Omega Specialty Lubricants
Lubrication Solutions
Omega specialty lubricants include the finest line of Quality Oils, Greases and Additives in the world.
Omega specialty lubricants are generally made from premium and limited source Paraffinic-type base oils because of their naturally higher viscosity index, stability and purity. Besides, Omega specialty lubricants contain scientifically-developed exclusive supplements called - "Megalites".
These supplements are a technologically-advanced family of exclusive and unique agents designed to provide maximum protection for costly machinery, vehicles & plant equipment.
Omega supplies Total Concept Lubricants engineered and developed with the single aim of enabling machinery to perform more efficiently, with less wear and extended service life.
Lubrication Preventive Maintenance
Lubrication is the process of reducing friction. Friction, unchecked, causes wear, wastage of energy and rising temperatures that can cause great damage to machines and equipment, but it will never be completely eliminated. The single important criteria of lubrication is the maximum reduction of friction.
Lubrication is the key to reducing energy wastage and parts deterioration. Wear reduction can become the key to maintaining mechanical equipment at their optimum efficiency and to extending machine life.
Lubricants can be either gas, liquid, solid or synthetic. They are important in keeping contaminants from delicate machinery parts in environmentally-polluted areas. Heat build-up is a major problem area for maintenance engineers as machines work longer and faster without stoppage. Special additives are increasingly important to help reduce generated heat which would otherwise cause the machine to break down.
The direct results of lubrication:
- Retardation of wear
- Minimization of temperature rise
- Reduction of friction
- Longer machine life
- Reduction in downtime
- Lower production costs which result from uninterrupted machine operation, lower maintenance costs and less need to replace parts.
Effective lubrication
To maintain efficient and continuous performance of plants, factories and workshops, it is essential to set up 'corrective' and 'preventive' maintenance systems.
Corrective maintenance is when slight damage to equipment or machinery occurs. It encompasses the repair of the part and is generally the policy in smaller industries which have a small number of machines and any damage would not normally affect the flow of production.
Preventive maintenance is directed towards getting the longest period of machine performance without problems or damage which would cause a disruption of production flow. With effective preventive maintenance, it is possible to maintain maximum efficiency in industrial production with minimum time loss caused by interruptions. This makes it possible to obtain the lowest cost for the final product.
Preventive lubrication is perhaps the most important aspect of preventive maintenance: From statistics collected over many years, Omega researchers have calculated that general maintenance costs about 5-10% of the total operational cost and the maintenance lubrication costs only 2.5% of the general maintenance cost. In other words, the cost of maintenance lubrication when compared with the total cost of production, comes to between 0.125-0.25%.
Analysis by Omega Manufacturing Division of maintenance lubrication needs show that this is the main support of general preventive maintenance program and that inadequate lubrication will cost disproportionately more than the money foolishly saved by using low-quality lubricants.
Benefits of adequate lubrication
Modern machinery is complicated, compact and requires precise adjustments in operating conditions that are severe and varied. This has resulted in a great number of different types of lubricants being used, but it takes a great deal of attention and effort to ensure proper application.
Cost saving - the possible savings by Omega lubricants are about 100 times the cost of lubrication.
Performance observation - Better quality Omega Lubricants last longer even working at maximum speeds and generally, lesser quantities are required to do the job than with a less expensive lubricant.
Maintenance costs - High quality Omega Lubricants result in less replacement parts and less damage to machinery.
Minimum breakdown - Breakdown is not only expensive to repair but also very costly in terms of production failure. This is true not only in highly-automated factories, even a small farm that has a tractor down can lose a lot of money. Lubrication with Omega cuts down the number of breakdowns dramatically.
Less production rejection - Many products are rejected when undergoing inspection. Many rejected products are the direct result of the machinery not performing according to plan because of wear due to inadequate lubrication.
Preventative lubrication program
The first step to ensure proper lubrication is to develop an Omega lubrication program. First, you need to:
- Determine lubrication intervals
- Classify and code the different lubricants required
- Establish a recording system
- Draw up lubrication routes
- Form a central archive for control
- Set up intervals for lubrication
- Set up daily record of lubrication
- Ensure an adequate stock of Omega lubricants
For more information on Omega Lube, click the button below.
Magna Welding Alloys
It happens frequently that electrode users analyze the core wire of an electrode to predict or consider the weld metal composition. This procedure falls down completely. The analysis of the core wire of an electrode is by no means the same as the deposit chemistry.
Many people presume that if they are welding a specific base metal, they will have an identical and satisfactory weld if they use an electrode having a core wire of the same composition as the base metal. As an example, they presume that by welding a base metal of Type SAE 4130 (chrome moly steel) with an electrode with a Type SAE 4130 steel core wire, the weld deposit will match exactly the base metal and the weld will perform identically to the base metal.
