visible if the operating temperature or grease mixture shearing rate increases. Incompatible grease may also display bleeding, or abnormal oil separation, at higher temperatures. If incompatible greases are mixed in the application, it could result in oil leakage, premature aging and insufficient oil bleeds in the contacting zones. Grease’ performance additives could adversely affect the lubrication and protection against friction, wear, rust and corrosion.

Laboratory Investigations
Industry Standard ASTM D6185 establishes protocol to evaluate the compatibility of binary mixtures of lubricating greases. The test comprises of blending and shearing the two greases under controlled and identical conditions. After a short amount of time at room temperature, the grease structure is compared to fresh greases’ stability to see if there are any changes.

Three properties are evaluated in a test: dropping point; shear stability by 100 000-stroke worked penetration; and storage stability at elevated temperatures via change in 60-stroke penetration after storage. The overall assessment will determine if the greases are compatible, borderline compatible or incompatible. It’s recommended that compatible mixtures go through a secondary testing process when the need to qualify the performance level of grease mixtures is indicated. Despite all the testing, you still need to be cautious when mixing greases. The tests don’t determine if the mixture will protect seals, prevent rust and yellow metal corrosion or reduce wear under heavy loads. They also can’t predict the long term effect that could potentially occur from chemical interaction between the additives from different greases. It could result in synergies impacting the grease mixture’s ability to perform an application.

Compatibility Test Results
The true compatibility of grease is affected by field operating conditions such as shear rates, temperature, the state of the used grease and the ratio of greases in the mixture. If two greases are rated as compatible, it implies that there is a low risk of structural instability occurring, especially if the operating conditions are mild. If they are incompatible, there is a high risk that softening or hardening of the grease mixture or oil separation will occur.

When changing grease from one type to another, it’s best to fully purge out the old grease with new grease. If this can’t be done, re-lubrication frequency should be increased to allow a purge of oil grease in a timely manner. To avoid over-greasing during the purge, remove relief plugs during the first hour of operation to allow the excess grease to freely flow out of the bearing housing. The regular monitoring of the temperature, vibration and leak checks will allow for corrective measures if incompatibility is presented. The application of best practices are highly recommended if the greases being used are deemed to be not compatible.

The Breakdown of Rotary Screw Air Compressors

Thu, 01 Mar 2012 00:00:00 +0000

Rotary air compressors are a type of gas compressor that uses the rotary type of positive displacement mechanism. When it’s an oil-flooded rotary screw compressor, the oil is injected into the compression compartments to aid sealing and provide cooling. In this article we will touch on the compressor components, the lubrication process and routine checks.

Packaged air compressor units with oil-flooded rotary screw air compressors are usually self-contained and mounted on a skid base. These units are usually driven by electric motors and range in size from 25 to 450 horsepower. The compressor may be enclosed in a housing which can be accessed by removing or opening a panel to service the unit.

The Components
The components of an oil-flooded rotary screw compressor includes a housing, two screws (a male and female rotor), bearings and bearings support. The male rotor is either motor driven or driven through step-up gears in the housing. It has four lobes and drives the female rotor which has six lobes. The two rotors groove and mesh together to compress the inlet air during one of the compression stages. The compressed air is then discharged at a temperature of approximately 185ºF through the end plate port.

The related components in the compressor include the intake air filter, oil pump and inlet valve. The air filter is typically a dry tape paper filter that has replaceable elements. The oil pump is responsible for providing oil to the bearing, timing gears (present in specific models) and compressor rotors. Differential air pressure can be used as an alternative to an oil pump in certain compressors.

The control panel displays the conditions of the operations, air intake filter, air/oil separator and oil filters. The unit usually has two filters: the primary filter which all the oil has to pass through and the secondary filter which is just for gear and bearing oil.

The Lubrication Process
Oil injected into the compressor during the compression cycle lubricates the bearings, gears and rotors. It cools the compressed air and seals running clearances in the rotor housing. Oil passes through and mixes with air and then is discharged into the air/oil separator. Majority of the oil drops out due to the velocity change or impingement. The separated oil drops to the bottom of the separator filter and then returns via an oil return line back into the system.

ExxonMobil’s primary recommendation for oil flooded rotary screw compressors is the Mobil Rarus SHC 1020 series of synthetic lubricants. The ISO viscosity grades that are usually recommended are the 32, 46 or 68. Synthetic lubricants are best as they may allow extended oil drain intervals of up to 8,000 hours whereas mineral oil based compressor oils usually only extend up to 1,000 hours.

When changing the lubricant, it is very important to check the compatibility. Mobil Rarus SHC 1020 series is compatible with most mineral and synthetic compressor lubricants.

Routine Checks
The oil level of the sump needs to be checked daily and the correct oil level in the sight level gauge needs to be maintained. The control panel needs to be checked at least weekly to ensure everything is running correctly. The oil return line sight glass needs to be checked to ensure oil is being removed from the air. The synthetic lubricant needs to be changed when the oil analysis shows the need; the oil strainer should be cleaned at this time too. The used oil needs to be disposed of correctly according to the local community’s specific requirements. To maintain safety, the air compressor needs to be started and stopped according to the manufacturer procedures.

