2019-01-10
Grease Lubrication
of MOV Components
MOV Users’ Group Meeting
Desert Springs, CA, January 14-16, 2019
Ken J. Brown, Eco Fluid Center (Canoil)
Richard Wurzbach, MRG Labs
Domingo Cruz, Palo Verde GS
Why is this important?
First, for early failures many equipment and particularly
bearing failures are easily preventable!
Preventing them requires better information about
how to lubricate, what to use, how often and how to
monitor them.
Unfortunately, for a variety of reasons new
technologies are slow to be accepted, training is
inadequate and corporate practices tend to focus on
penny control and immediate benefits. It is also
becoming very difficult to get good intel.
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2019-01-10
How Are We Doing?
Rolling Element Bearings
Note:
Only 3%
reach
their
design
life!
According to SKF (bearing manufacturer)
contaminants cause 50% of bearing failures.
Do We Design Correctly?
Ball Bearing Fatigue Lives - Now
New life theory (ISO 281:2007) takes into account the viscosity
ratio of actual vs. required, type of bearing, type of loading and
cleanliness of the oil.
Lnaa = a1 aISO(C/P)3
Lnaa = adjusted rating life in millions of revolutions
a1 = life adjustment for reliability (i.e. 10% failure)
aISO = life adjustment factor based on new life theory
C = Basic load rating
P = Equivalent dynamic bearing load
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2019-01-10
Rolling Element Bearings Lives - Now
Life Modification Factor aISO
Among other things considers the influence of: Note:
• Fatigue limit of the bearing material by the Using
fatigue load limit C. lube as
• Grade of contaminations by the factor ec. supplied
• Lubrication conditions by the viscosity ratio K. can
Note: ISO 281:2007 does not cover the influence of wear, corrosion and reduce
electrical erosion on bearing life. life by
50%!
Ref: [Link]
What to use?
• Right consistency
• Right additives
• Right amount/level
• Right cleanliness
• Right procedures
• Right monitoring
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2019-01-10
Note:
Grades
increase
by ~50%
Ref: 2013 PC Lube Handbook
Grease Stiffness Grades
NLGI Grade Penetration
000 445-475
00 400-430
0 355-385
1 310-340
2 265-295
3 220-250
4 175-205
5 130-160
6 85-115
Note: The grade has nothing to do with quality.
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2019-01-10
Greasing Bearings
Note: There are many
different
configurations. How
to grease and how
the grease gets
purged must be
understood.
Volumetric Grease
Relief Port
‘Normal’ Temperature Rise
Note:
Lubricators need
to communicate
Possible Alarm
Level 2x Typical with operators.
Do not raise
temperature
limits or use less
than required
grease amounts.
Ref: Harris, A.F., ‘The Lubrication of Rolling Bearings’, p. 118, Shell Int’l
Petroleum Co. Ltd., 1972
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2019-01-10
How Do You confirm “When”, or measure
grease or equipment condition?
Now getting a grease sample is just as easy as an oil
sample. Just screw in place of the drain, or use a
handle that allows you to extract from the “live zone”
MRG Grease Thief
Grease Quantities – as a ‘guesstimate’
Note: Also
For replenishment from the side of a bearing;
check the
Gp = 0.005 D B manual
and take
For through the bearing outer or inner ring; into
account
Gp = 0.002 D B any
lessons
learned.
Gp = grease quantity, g
D = bearing outside diameter, mm
B = bearing width (thrust bearings use height H), mm
Ref: SKF 2007
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2019-01-10
Regreasing Amount Example
6316 ball bearing; ID 80, OD 170 mm Width 39 mm
It should get about 0.005 X 170 mm X 39 mm
= 33 g (1.2oz) of new grease.
With the 70MPa (10,000psi) high pressure grease guns often
used, this can require 43 strokes.
Note: Verify delivery rate of the grease gun being used. Pump
into a paper cup or onto a paper towel. Density of grease is
about the same as water. In this case 33 g ~ 33 ml or 1/8 cup
Can you afford not to do it?
Make it easier to do it right
Provides for pressure- Coloured grease fitting
specific shut-off (for caps
example, 20 psi). At the
$0.20 each
given shut-off pressure,
the grease flow will stop.
$0.35 each
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2019-01-10
Can you afford not to do it?
Make it easier to do it right
Example of ultrasonic set-up on a grease gun. Add
grease until reading starts to drop.
Ref: [Link]
Can you afford not to do it?
