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Power Generation at Coal-Fired Plants Asset Reliability Solutions Does your lubricant supplier do all of this? If your lubricant supplier does not provide the products, services POWER and results listed below as part of its lubrication reliability program, perhaps it is time to change suppliers. ✓ Professional, onsite equipment reliability assessment GENERATION ✓ Comprehensive lubricant line (industrial oils, engine oils and greases) at Coal-Fired Plants ✓ Web-based oil analysis, with results reviewed by experts ✓ Storage systems, including stackable bulk units ✓ Visual identification, including tags, labels, color-coding and wall charts ✓ Handling and transfer equipment, including portable transfer containers, clear grease guns, grease pumps and lube reels ✓ Single- and multi-point automatic grease lubricators and lubricating systems ✓ Contamination exclusion and removal tools, including oil reservoir sight glasses, desiccant breathers and filtration equipment ✓ Local, factory-trained specialist available 24/7 Monolec®, Pyroshield®, Duolec®, Almasol®, Quinplex®, Almagard®, Multilec®, Synolec®, L-X, Monolec Ultra®, Wirelife®, and Monolex® are registered trademarks of, and ≈tract™, Xamine™, Equipower™, and Full Torque™ are trademarks of Lubrication Engineers. LI10012 10-11, rev. 6-21 1919 E. Tulsa • Wichita, KS 67216 • Fax: 800-228-1142 www.LElubricants.com • 800-537-7683 Available Worldwide www.LElubricants.com • 800-537-7683 LE operates under an ISO 9001 Certified Quality System. Suffering points got you down? Keep equipment up & running with LE’s comprehensive approach. Operators at coal-fired power plants must keep all of their equipment operating as efficiently as possible under harsh LE Solutions conditions such as high operating temperatures, heavy loads, Implementing a comprehensive approach with the 24/7 operation and dusty, hot environments. Any downtime following solutions will extend the life of your lubricant is costly and can lead to an interruption in power supply, so and equipment by two to three times. the proper care of critical equipment is of utmost importance. We’ve identified three of the most common suffering points, Duolec® Industrial Gear Oil along with specific problems associated with each and our • Lowers operating temperatures Before: This pinion gear from After: After a seamless conversion • Reduces wear on gears recommended solutions. Implementing a comprehensive Before: A major oil manufacturer’s turbine oil in the reservoir of a power a scrubbing unit limestone to LE’s Pyroshield Syn Open Gear • Improves efficiency approach with these solutions will enhance the performance plant’s steam turbine shows significant foaming. Unable to remove all the processing ball mill is coated Lubricant, the same pinion is clean and extend the life of your lubricant and equipment. water caused by a damaged steam seal, the operator had to hire a vendor with a thick accumulation of and easy to inspect for condition with a costly vacuum dehydration system to try to do the job. Continued traditional asphaltic open gear and wear. Pyroshield is much easier Xtract™ Standard Filter Cart lubricant. This type of lubricant problems led to two oil changeouts. to apply, contain and dispose • Removes contaminants Steam Turbines & Boiler Feed Pumps is a housekeeping nightmare and of than traditional open gear makes it very difficult to inspect • Filters out big particles with a course filter, then Problems lubricants. the gear for wear. smaller particles with a fine microglass filter Water contamination, oxidation, thermal degradation • Keeps oil & oil reservoir clean • Foam, rust, varnish & sludge • Additive depletion Xamine™ Oil Analysis • Reduced lubricant performance LE Solutions • Routine oil analysis recommended monthly • Corrosion Pyroshield® Syn Open Gear Lubricant • Monitors for contaminants • Decreased equipment efficiency • Reduces gear temperatures • Determines need for additional filtration or • Shortened life of lubricant & equipment After: The same reservoir shows very little foam after the plant switched to LE’s specially formulated Monolec Turbine Oil, despite the unit running • Withstands high-load, heavy-shock applications with equipment maintenance with approximately 30 gallons of water intrusion per day. Using an in- exceptionally high film strength LE Solutions house centrifugal purifier, the operator is able to remove the incoming • Appears translucent in use, enabling visual inspection Monolec® Turbine Oil water. Testing indicates the oil is still in good condition after four years • Clings to metal without accumulating • Separates readily from water with this difficult operating condition. - Lowers lubricant consumption • Provides excellent resistance to foaming Note about oil color: Since the time of this