Maintaining Electric Motors

Tue, 28 Feb 2012 00:00:00 +0000

The electric motor is a crucial part of every manufacturing process. But due to its simplicity and reliability, frequent maintenance is often overlooked. If motor damage has been sustained, minor repairs are often too late. In this article, we will touch on maintenance practices, correct lubrication and common motor failures.

Motors need to be in Prime Condition
New and rebuilt motors need to be in good condition at the time of purchase. Vibration checks should reveal defects. Mechanically balanced motors should also be requested, especially if high efficiency or high speed models are being used. Acceptable motor balancing limits are set by the International Standards Organization (ISO). Motors also need to be stored correctly. The bearings should be fully packed with grease to prevent moisture from corroding the motor before installation. The motor should also be rotated by hand every month to maintain a good condition and to prevent fretting corrosion.

Replacement Bearings should be Handled with Care
If a bearing needs to be replaced, the replacement bearing should be identical to the previous one. The bearings need to be stored in their original, unopened packaging in a clean, dry location. It is best to store them horizontally and rotate them monthly. Greased bearings should be turned over regularly to prevent grease buildup on one side. Never wash bearings before installation, as the bearings are already clean.

Ensure Proper Installation and Maintenance
A bearing needs to be handled with care and must not be pounded on directly. If it falls, it is best to avoid using it. The shaft and housing of the bearing also needs to be inspected carefully for size and damage. Any obvious damage should be repaired. Overheating of the motor should be prevented. A flame must never be in direct contact with the bearing nor should it be heated over 230ºF. It is also important that the right tools be used to decrease the risk of damage. Bearings need to be installed to fit properly by applying pressure to the outer race. Uneven pressure on the ring will damage the raceways.

Better Lubrication Choices
Proper lubrication is critical for motors, as it prevents wear and protects the elements against rust. The correct lubricant will also seal out dust, dirt and waste. ExxonMobil’s industrial lubricant recommendations for electric motors are the Mobilith SHC 100 and the Mobil Polyrex EM. There are three signs that indicate improper lubrication: excessive noise, vibration and high temperatures.

Common Failures
More then 90% of motor bearing failure is due to over-greasing, which causes the seals to burst. Misalignment is another problem that leads to motor damage. The most important part is to align the tight tolerances. The bigger and faster the motor, the tighter the tolerances need to be. Dirt buildup on the motor also needs to be avoided to prevent motor damage and failure. Dirt generates heat which then impacts the bearing life negatively.

Bearings can last up to ten years, therefore frequent failures need to be questioned. If failures occur often, it may be to do with installation or lubrication problems and this will need to be investigated.

Regreasing of Element Bearings

Thu, 23 Feb 2012 00:00:00 +0000

Rolling element bearings need to be relubricated regularly to replace the grease that’s been lost through deterioration, leakage or contamination. This article will touch on when you should relubricate but there is no set time or schedule to reference. The timeframe can range from a daily to an annual relubrication.

When to Relubricate
There are many factors that influence the frequency of the relubrication process. Generally, the smaller the bearing, the faster the speed therefore less frequent grease relubrication is needed. The larger, slower bearings require it more consistently. The type of bearing also has an affect. A radial ball bearing has base intervals, whilst the cylindrical roller will be five times as frequent. The thrust-ball and roller will be ten times the regular intervals.

Operating temperatures also affect the frequency. Higher operating temperatures increase the need for relubrication due to high temperatures increasing the oxidation rate of grease. The rate doubles for every 18ºF rise above 150ºF. Grease also softens with increased temperatures which could lead to the grease leaking out of the housing. High temperature greases are therefore better to use as they can help reduce the frequency. Another frequency factor would be if the bearings were contaminated, they would need lubrication more often.

Flushing Intervals
Most rolling element bearings require the relubrication of grease between flushing intervals. This practice is best done with a low-pressure grease gun. If the seals are in good condition, the need for grease might be small and sporadic.

To begin the process, check the grease amount in the bearing. The fitting or grease plug needs to be removed to see if excess grease comes out. The bearings and seals need to be checked for excess leakage. Grease needs to be applied in small amounts at a time and it’s very important to not over lubricate.

Grease Flushing
Follow these “pressure-relief” methods that are recommended for grease flushing.

Bearings with a fitting and a drain

The lower drain plug needs to be removed and cleaned out of hardened grease and wiped clean. Pump grease into the fitting until the old oil comes out and new oil appears. If it’s safe and possible, run the machine throughout the cleaning process. Running it at operating temperatures allows the grease to expand and force out the old oil. Clean the drain plug and reinstall it.

Bearing with a fitting and no drain

If it’s safe, remove the fitting whilst the machinery is still running. The fitting then needs to be cleaned and replaced. A limited amount of grease must then be pumped into the bearing to prevent the grease seal from rupturing. Remove the fitting again and allow the machine to run for a few minutes to purge it of the old grease. If no grease comes out, the bearing is dry. Repeat the previous steps and pump grease until old grease appears. Reinstall the fitting.

Bearing with a relief-type fitting and no drain

Clean the fitting and pump grease into the bearing until grease is relieved from the relief fitting. If grease doesn’t come out after a considerable amount of pumping, the relief slot may be plugged. Remove the relief fitting and clean the slot or replace the fitting with a new one, then repeat the cleaning and pumping process. Run the equipment at operating temperatures to check for excess grease at the relief fitting.

