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Aging marker reduces risks

Dow Corning - EEI : 03 May, 2007  (Company News)
The oil analysis service optimizes equipment protection by tracking the condition of Molykote brand lubricants based on comparing running oil samples with their original properties. Unlike most alternative oil analysis programs, the Integrated Oil Analysis Program from Dow Corning tells exactly how Molykote lubricants have aged and, given specific application requirements, precisely when to change them.
This prediction is possible due to unique features in the company’s lubricants and the analysis protocol. The analysis is structured to test the 6 key values of the lubricant, not just wear metals or corrosion as is typical for combustion engine programs.

The keys to the program’s success are the lubricants themselves, which contain a proprietary anti-oxidant additive that oil sample tracking identifies as an aging marker. The ability to predict the condition of the remaining oil is then possible due to the computer-driven analysis protocol, which integrates the oil-aging data with information about the lubrication performance and the typical requirements of the application. The resulting data is then translated into information that advises whether it is time to replace oil in a specific application, or continue operating the equipment with a recommended schedule for future sampling.

“And with multiple-sample tracking trend information,” says Jim Stutelberg, Molykote channel manager, “This program reduces the risk of wasting time and money by changing oil too soon, or the potential for equipment damage by waiting too long. As a result, customers get to minimize needless oil changes dictated by simplistic preventive maintenance schemes and, in so doing, help extend equipment life and reduce overall maintenance costs.”

Six Tests: Criteria to Optimize Equipment Protection, Reduce Costs

Dow Corning’s Integrated Oil Analysis Program tracks six very comprehensive, critical life-related parameters of the oil. Each report integrates analysis data of each parameter in (up to) two previous samples as well as the current sample level. Alone or in combination, the information can indicate the condition of the equipment and/or lubricants. It also can provide information that ultimately helps customers make the next fill of oil last longer and better which, in turn, helps equipment run better and longer, too.

“The bottom line is that customers get more than just a superficial snapshot of current lubricant condition. Instead, they get nothing less than actionable lubrication management information to optimize their equipment protection while minimizing lubrication costs. No other single oil analysis service is nearly as comprehensive,” explains Stutelberg.

Six tests conducted under Dow Corning’s Integrated Oil Analysis Program include:

Antioxidant level, to indicate general aging of the lubricant, by tracking amounts of a sacrificial component.
Total acid number (ASTM D-974), to track levels that can cause oxidation of the fluid. It is a key indicator of lubricant condition.
Particle count, to monitor system cleanliness, and how well filters are working.
Water, to measure levels of this key contaminant in parts-per-million (ppm).
Metals analysis, to detect typical machinery wear and monitor additive metals
Kinematic viscosity, to watch this key “aging” indicator as a reflection of lubricant condition. An increase in viscosity is associated with lubricant aging.

Lubrication Management Software
The Integrated Oil Analysis Program supports Lubrication Management Software, also available from Dow Corning. Lube-ItTM management software and SurveyViewTM data base software, by Generations Systems, help customers achieve significant savings by enabling them to automate their lubrication management process. This state-of-the-art software tracks and schedules thousands of lubrication operations to ensure accurate, cost-effective maintenance of plant lubrication. It does so by helping customers optimize lubrication routes and schedules, and by keeping records and procedures on every lubrication point in their plant, or multiple plants. In so doing, this software provides lubrication maintenance crews with the critical information they need, when they need it, and in virtually the most reliable, cost-effective manner possible.

Total Lubricaton consolidation
The Oil Analysis service and the lubricaton managemenet software are part of the Molykote brand Lubrication Management Program, also from Dow Corning. The Program offers a comprehensive package of lubricants and related services designed to help customers reduce overall maintenance costs, extend equipment life and simplify the purchasing process by consolidating all lubrication-related purchases with one company. It features the introduction of 42 new industrial fluids that are marketed under the Molykote brand name, the oil analysis service, and the lubrication management software. They complement the company’s traditional line of Dow Corning brand industrial lubricants and related services that meet virtually every plant lubrication need.

With the addition of its new line of Molykote fluids to its line of Dow Corning brand industrial lubricants, the company says it now offers the most complete selection available to meet virtually every industrial plant lubrication requirement. The selection includes synthetic and ultra-high-purity mineral-oil fluids, specialty lubricant compounds, greases, pastes, anti-friction coatings, and dispersions

A company that consolidates with this product and service package may typically expect to achieve six categories of benefits, including:

Better return on capital investment through longer machine life
Improved overall productivity through extended fill intervals
Streamlined inventory through elimination of items with similar properties
Better preventative maintenance through integrated oil analysis
Better equipment performance through selection and quality of lubricant, and
More effective maintenance management through better informed decision-making

The package of Molykote and Dow Corning brand lubricants and services is being offered as a comprehensive lubrication consolidation program through Dow Corning’s channel partners, which have over 3,000 field locations.

Dow Corning currently offers more than 7,000 products to customers around the world. The company is a global leader in silicon-based materials with shares equally owned by The Dow Chemical Company and Corning Incorporated. More than half of Dow Corning's sales are outside the United States. Molykote has been a well-known brand for industrial lubrication throughout Europe and Asia since the 1950s.
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