Make it easier to do it right
[Link]
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2019-01-10
SMB Internals
SMB Grease Volumes and Weights
Actuator Size Approximate Approximate
Volume Weight
Gal L lb kg
Note: This is
SMB /SB/SBD-000 0.5 1.9 3.5 1.6 valid for
SMB /SB/SBD-00 1.0 3.8 8.5 3.8 MOV Long
SMB /SB/SBD-0 1.5 5.7 12 5.4 Life Grade
SMB /SB/SBD-1 2.1 7.9 17 7.7
0. The
SMB /SB/SBD-2 3.0 11.4 24 10.9
SMB /SB/SBD-3 6.0 22.7 50 22.7
weights are
SMB /SB/SBD-4 9.4 35.6 75 34.0 more than
SMB-4T 8.7 32.9 70 31.8 for Nebula
SMB-5T 10.0 37.8 80 36.4 EP used
SMB-5 11.2 42.4 90 40.9 until 2002.
Ref: Limitorque FCD LMAIM1401-00 (Replaces 140-11000) 2004
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2019-01-10
How Often ?
The following lubrication inspection schedule is
recommended until operating experience indicates
otherwise.
• Main Gear Case Inspect lubrication every 18 months or
500 cycles whichever occurs first.
• Geared Limit Switch Inspect lubrication every 36
months or 1000 cycles whichever occurs first.
• Drive Sleeve Top Bearing Lubricate every 6 months
through housing cover pressure fitting.
Ref: Limitorque FCD LMAIM1401-00 (Replaces 140-11000) 2004
SMB How Much?
SMB and SB actuators are built to operate on the
immersion principle.
CAUTION: Ensure there is enough lubricant so that
the Worm and the Worm Gear are totally immersed
in grease regardless of the
position. Use the “fill” and “drain” plugs provided on
the actuator housing to verify this.
Ref: Limitorque FCD LMAIM1401-00 (Replaces 140-11000) 2004
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2019-01-10
SMB How Much?
But there is
more to
greasing!
Follow
reassembly
instruction.
For
example,
bearings
should be
hand
packed.
Ref: Technical Repair Guidelines for Limitorque Model SMB-00
Valve Actuators, EPRI NP6631 R1s, June 1995
SMB Where?
Ref: Technical Repair Guidelines for Limitorque Model SMB-00
Valve Actuators, EPRI NP6631 R1s, June 1995
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2019-01-10
Some nice colors but how did they perform?
OEM Requirements
Requires the following lubricant qualities as a minimum.
The lubricant must:
• Contain an “EP” additive.
• Be suitable for the temperature range intended.
• Be water and heat-resistant and non-separating.
• Not create more than 8% swell in Buna N or Viton.
• Not contain any grit, abrasive, or fillers.
• Comply with Slump-prefer NLGI grades 00 to 1.
• Not be corrosive to steel gears, ball or roller bearings, or
yellow metals (bronze, brass, or copper alloys).
• Have a dropping point above 316°F (158°C) for temperature
ranges of -20°F (-29°C) to 150°F (66°C).
Ref: Limitorque FCD LMAIM1401-00 (Replaces 140-11000) 2004
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2019-01-10
Where not to Grease
Where are the Savings?
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2019-01-10
Stem Nut Wear
David Przyjemski, Susquehanna,
INSPECTION & MONITORING OF MOV
STEM NUT THREAD WEAR, January
2008, Orlando, Florida
• Inadequate lube of MOVs stems led to failures, NRC INFORMATION
NOTICE 2010-03:FAILURES OF MOTOR-OPERATED VALVES DUE TO
DEGRADED STEM LUBRICANT
• Five MOV stem lubrication events
• Commanche Peak 2011 failure due to lack of lubrication from valve stem
inaccessibility
David Przyjemski, Susquehanna, INSPECTION & MONITORING OF MOV STEM
NUT THREAD WEAR, January 2008, Orlando, Florida
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2019-01-10
Timken ‘Okay’ Loads
kgf lb
MOV Long Life Grade 0 24.9 55
Grade 1 27.2 60
Grade 2 27.2 60
MOV Extra Grade 0 22.7 50
Grade 1 25 55
NEBULA EP0 21 45
EP1 21 45
Mobilgrease 28 5.4 12
An EP grease is generally 15 lbs minimum!
Stem Thief
• Stem protector removed and
pipe-to-straight thread adapter
installed
• Relubricator is solid aluminum
body with O-ring to mate to top
of stem nut
• Zerk fitting works with high
pressure grease gun to pump
grease through nut, displacing
old grease and applying a new
layer to threads.
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2019-01-10
StemThief - Palo Verde
• August 2014: 1 SMB-00 Stem Thief was initially purchased for evaluation
and testing. December 2014: 2 additional SMB-00s. February 2015: 3 SMB-
3s.