Precautions to be Aware Of
Excess grease and dirt needs to be cleaned up from the bearing and the surrounding area. This acts as an insulator and prevents heat dissipation. Procedures need to be followed closely, especially when there are electric motor bearings concerned. Where there are hard soap deposits, flush the bearing housing with hot oil from a grease gun. All old oil must be purged before machinery operation is continued.

Danger signs such as excessive noise, vibration and high temperature are signs of improper bearing operation. Condition monitoring instruments can also be used to detect problems quickly. Proper vigilance of operations will go a long way in the bearing maintenance process.

The Technicality of Grease

Thu, 09 Feb 2012 00:00:00 +0000

Grease isn’t just a thick oil; it is made up of all different components. This article will break down what grease is about, when to use it and what happens when different grease samples are mixed together.

The Components that make up Grease
Grease is manufactured by the combination of three essential components: base oils, thickeners and additives. The base oil is the liquid and the largest component of the grease, typically making up 80 to 97% of the compound. It is a common lubricating oil and is usually mineral, synthetic or any fluid that contains lubricating properties. The viscosity may range from light (like mineral seal oil) to heavy (like heavy cylinder stock). The thickeners are any material that is combined with the base oil to produce a semi-fluid to solid substance. Lithium (being the most common), aluminium, calcium, clay and polyurea can be used alone or as a combination. Additives add special properties or enhance the existing properties of the grease. The additives or modifiers that are usually used are oxidation or rust inhibitors, pour point depressants, extreme pressure additives, anti-wear agents, lubricity-or-friction-reducing agents, molybdenum disulfide, graphite, and dyes or pigments (which only affect the colour and not the lubricating capability).

Mixing Incompatible Greases and the Consequences
An important factor to keep in mind is that mixing different grease types can result in incompatibility problems. This results from chemical interactions between the thickener or additive systems of dissimilar greases and can lead to equipment failure or damaged lubricant components. It is therefore imperative to test the compatibility of greases in a laboratory before changing from one grease to another.

When Grease is Used
Grease is often used as an alternative for a lubricant fluid when it’s required to maintain the original position in a mechanism. This alternative is especially used when frequent re-lubrication may be limited or not economically viable. The may be due to the physical configuration of the mechanism, motion and sealing type, or the need for the lubricant to perform the sealing function in the incident of lubrication loss or entrance of contaminants. The solid nature of grease represses its cooling and cleaning efficacy compared to a fluid lubricant. Other than those two elements, grease performs all other requirements a fluid lubricant fulfils.

How Grease is Graded
Consistency can be defined as the degree to which plastic material resists deformation under pressure. In grease, it’s the measure of relative softness or hardness and may indicate something of flow and dispensing properties. The consistency is measured in line with ASTM D 217 and Cone Penetration of Lubricating Grease. It is then documented with the National Lubricating Grease Institute (NLGI) grade.

The consistency is measured after the sample has been worked 60 strokes in the ASTM grease worker and is at a temperature of 77ºF. When the sample is ready, a penetrometer cone is released and sinks into the grease under its own weight and left for five seconds. The depth is then measured in millimeters and recorded. The NLGI uses a standardised numerical scale in order of increasing hardness for classifying grease consistency.The consistency is a result of the base oil and thickener ratio and not the base oil viscosity.

With this information, it will be easier to decide which fluid will be most suitable for your machinery: a grease or a lubricant.

Plant Safety Practises

Tue, 31 Jan 2012 00:00:00 +0000

To avoid injury in an industrial plant, strict safety regulations need to be adhered to. These regulations should be visible to employees at all times.

There are some safety tips to consider when handling a high pressure grease gun, as an injury from this gun is treated as a surgical emergency. To avoid injury, do not touch the nozzle of the grease gun. If an injury has occurred, seek immediate medical attention and identify the brand of the injected product. Also contact the manufacturer for further information. A body part shouldn’t be used to test the grease gun for grease flow, nor should it be used to stop a hydraulic leak. A high pressure injection can still occur from a leak and the hoses should be checked regularly for leaks or potential weak spots to prevent such injuries from occurring.

The transporting of a drum should be monitored so that it doesn’t get out of control and fall, potentially bursting or injuring someone. Two people should move a drum or a drum sling should be used. Don’t use air pressure to empty the drum as this could also result in the drum bursting. Oil leaks also need to be monitored and dealt with immediately with an absorbent drying pad. Leaks should be repaired and leaking dispensary devices should be replaced.

Machinery should be handled with care. When applying lubrication to a machine, do not do so whilst it is in operation, unless it has a central lubrication system. A worker should also never reach around moving machinery. When using a ladder, do not overextend an extension ladder. Use one that reaches to the correct height and avoid using a metal one when there is electrical wiring present. Ladders, as well as work lifts, should be frequently checked for safety violations.

Safety clothing rules should be set by the plant and adhered to. No loose clothing should be worn near machinery, whilst long sleeves should be worn around hot surfaces. Rubber gloves should also be used to avoid hazardous materials from coming into contact with the skin. Affected skin should be washed regularly to prevent rash and irritation.

