ntm corp: mobil shc presentation on power cost reduction using mobil shc - customer deck 120330
DESCRIPTION
Presentation on power cost reduction using Mobil SHC Industrial Lubricants as part of the offer on value proposition. NOTE: This contains parts of the standard Mobil SHC presentation decks.TRANSCRIPT
Where industrial productivity begins.TM
1
Industrial Synthetics
Mobil SHC:
Energy Efficiency
kasjacaNTM Corp 2012
2
Where industrial productivity begins.TM
Content Overview
• Industrial Maintenance Budget
• Energy Efficiency Management
• Opportunities for Mobil SHC
• Seven (7) advantages of Synthetics
o Advantage in Focus
• Engineering Activity on Energy Efficiency
o Methodology
o Tools
o Benefits Presentation
• Mobil SHC Lubricants for different applications
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Where industrial productivity begins.TM
Percentage Breakdown of an Industrial Maintenance BudgetSource: Society of Tribologists and Lubrication Engineers (www.stle.org)
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Where industrial productivity begins.TM
Breakdown of the labor and materials in an Industrial Maintenance Budget
Percentage Breakdown of an Industrial Maintenance Budget
Portions of the maintenance budget directly influenced by plant lubricant practice
Source: Society of Tribologists and Lubrication Engineers (www.stle.org)
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Where industrial productivity begins.TM
Energy Cost – A New PerspectiveSource: http://www.machinerylubrication.com/Read/214/lubricant-enery-savings
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Where industrial productivity begins.TM
Builder recommendation
Significant component failures and unplanned equipment shutdowns
Extreme temperatures
High load, high or very low speed
Short oil drain intervals
Short grease re-lubrication intervals
High energy consumption
High spare parts consumption
Environmental issues (less waste oil)
Risk of food contamination
Opportunities for usage of synthetic lubricants
Mobil SHC vs. Mineral Lubricants
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Where industrial productivity begins.TM
7 Advantages ofSynthetics
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Where industrial productivity begins.TM
1) Excellent viscosity/temperature properties and shear stability
2) Good low temperature property
3) Good high temperature oxidation and thermal stability
4) Low volatility
5) Good Traction property
6) Compatibility with mineral oils
7) Longer oil life
Seven (7) advantages of Synthetics
High Energy Consumption
Short Drain Interval
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Where industrial productivity begins.TM
Advantage in Focus:#7 – Longer oil life – up to 6 times better than mineral oil
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Where industrial productivity begins.TM
Monitoring of Oil Condition – Signum Oil Analysis Program
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Where industrial productivity begins.TM
• In today’s industry, condition-based maintenance practices have gained widespread acceptance.
• Key industry leaders increasingly realize that oil analysis is a critical component in any equipment monitoring program.
Condition – Based Monitoring
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Where industrial productivity begins.TM
FlexibilityPerform many tasks more efficiently with Signum Oil Analysis online capabilities.
ExpertiseThrough global Original Equipment Manufacturer (OEM) relationships and hands-on lubrication experience, ExxonMobil supports your maintenance activities.
QualityMake decisions with confidence by leveraging the quality assurance offered by ExxonMobil.