• 18 short stroke SMB00’s within the HPCI system, (89-10 valves). If COF
trend +/- Stem Thief is used instead of pulling stem nuts.
• StemThief allows testing and restoration in a 2 hour LCO window. Not
possible to pull stem nut in that time.
• 12 to 15 BOPs with short stroking globe valves with no accessibility to the
stem/stem nut interface. StemThief eliminates need to pull stem nuts and
MG.
• Plans in place to increase the scope of valves tested with the StemThief.
• StemThief saves time and improves efficiency, safety
• At PVGS we had experienced As Found to As Left COF changes from 0.15
to 0.10 by using the Stem Thief. PVGS MOV typical CF is 0.10.
• Grease analysis performed in-house.
Grease Sampling
• Old method – does not
prevent non-active grease
from being sampled
• EPRI Research – “Effective
Grease Practices Guide”
• New method—using
Grease Thief and T-handle
produces representative
sample
Ref: Easy Testing for Grease Thickness, Bob
Bolt, Bolt and Associates Chesley Brown, Texas
Utilities Mike Pugh, EPRI, Machinery
Lubrication 5/2003
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2019-01-10
StemThief - Stem relubrication and Grease
Sampling from stem and gearbox
MOV Main Gearbox Grease Sampling
ASTM Standard D7718 outlines methods for accurate
sampling. MOV sampling kit designed to meet that
guidance, that allows a blind sample to be taken from
the worm-gear area by contacting the surface with a
plastic stinger probe, which starts the coring process
directly adjacent to the gear teeth.
For known-depth sampling, the T-handle is used to
core a fixed-depth sample from within the gearbox.
Other samples can be taken with the Pillow Block kit.
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2019-01-10
Grease Condition Monitoring
Screening test for grease analysis that includes ferrous
debris level in ppm, grease colorimetry, and FTIR analysis,
all per ASTM D7918.
There is also a Basic Analysis test slate that adds Die
Extrusion (consistency/flow properties), Moisture (ppm),
RULER for anti-oxidants and RDE spectroscopy for 21
elements.
An Advanced Analysis test slate adds Analytical
Ferrography and Rheometry for advanced flow
properties.
Grease Mini-Lab for onsite testing, ferrous debris (ppm),
colorimetry (CIE scale), and moisture (ppm) with no
chemicals required.
Limit Switch Gearbox Grease Failure –
Grease or Maintenance Required?
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2019-01-10
Limit Switch Gearboxes – How Much?
• Verify all internal parts are dry and the solvent is gone before
reassembly and greasing.
• Install the bottom gear frame cover bowed outward with a lubricated
gasket and the four (wider head diameter) fasteners (Figure 17-20).
• Add approved grease to the gear frame leaving a small air space.
9. Verify the grease level is above the top of the smaller gears and that
the gear frame is not completely filled. Add or remove grease as
necessary.
10. Coat the mating surfaces of the gasket (51 ) with a thin film of gear
frame grease, if not previously lubricated.
Ref: Technical Repair Guidelines for Limitorque Model SMB-00
Valve Actuators, EPRI NP6631 R1s, June 1995
Limit Switch Gearboxes –
Really How Much?
The MOV Long Life is doing really well for us, we
haven’t had any issues with it.
FYI, we fill the limit switch gearboxes ~80% full.
Ref: 2018 from a user at a very large US nuclear station
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2019-01-10
Lessons Learned
1. Most bearings fail early.
2. Many failures are because of improper lubrication.
3. Many failures can be easily prevented.
4. Do not overfill the limit switch gearboxes.
5. Use the right grease, applied the right way and verify
performance.
MUG Presentations
2019 Grease Lubrication of MOV Components
2017 What You Need to Know about Oil & Greases and Compatibility
Testing
2015 Understanding Low Temperature MOV Greases
2014 MOV Stem Nut Wear Testing – An Update
2013 Stem and Stem Nut Relubrication (Wurzbach)
2013 MOV Long Life Grease a Decade Later- Approvals and Lessons
Learnt
2010 Semifluid Grease for Oil Filled MOV’s
2009 MOV Long Life – Reducing Oil Seepage
2008 Commercial Grade Dedication and In-service MOV Long Life
Grease Testing
2007 MOV Stem Grease Wear Testing
2006 MOV Long Life Condition Monitoring Update
2005 MOV Long Life Condition Monitoring
2004 MOV Long Life Limitswitch Applications
2003 All-In-One, An Update on MOV Long Life
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