Gasoline shouldn’t be used for cleaning and there should be no smoking around a plant, as these are both fire hazards. If a fire does occur, notify the plant’s emergency team and locate fire extinguishers to fight the fire. Stay upwind and avoid breathing in potential toxic smoke and fumes. Use dry chemicals, foam or CO2 extinguishing agents to fight the fire effectively. Emergency exits should be clearly identified, as should safety routes.

These points, and further safety tips of the plant, should be visible to the employees at all times to avoid any unnecessary injuries.

Synthetic Lubricants, the Superior Choice

Wed, 25 Jan 2012 00:00:00 +0000

Industrial plants choose synthetic lubricants over conventional mineral oils because they can contribute to the increased productivity of the industrial equipment and therefore decrease maintenance costs. That alone is reason enough to choose the synthetic kind.

Mineral lubricants can be traced back to crude petroleum, otherwise known as crude oil or simply crude. Crude is a complex mixture of hydrocarbons and possesses basic elements. Light gases (such as ethane, propane, methane and butane) are removed from the crude by atmospheric distillation. Gasoline and other fuels are also distilled by crude, but this results in residuum. Mineral lubricants are derived from that residuum.

Synthetic lubricants are produced by chemical reactions therefore the pressure, temperature and ratio of component elements can be carefully controlled. This results in a pure compound with maximized properties and molecules that are uniform in size. The uniform size is important as this reduces the traction coefficient (the force required to move a load divided by a load) of a synthetic lubricant. Mobil synthetic lubricants have an edge of up to 30% over mineral oils with regards to traction coefficient. The uniform molecules distribute the load easily as the molecules are all the same size therefore less force is used. A decrease in force will also result in an energy decrease.

Research shows that low traction synthetic oil reduces the power consumption by up to 5% per reduction in a spur or helical gear and up to 8% in high reduction worm gears. Energy in a gearbox is lost through movement and heat. If the temperature of the gearbox is reduced, less energy will be used to produce the same amount of work. This practice is well documented in laboratories. The decrease in temperature will then increase the gearbox efficiency, which will reduce operating costs. The component life will also be extended.

The higher oxidation stability of the Mobil SHC fluid means a longer life compared to mineral oils, even under severe operating conditions. Longer life means a decrease in maintenance, labour costs and downtime. This positively impacts the maintenance budget. The Mobil SHC synthetic gear oil usually lasts three or four times longer than a conventional mineral oil. Drain intervals are also extended which reduces waste oil and affects the budget spent on lubricants annually.

Synthetic lubricants also offer superior protection to the plant equipment and extend the component life which lowers maintenance costs, replacements costs and downtime. With such reductions in the financial department, synthetic lubricants are the choice of the future.

Common Plant Injuries

Wed, 18 Jan 2012 10:47:51 +0000

The number of injuries taking place at industrial plants has increased over the past few years. Not only does it affect the staff but it also affects the plant, as it suffers from personnel and monetary losses. Most of the accidents taking place would not have occurred had the safety regulations been adhered to. Plant employees often work alone and in dangerous environments, therefore they need to pay special attention to the safety regulations.

Different injuries need different responses, but most will need medical attention. High pressure injection hazards are also known as grease gun injuries. These injuries occur when there is an accidental injection of foreign material, such as oil or grease, into the skin. This injury should be treated as a surgical emergency. Immediate medical attention should be sought out, regardless of the appearance or size of the wound. These pressurised grease guns are mostly used in service stations, garages and industrial plants and have the velocity of a muzzled rifle bullet. The most common injury is to the hands or fingers as a result of wiping the nozzle or when the nozzle slips off the grease fitting. A worker can also be injected from a gas leak in a grease line and should avoid stopping the leak with a body part to evade injury.

There are also mechanical hazards involved with working at a plant. Drums should be transported correctly to avoid straining muscles or losing control of the drum. Oil and grease spills should be monitored as an employee could have a serious fall and it’s a potential fire hazard. Employees also need to take care when handling machinery, which needs to have safeguards, as a machinery injury could result in amputation. Metal ladders shouldn’t be used near electrical wiring as a person could be electrocuted or a fire could start.

Depending on the nature of the plant, there are different work-related injuries that need to be taken into account and prevented at all costs. And when in doubt, seek medical attention.

The Winds of Change

Thu, 12 Jan 2012 22:00:00 +0000

Wind turbines are used to convert kinetic energy into mechanical energy and can be used to produce electricity or drive machinery. It can also be used as a renewable energy source.

Wind turbines are highly engineered, sophisticated machinery that mainly operate in harsh environments. The main gearbox is the pivotal component of the turbine and therefore needs extra attention and correct lubrication.

To maximize the lifespan of the gearbox in a wind turbine, the gear oil should offer long term gear and bearing protection, excellent oxidation stability, rust and corrosion protection and have exceptional filtration capabilities. The correct oil can extend the lifespan, reduce downtime and maintenance costs, and improve productivity.

When choosing a lubricant, there are different requirements such as weight restrictions that require protection against micro-pitting and scuffing. Lubricant property retention as well as long term protection against aging is also important. Oil filtration capabilities under dry and wet conditions is critical, as is the flow ability of the oil at low temperatures and the anti-wear capability at high temperatures. Off-shore applications also need to have rust and corrosion protection against salt water.