Informative reports on the condition of lubricants and equipment
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Where industrial productivity begins.TM
1. Establish Goals and Metrics
2. Obtain Management Commitment
3. Train and Educate Personnel
4. Identify Equipment and Sample Frequencies
5. Implement the Program
6. Respond to the Analysis Results
7. Measure Program Results Versus Goals and Metrics
8. Review and Modify Program
9. Document Savings
Steps to Establish and Maintain a Successful Oil Analysis Program
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Where industrial productivity begins.TM
General Approach on Monitoring of Oil Condition
TrialRunning Hours (RH)
0 2000 4000 6000 8000
1 S S/C
2 S/C
3 S/C
4 S/C
Legend:• S – Oil Sample taken for analysis• C – Oil Changed as part of maintenance
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Where industrial productivity begins.TM
Advantage in Focus:#5 – Good Traction Coefficient
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Where industrial productivity begins.TM
Under conditions of an EHL contact energy is required to shear the lubricant film
Traction coefficient is a measure of this energy
Traction coefficient depends on molecular shape
Some synthetics have significantly lower traction coefficients than mineral oils
Traction coefficients
Good Traction (Friction) Properties5
Mineral oil
Synthetic oil
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Where industrial productivity begins.TM
Focus on Advantage #5 – Good Traction Properties
Synthetic Oil
Mineral Oil
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Where industrial productivity begins.TM
Good Traction (Friction) Properties5Mobil SHC 600
Sump Temp 75C
Efficiency 76%
Incr
easi
ng
tem
per
atu
re
Note: Results can vary slightly from batch to batch
Competitive Synthetic runs hotter than the mineral oil product & nearly 8C hotter than Mobil SHC 600
Mineral
82°C
74%
82C
74%
Competitive Synthetic
83C
74%
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Where industrial productivity begins.TM
Mineral Grease, MAX Temp = 58C (136F) Mobilith SHC, MAX Temp = 44C (111F)
Good Traction (Friction) Properties
Thermographs of FE-8 test rig bearing
Lower traction builds a better film, leading to lower bearing temperatures
5In
crea
sin
g t
emp
erat
ure
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Where industrial productivity begins.TM
Mineral
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0 5 10 15 20 25 30
%Slide-Roll Ratio
Trac
tio
n C
oef
fici
ent
1. Start of meshing cyclePositive sliding
Pressure
1
Traction in Meshing Gear Teeth
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Where industrial productivity begins.TM
Mineral
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0 5 10 15 20 25 30
%Slide-Roll Ratio
Trac
tio
n C
oef
fici
ent
2. Pitch lineZero sliding
Pressure
2
1
Traction in Meshing Gear Teeth
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Where industrial productivity begins.TM
Mineral
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0.08
0 5 10 15 20 25 30%Slide-Roll Ratio
Trac
tio
n C
oef
fici
ent
1 3
2
1. Start of meshing cyclePositive sliding
Pressure
2. Pitch lineZero sliding
Pressure
3. End of meshing cycleNegative sliding
Pressure
Traction in Meshing Gear Teeth
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Where industrial productivity begins.TM
Mineral
Mobil SHC
1. Start of meshing cyclePositive sliding
Pressure
2. Pitch lineZero sliding
Pressure
3. End of meshing cycleNegative sliding
Pressure
Mobil SHC saves energy over most of the meshing
cycle
0.08
0
0.01
0.02
0.03
0.04
0.05
0.06
0.07
0 5 10 15 20 25 30%Slide-Roll Ratio
Trac
tio
n C
oef
fici
ent
1 3
2
Traction in Meshing Gear Teeth
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Where industrial productivity begins.TM
Good traction properties improve lubrication
Good Traction Coefficient means..
..lower friction between oil molecules,
..lower energy losses due to friction in lubricated components,
..lesser work on motors driving the equipment,
..lower power consumption on the equipment!!
which leads to..
which leads to..
which leads to..
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Where industrial productivity begins.TM
0.0
2.0
4.0
6.0
8.0
10.0
Laboratory Tests Gear Manufacturer's Tests Users' Experience
2.2%
5.6%
7.7%
3.8%
4.4%
8.8%
2%
6% 5.8% 6%
Bo
sto
nG
ea
r
Du
ran
d G
ea
r
Co
ne
Dri
ve
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ar
Hu
b C
ity
Co
ne
Dri
ve
Win
sm
ith
Div
isio
n o
f U
MC
In
du
str
ies
, In
c.
Tex
tile
Co
.
Fo
od
Pro
ce
ss
ing
Co
.
Ste
el
Co
.
Ste
el
Co
.