conversion, LE has removed - Requires less maintenance & housekeeping • Imparts superior rust protection the red dye from its formulation. Monolec Turbine Oil is now light amber • Can be applied manually or through automatic spray systems • Resists formation of varnish & sludge in color, which allows greater visibility and improves condition monitoring • Contains no lead or heavy metals • Provides long-term oxidation resistance & thermal stability during turbine oil analysis. - Can be disposed of like any other nonhazardous • Enhances wear-reducing properties without petroleum oil affecting R & O inhibitors • Can be filtered for long-term use Ball & Rod Mills Seamless onsite conversion process Xtract™ Sight Glass Used for crushing and grinding coal or limestone, these • LE provides expert assistance • Enables visual inspection of oil are typically horizontal mills with large open gears. • No expensive shutdown required Xamine™ Oil Analysis Problems • Determines need for additional filtration, water removal Damage to equipment or equipment maintenance • Gears running hot Bowl Mills Used for pulverizing coal, these are typically vertical • LE’s routine oil analysis program recommended monthly • Premature gear degradation & failure Vertical bowl mills used for For bowl mills, LE recommends a mills with enclosed gears. - Monitors for contaminants pulverizing coal require a lubricant filterable oil and a high-flow, high- Ineffective lubricant Problems solution that will help them run capacity filtration device such as • Full turbine oil analysis (TOA) recommended efficiently and reliably in a dusty, this Xtract™ Standard Filter Cart. periodically, depending on condition of oil • Lack of translucency prevents visual inspection of gears Strenuous operating demands & harsh environment with strenuous - Monitors for all factors that can affect performance • Excess lubricant usage dusty, harsh environment operating conditions. & lifespan of oil & equipment • Difficult to apply with automatic systems • Excessive load - Includes rust, oxidation, varnish, foaming, viscosity, • Frequent relubrication and cleanup required • High temperatures air release, water separation & more • Environmental concerns, including costly disposal • Particle contamination Equipment Reliability Handling & Transfer Assessment Keeps lubricants Maximizes equipment life, contamination-free and keeps reduces downtime, consolidates equipment properly lubricated lubricant inventory for optimum performance • Professional onsite Storage • Transporting, pumping and assessment of all dispensing equipment equipment requiring • Customizable automatic lubrication lubrication systems • Detailed recommendations • Single- or multi-point grease for lubricants, application Oil Analysis lubricators methods, usage amounts (LEAP & TOA) • Clear Grease Guns with and drain or lube intervals color-coding options • Also recommended: • Color-coded grease fitting solutions for transfer, Enhanced Lubricants protectors contamination exclusion, • Color-coding and ID tags to contamination removal, prevent misapplication and education and training Protect Your cross-contamination Equipment Reliability Contamination Enhanced Lubricants Assessment Reduce friction and wear, Exclusion & Removal enabling equipment to operate EQUIPMENT Protects and enhances longer and more efficiently performance of valuable • Technologically advanced Lubrication Engineers will work closely with you to lubricants and machinery oils and greases with LE’s learn about your specific equipment and lubrication • Desiccant breathers for • Proprietary, high- needs. Only then can we create an effective lubrication absorbing moisture and performance additives Full Circle reliability program that will provide the equipment preventing particulate • Selected to meet needs of ingestion protection and enhanced profits you are seeking. • Adapters and quick connect specific applications of Reliability couplers for preventing This starts with an onsite assessment of contamination at drum and Oil Analysis all equipment requiring lubrication. equipment level Establishes optimum drain Starting with A trained, local LE lubrication • Mobile and stationary intervals and detects wear consultant will provide you with a filtration carts for achieving or contamination before it detailed report recommending lubricants, oil’s ISO cleanliness target damages equipment our enhanced • Sight glasses for monitoring • Xamine Oil Analysis for application methods, usage amounts, and oil levels, inspecting oil and routine monitoring of oil lubricants drain or lube intervals. In addition to LE’s removing water and equipment comprehensive line of premium lubricants, • Color-coding and ID tags to • Xamine TOA for periodic your LE consultant can offer you all of
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