Mobil SHC XMP 320 lubricants are engineered for the lubrication of the main and ancillary gearbox and meet the demands of wind turbine applications. In the past ten years, this lubricant has been used in over 30,000 wind turbines worldwide. The lubricant must perform well on multiple dimensions to meet the demands of wind turbine gearboxes. The Mobil lubricant offers outstanding anti-wear and load carrying properties, provides long term protection against rust and corrosion, superb filterability and water tolerance. These characteristics are what make Mobil SHC XMP 320 the product of choice for the wind power industry.

Solutions for Cement Manufacturers

Tue, 10 Jan 2012 22:00:00 +0000

Extending equipment life is a crucial requirement for cement manufacturers. The overall cost of damaged equipment, production loss and labour expenditure is due to poor lubrication. This has lead to manufacturers choosing the best overall lubricant, as opposed to the one with the lowest price.

Lubricant advances have seen the extension of equipment life and oil drain intervals. High quality, synthetic lubricants like the Mobil SHC range offer benefits that mineral oils cannot. Synthetic lubricants are the best option, as they can hold their own in severe operating conditions, such as hot temperatures, heavy loads and high pressures. The Mobil SHC 639 series of lubricants are designed to provide long-term equipment protection, oil life and problem-free operation.

The Mobil Industry Lubricants are also working with India's leading cement company, ACC Ltd, as they are struggling with ID spindle bearing failures and significant downtime. Mobil engineers suggested using Mobil SHC 100. The anti-wear and extreme pressure grease is primarily recommended for higher speed applications where reduced frictions, low wear and long service is required. The solution resulted in the bearing running for 1000 consecutive hours and a huge saving.

Zhujang Cement in China also benefited from Mobil's assistance. Due to increased product capacity, the operating temperature of bearings increased from 50ºC to 90ºC. The engineers recommended upgrading to Mobil SHC 460 synthetic grease. This grease is engineered to exceed requirements for severe applications operating at extreme temperatures. The solution increased productivity, therefore increasing savings. The full range of Mobil products aim to reduce energy cost and environmental footprints. The Mobil SHC 600 series high performance gear oils can reduce power consumption of some gearbox applications by up to 8% compared to mineral oils.

Mobil's recent development, SHC Pegasus, is a high performance natural gas engine oil created to support cement companies using natural gas operations. It optimises equipment and protection; it also maximises productivity and reduces cost by incorporating oil and equipment condition-monitoring programs to work with high quality lubricants. Oil analysis should include fluid viscosity measurement, water content, dissolved metals and a particle count to show how well the system is working. Oil analysis over time is called trending and is crucial to assess the condition of the lubricant. By trending oil data, it is possible to identify and address problems before they occur. A visual system inspection should also be conducted regularly, as well as comprehensive leak detection.

Ultimately, cement manufacturers gain an edge by investing in high quality lubricants and associated services to help achieve corporate goals.

Maintenance and Care Tips for Air Compressors

Thu, 05 Jan 2012 22:00:00 +0000

The operating costs of plants have increased substantially, making it more important to know where to reduce costs in the running of a plant. There are three basic factors in the total cost of producing compressed air in plants: power costs (65%), operating costs (25%), and asset costs (10%).

There are many different elements to ensure effective cost reduction in the plant costs. Some of those elements are:

Clean, cool inlet air
Cooler inlet air decreases the need to produce line pressure. The air intake should be located outside the plant and six feet from the ground. It should be in a dry, shaded and clean area.

Correct air filter condition and capacity
Regular readings should be taken from the installed instrumentation in the suction line between the filter and the compressor. This should be done to check for leakage or excessive restriction. A correct filter helps reduce costs through longer filter change intervals and reduced load time.

Optimum operating temperature of compressor
It is important that the correct operating temperature is maintained as an abnormally high operating temperature may result in an explosion or fire. To prevent this, maintain the temperature that was recommended by the compressor manufacturer. A proper operating temperature can also be ensured by never starting a compressor with water flow and ceasing flow when the compressor is shut down.

Correct lubricant and feed rate
Select a lubricant that has characteristics that are suited to the plant's service needs. Ensure cleanliness in the storing and dispensing of lubricants. Cylinder oil lubrication is also an important factor. Maintaining a correct feed rate protects metal surfaces, and prevents sludge and deposit build up. If the correct amount is not used, it may result in high wear rates, over heating and high oil consumption. Centrifugal lubrications also help protect bearings. If the correct oil is used it minimizes wear, resists oxidation and is able to perform with water present. When wet, a properly cooled oil is required to absorb heat caused by compression and lubricate the rotors and provide sealing. Oil-to-air or water-to-air heat exchanges help ensure a cool oil supply and minimizes carbon deposits on compressor components.

Efficient air-cooling systems
Clogged dirt restricts proper cooling. Therefore separating, trapping and draining water condensed from air is essential. Ensure that proper water draining is taking place.

Safe storage of reserve air
The air receiver is a key part in most plant air systems. It needs to be arranged in a way that will drain oil or water that is condensed from air or carried over from after-coolers. A spring-loaded safety valve needs to be installed at the receiver and tested regularly to ensure safe running.