Good Traction (Friction) Properties
Lower traction coefficient results in reduced energy consumption
Percent increase in efficiency (2% to 8.8%)5
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Where industrial productivity begins.TM
Good Traction (Friction) Properties5
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Where industrial productivity begins.TM
2%350
820
Previous w/ SHC 6XX Previous w/ SHC 6XX
1 Equipment 01 23,380.0 22,912.4 3,740.80 3,665.98 74.82 26,185.60 2 Equipment 02 17,976.0 17,616.5 2,876.16 2,818.64 57.52 20,133.12 3 Equipment 03 14,980.0 14,680.4 2,396.80 2,348.86 47.94 16,777.60 4 Equipment 04 16,716.0 16,381.7 2,674.56 2,621.07 53.49 18,721.92 5 Equipment 05 14,800.0 14,504.0 2,368.00 2,320.64 47.36 16,576.00
TOTAL 98,394.24
Power Consumption (W) Power Cost / Day Savings /
DayAnnual Savings
Target Savings
Working Days / Year
Power Cost / KW-Hr
Average RH/Day
# Equipment ID
Conservative only at least 2% reduction from the information shown in the previous slide..
Each of the 5 subject equipments is driven by a 440-V DC Motor with an average Current of around 70 Amps running at the indicated operating conditions.
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Where industrial productivity begins.TM
Methodology
1) Gathering of baseline information. Equipments in subject (Brand, Make, Model, Capacity, Maintenance Background, etc..) Maintenance logs, records, maintenance methods and systems.
2) Focus on the Power Equation (P = V * A) This equation is simple but reliable as Current directly affects Power while Voltage,
though fluctuates, can be considered constant. Note that we need to specify if the electric motor to be tested is a DC or AC motor, DC
Motors are best used for this test. This is to eliminate Power Factor Correction, and results can be taken as calculated. This will make our evaluation easier yet reliable.
3) Gather initial values from the existing equipment BEFORE changing to our SHC. This will be
used as baseline data/values. NTM to request verification and acknowledgement of the initial figures customer personnel. We will refer our proposal to these figures.
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Where industrial productivity begins.TM
Methodology
4) NTM to present the proposal as shown in Slide 17.
5) AFTER the oil is changed to Mobil SHC, monitor Current values at the same times as when the initial values were taken. (i.e., 8AM? 10AM? 2PM? 4PM?, 2x/day? 3x/day, etc..)
6) Plot the values gathered using the same template as the proposal then compute for the new efficiency.
7) Plot the values gathered using the TCO / UCP Templates to show the benefits gained.
8) Present formal report of the documented benefits.
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Where industrial productivity begins.TM
1) Some equipments have their own Power Meters to be attached on their equipment for specific purposes.
2) Some equipments will indicate Voltage and Current values in its monitor/panel.o Atlas Copco compressors are examples of these. Some
even store values in its memory for monitoring purposes.o Other refrigeration compressors have these features
3) Another reliable tool is to use a Clamp Meter for directly reading Current values.
Tools for measuring important parameters
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Where industrial productivity begins.TM
Presentation of Documented Benefits
1) Annual Maintenance Cost of:
Lubricants Consumption
Energy Consumption
Parts Replacement
Labor Cost
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Where industrial productivity begins.TM
Application Product Series / NameAvailable
ViscositiesRemarks
Worm Gears Mobil Glygoyle 460 460Brass and Bronze metallurgy
Enclosed Gears Mobil SHC 60068, 150, 220, 320, 460
Enclosed Bearings Mobil SHC 60068, 150, 220, 320, 460
Open Bearings Mobilith SHC 220
Air Compressors (Screw) Mobil Rarus SHC 1026 68
Air Compressors (Reciprocating)
Mobil Rarus 827, 829 100, 150
Refrigeration Compressors Mobil Gargoyle Arctic SHC 226E 68
OK for Ammonia and Hydrocarbon Refrigerants
Mobil SHC Products for different industrial machinery applications
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Where industrial productivity begins.TM
The cost of the Right Oil is not the real cost of Lubrication