Dry air delivered at required pressure to point of use
Maintenance costs can be spent fighting the damage caused by unwanted moisture in compressed air systems. Air is often cooled after being discharged from the compressor to remove water and decrease condensation from occurring in the air distribution system. Regular inspections ensure dry air and delivery at intended pressure.

Air line lubrications
Air line lubrications provide lubricant for devices that are run by compressed air. A lightweight oil that is easily carried by air helps operational efficiency. It is best to keep the oilers fill and replace any dirty or milky oil.

Decreased air leaks
Leaks in the air system can cause the compressor to compress more air, therefore increasing operational costs. This can be prevented by using ultrasonic leak detectors to pick them up early.

A plant using these methods should be able to reduce their operational costs, saving money and energy.

Mobil & McLaren: 11 Years of Racing & Innovation

Mon, 26 Dec 2011 22:00:00 +0000

This video tells of the 11-year-long business relationship between ExxonMobil and McLaren. It takes a look at what they've done together and the new range Mobil is working on.

Mobil SHC Gear Series Launched

Wed, 21 Dec 2011 22:00:00 +0000

ExxonMobil's new lineup of high-performance, fully-synthetic industrial gear lubricants is called the Mobil SHC Gear series. These SHC Gear Lubricants contain advanced ExxonMobil additive technology designed to provide industrial gearboxes with excellent protection against conventional wear modes, such as scuffing, and a high level of resistance against micropitting fatigue.

Mobil SHC Gear series offers the potential for improved energy efficient benefits over many gearbox applications and shows energy savings of up to 3.6% versus conventional oils in statistically validated laboratory tests*. This can translate to valuable cost savings for both plant and procurement management.

The Mobil SHC gear series' high oxidation resistance allows oil life to extend up to six times compared to standard mineral gear and bearing lubricants, especially when operating at elevated temperatures. Backed by extensive research and testing, the Mobil SHC Gear oils also demonstrate great water-handling properties, enhanced resistance to micropitting fatigue, improved seal compatibility and shear stability.

Mobil SHC Gear lubricants feature the most advanced technology so that industrial customers can reduce their equipment downtime, decrease maintenance costs and increase productivity. The Gear fluids also exceed most of the specifications by other major industries and OEMs (Original Equipment Manufacturers) for industrial gearbox applications.

*Energy efficiency relates solely to the fluid performance when compared with conventional reference oils of the same viscosity grade in gear applications. The technology used allows up to 3.6% efficiency compared with the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operation conditions and application.

Mobil SHC Pegasus Ready to Soar

Sun, 18 Dec 2011 22:00:00 +0000

Mobil SHC Pegasus is helping gas engine operators maximize productivity whilst reducing costs. The benefits of using Pegasus are oil drain interval, extended equipment life and reliability, increased equipment operating efficiency and up to 1.5% energy efficiency savings. Other benefits include reduced resource use, reduction in oil disposal costs, greater fuel efficiency and reduced emission results.

Enogex, one of the largest natural gas transmission and midstream services in the U.S., has conducted field testing using the Mobil SHC Pegasus. It was discovered that the engine ran for more than 16,000 hours without drain, whereas a regular oil change occurs every 3,000 hours. The engine parts were in excellent condition, there was minimal wear, and minimal 'sludging' carbon deposits.

Another field test showed an energy saving of 1.5%. Mobil Industrial Lubricants has been working closely with three of the biggest OEMs (Original Equipment Manufacturers) in Europe and the US, conducting proof of performance field testing with each OEM. Mobil SHC Pegasus optimizes equipment productivity and protection.

It was one of the first gas engine oil formulations to deliver real energy saving potential. Extensive independent university laboratory and field testing has taken place and demonstrates that using Pegasus reduces fuel consumption up to 1.5%.

The oil delivers increased oil drain intervals for more than 16,000 hours as opposed to 3,000 or 4,000 for conventional oil. Field tests have also taken part on older gas model engines. There was next to no 'sludging' or carbon deposits, and up to 4 to 8 times longer oil drain intervals. There are also additional products in the Pegasus range. The Mobil Pegasus SR is a high performance gas engine oil specifically formulated for the lubrication of modern, medium and high-speed four cycle engines operating on aggressive gases typically containing siloxanes where high wear or scuffing is an issue. Mobil is confident Pegasus is applicable to all natural gas engines, and can deliver significant benefits to engines regardless of the model.

Safety First: Lubricants for Food Machinery

Sun, 11 Dec 2011 22:00:00 +0000

Lubricating oils play a very important role in the smooth running of food machinery such as mixers and conveyors. The risk is that leakage may occur and get into or on the food. With that comes huge pressure on the food processing sector to minimize that risk of contamination. If contamination does occur, product has to be recalled, there are public notices, negative publicity and potential litigation. It could destroy a brand.

Contamination risk can be reduced by using appropriate food registered machinery lubricants. High quality lubricants for food machinery should meet legislative and regulatory requirements and customer needs. It should also be fit-for-purpose and show high performance. The U.S. FDA (Food and Drug Administration) manages a list of the components that are allowed in food machinery lubricants. These lubricants are specially formulated with base oils and additives that comply with FDA requirements. These approved base oils and additives have advanced with time and shouldn't affect the performance of the lubricant. The lubricant formulation then needs to be submitted to the NSF (National Sanitation Foundation) which then reviews the data and checks FDA compliance. If the submission is successful, the lubricant will be allowed to use the NSF logo on their packaging and labels. An NSF H1 label means that the lubricant is "suitable for use where incidental contact may occur between the lubricant and food". HACCP (Hazard Analysis and Critical Control Points) also help manufactures recognize high risk areas where leakage can occur.

The risk before final delivery to customers also needs to be reduced by having a robust process used to control blending, transportation and packaging. Customers are choosing more factories that are using food registered lubricants throughout the factories to minimize contamination risk. ExxonMobil offers a range of NSF H1 registered lubricants based on synthetic base oils. These oils add benefits of longer life, lower maintenance costs and potential energy savings compared to conventional oils. These lubricants can be used above and below processing line, which reduces inventory and risk. The Mobil lubricants not only help customers reduce risk if contamination occurs but also ensure maximum performance and longevity of equipment.

Mobil-branded NSF H1 registered food lubricants comply with the FDA listing, are multi purpose and offer outstanding performance. Backed by over 100 years of industry experience and expertise in lubrication, the new Mobil SHC Cibus Series oils for food machinery are specially formulated to help maximize productivity, ensure food quality, and provide high-performance lubrication for a variety of food processes, including meat, dairy, baked goods, beverage, brewery, pet food, sugar, pharmaceuticals, and grain. Mobil SHC Cibus Series lubricants that include compressor, hydraulic, and gear oils, together with the Mobilgrease FM Series and Mobil SHC Polyrex Series of greases and other Mobil-branded lubricants, have been designed for the diverse range of operating conditions found in the food processing industry. These conditions range from extreme freezing and baking temperatures to frequent high-pressure washdowns, and hot, corrosive atmospheres.

The Mobil SHC Cibus Series of colorless food machinery lubricants is formulated for food products destined for many global markets and is manufactured for use in Halal and Kosher (Parve) food preparation. It has also been specifically designed to comply with your Hazard Analysis and Critical Control Points (HACCP) planning schedules, a globally accepted systematic risk-management approach to food safety.

Thinking inside the box: Improve wind turbine operators bottom line

Mon, 19 Sep 2011 14:29:50 +0100

Every month on DNet, we bring you the latest technical information from ExxonMobil experts to help equip you with the knowledge you need to help your customers enhance productivity. This month, we speak to Michael Hawkins, Global Brand Manager for ExxonMobil’s Mobil SHC brand of synthetic lubricants, about how its flagship lubricants and application expertise are helping the wind energy sector to expand and become more cost competitive.

How extensive is ExxonMobil’s portfolio of lubricants for wind turbines?

Hawkins: ExxonMobil has been pioneering synthetic lubricant technologies for nearly half a century and has a long-standing reputation for serving even the most demanding applications, including wind turbines. Today, we have an extensive portfolio of expertly formulated lubricants that deliver exceptional, long lasting performance for wind turbine operations.

Perhaps the most recognized product is our flagship Mobilgear SHC XMP 320, a high-performance synthetic gear oil for wind turbine gearboxes. Mobilgear SHC XMP 320 is used in more than 30,000 wind turbines worldwide and is the initial-fill gear oil of choice for the majority of the world’s top 12 wind-turbine builders.

We recently analyzed more than 15,000 used-oil samples of Mobilgear SHC XMP 320 and the results demonstrated that the oil delivered superb wear protection, with few issues related to aging detected during the analysis. An easy choice for any of your customers wanting increased protection for their applications.

As well as Mobilgear SHC XMP 320, we offer a wide range of lubricants that are formulated to deliver exceptional protection for all parts of a wind turbine. Mobil SHC Grease 460WT is our premier synthetic grease for the lubrication of main, pitch and yaw bearings. It offers exceptional low and high temperature performance, structural stability even in the presence of water, false brinelling protection, excellent wear protection and rust and corrosion inhibition.

In addition, Mobil SHC 524 high performance synthetic hydraulic oil delivers exceptional performance in critical wind turbine applications, such as the hydraulic pitch control of rotor blades.

Why is lubrication such an essential component of wind turbine performance?

Hawkins: Wind turbine maintenance presents many challenges that can impact productivity. The main gearbox is the heart of a wind turbine and drives the generator. With their advanced designs and overall importance to system performance, gearboxes can be very costly to repair or replace after the warranty expires.

For example, when factoring in all expenses, replacing a gearbox for a 1.4 MW turbine can cost a company more than €400,000, including the price of a new gearbox, labour costs, crane rental and lost revenue from turbine downtime. In remote locations like offshore, costs might be even higher and after the warranty period, the operator becomes responsible for keeping the turbine running for the remainder of its service life.

For the main gearbox, as for all pieces of industrial equipment, lubrication plays a vital role in optimizing performance and minimizing downtime.

What are the key challenges facing wind turbine operators and maintenance personnel?

Hawkins: Maintaining and prolonging the performance of the main gearbox is the greatest lubrication challenge in a wind turbine. The most common cause of gearbox downtime is related to bearing failure.

Considering the variable load, speed and dramatic temperature conditions wind turbines operate under, bearings are put under a significant amount of stress. These factors, combined with improper lubrication, can result in the need for bearing replacements; if damaged bearings are not replaced promptly, significant gear damage can result.

The drive to minimize up-tower weight has resulted in compact gearbox designs which, in combination with high loads found in wind turbines with hardened surfaces, makes these gears susceptible to micropitting, which can cause numerous surface cracks. The cracks propagate at a shallow incline to the surface, forming extremely small micropits that can reduce gear tooth accuracy and lead to significant gear damage.

In addition to protecting against micropitting and other forms of equipment wear, Mobilgear SHC XMP 320 exceeds the performance of traditional oils by extending the interval between oil changes from 18 months to three years or more. Extended oil life translates into a variety of benefits, including reduced volume of oil purchases, used-oil disposal volumes, maintenance effort and lubricant-related downtime for oil changes.

Why does using synthetic lubricants versus conventional oils make such a difference in wind turbine applications?

Hawkins: The need for manufacturers to minimize up-tower weight in wind turbines has resulted in compact gearbox designs that incorporate the case hardening of the gear surfaces. Case-hardened gears exposed to unpredictable winds and loads found in wind turbines are susceptible to micropitting, and require a gear lubricant that protects against this type of wear.

The extreme conditions wind turbines are subjected to are easily endured by high-performance synthetic lubricants. By comparison, conventional, mineral-based fluids really cannot deliver the same level of protection. Upgrading to synthetic lubricants brings a number of advantages which help maximize the performance of wind turbines.

Compared to conventional mineral oils, Mobil SHC fluids can actually help to reduce energy consumption in many applications. Other advantages include longer equipment life, high-temperature capability, excellent resistance to oxidation and protection against wear. These kind of performance advantages can help customers generate significant bottom line savings and, equally important, enable them to maximize their productivity.

Besides choosing the right lubricant, what other maintenance strategies are essential for maximizing wind turbine performance?

Hawkins: Oil analysis is one of the most widely used proactive maintenance strategies for wind turbines and employs a test slate that is designed to evaluate the condition of the in-service lubricant and the condition of internal hardware. Using routine oil analysis as part of a preventative maintenance programme, maintenance professionals can extend the useful lives of

both the gear oil and the gearbox by detecting and acting on early warning signs, such as contamination or increasing wear metals.

To obtain the greatest benefit from oil analysis, it is imperative that your customers work closely with an expert lubricant manufacturer and participate in oil analysis every three to six months. Identifying trends in the data will help maintenance professionals make better informed oil suitability decisions.

Describe the importance of ExxonMobil’s partnerships with wind turbine and gearbox manufacturers?

Hawkins: A key factor in the development of lubricants is the close working relationships that our ExxonMobil scientists and application specialists have with key OEMs. Through these technology partnerships, we are able to ensure that our product offerings deliver exceptional performance and are ideally formulated to meet the rapidly evolving gear designs and operation requirements.

Thinking inside the box

Mon, 19 Sep 2011 14:06:22 +0100

Mobil SHC Gear delivers optimum protection

ExxonMobil has recently introduced a new lineup of its high-performance, fully-synthetic industrial gear lubricants to the industrial lubricants market in Europe, Africa and Middle East. Branded the Mobil SHC Gear series, these lubricants have been expertly formulated to offer a number of performance advantages over conventional gear oil chemistries; including the opportunity for customers to increase productivity and reduce operating costs.

The new Mobil SHC Gear lubricants offer valuable energy efficiency benefits across a wide range of industrial gearbox applications. In statistically validated laboratory tests and field trials, Mobil SHC Gear fluids exhibited energy savings of up to 3.6 percent compared with conventional oils*, which can translate to valuable cost savings for both plant and procurement management.

In addition, the Mobil SHC Gear series’ high oxidation resistance enables extended oil life up to six times compared to standard mineral gear and bearing lubricants, especially when operating at elevated operating temperatures. Backed by extensive research and testing, Mobil SHC Gear oils also demonstrate excellent water-handling properties, enhanced resistance to micropitting fatigue, improved seal compatibility and outstanding shear stability.

Advanced Mobil SHC technology helps customers maximize productivity

As gearbox technology continues to become more advanced, industrial customers are increasingly seeking higher-performing, long-life synthetic lubricants to protect their industrial gearbox investment. Thanks to ExxonMobil’s exceptional application expertise and close cooperation with leading Original Equipment Manufacturers (OEMs), ExxonMobil is able to ensure that its new Mobil SHC Gear lubricants feature the most advanced Mobil SHC technology to help industrial customers reduce equipment downtime, minimize maintenance costs and maximize productivity.

Representing the latest addition to our Mobil SHC brand of high-performance synthetic lubricants, Mobil SHC Gear fluids are approved by Siemens for use in Flender gearboxes and meet or exceed nearly every other major industry and OEM specification for industrial gearbox applications. Today, Mobil SHC-branded synthetic lubricants are approved for use in more than 10,000 applications and have exclusive or preferential endorsements from leading OEMs for more than 2,200 applications, spanning a wide range of industries.

*Energy efficiency relates solely to the fluid performance when compared with conventional reference oils of the same viscosity grade in gear applications. The technology used allows up to 3.6 percent efficiency compared with the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operating conditions and application.