This is an understandable, but completely illogical conclusion for many reasons. Following are a few examples:
(1) The base metal is usually a hot or cold worked material, having had grain refinement from the working (such as rolling). The weld metal is a cast material and thus cannot exactly resemble the base metal if the analysis is the same, unless the electrode has additional properties to compensate for this vast difference.
(2) Weld metals are prone to pore-formation, which will also make a weld deposit differ from a base metal even if the analysis of the core wire is identical.
(3) Some ingredients of the core wire, such as chromium, are invariably lost in gaseous form into the atmosphere during the arc transfer.
(4) Ordinary welds are prone to contamination from many sources including:
(a) Carbon, phosphorous, and sulphur content of the electrode or the base metal fused into the weld deposit, which often cause interdenticle cracking in the weld deposit. These contaminants, and many others, segregate following solidification of the weld metal and follow the primary grain boundaries causing hot-cracks. Phosphorous also causes welds to be brittle at low temperature.
(b) Ordinary weld deposits are quite susceptible to oxygen contamination. Oxygen in solid solution reduces the impact toughness and tensile strength of steel. Welds made with other electrodes than Magna generally contain more oxygen than do ordinary steel base metals.
(c) Nitrogen absorption of welds made with ordinary electrodes is a matter of serious concern. Nitrogen in solid solution absorbed from the atmosphere during welding lowers the impact toughness of welds, lowers the elongation, and is generally responsible for "ageing", which is a precipitate process in welds which causes impact toughness and ductility to deteriorate to very low values. When one considers that 78% of the air is nitrogen and that nitrogen causes welds to be brittle, the need for prevention of nitrogen contamination becomes obvious.
Magna has recognized that a series of problems result from the old idea of presuming that the same type core wire as base metal is adequate and will supply good results for maintenance applications.
Magna research has proven that in virtually any maintenance weldment, the electrodes must have much higher alloy content and much higher physical properties than the base metal.
Magna Solutions
An electrode consists of two parts: a core wire and a coating. Magna uses high-purity core wire having generally a much higher content of noble or semi-noble metals (such as nickel, molybdenum, columbium, cobalt, silicon, manganese, vanadium, chromium, and other "super-metals") than ordinary electrodes.
The highly researched super high alloy Magna core wires with extra high alloy content, stabilizing agents, highly deoxidized metals, and high purity metals and other improvements completely change the character of the arc. The core wires of Magna Maintenance Welding Electrodes are carefully controlled so that metals or elements that - in excess - can cause difficulty or possible weld failure, such as carbon, sulphur, or phosphorous, are either refined out or held in exceedingly low amounts. This enables them to be stabilized by special additives which Magna incorporates in the formulation of the electrode. Nothing has been left to chance.
Magna conducts continuous extensive research in electrode coating chemistry and electrode coating technology. Magna employs leading scientists and many highly qualified chemists and technicians who perform studies in electrode coating technology. Among the reasons for Magna Maintenance Welding superiority is the advanced state of Magna' s Maintenance Electrode coating technology. It is believed that the coatings of Magna electrodes are the most advanced in the world with respect to maintenance applications. Magna electrode coatings contribute to maintenance weld quality in many special ways, including:
- Magna's unique coatings deoxidize the weld metal. Oxygen contamination is a major cause of weld failure. Magna electrodes contain special deoxidizers which completely remove most oxygen and reduce the balance to exceedingly finely dispersed inclusions. The deoxidizer system is of a proprietary and special nature not universally available.
- Magna coatings actually produce a super shielding gas to protect the molten weld metal. This gas envelope produced by the melting of the coatings is especially designed to prevent the weld from being contaminated by nitrogen, oxygen, hydrogen and other harmful elements that often cause failure in ordinary electrode deposits.
- Pore-resistant coatings. Magna electrode coatings contain scavengers, cleansers, degreasers, and have an ability to absorb foreign matter, dirt, contamination, and impurities, float them away, and hold them in the slag for easy removal. This special feature enables Magna maintenance welds to be made without the porosity that is common with ordinary electrodes.
- Magna Maintenance Electrodes provide a slag layer around the molten metal globules during transfer, and then form a protective chemical slag blanket over the complete weld deposit. With most electrodes, the slag is usually little more than a residue of the electric welding process. Magna Maintenance Electrodes have a completely different type coating which forms a protective blanket that not only provides a resistance to oxidation and other contamination but emphatically retards the cooling rate. A "Widmanstatten" structure occurs when ordinary electrodes are used which allow the weld to cool too rapidly. The Widmansttten structure caused by rapid cooling with ordinary production electrodes is harmful. Rapid cooling causes the ferrite to form needle-like plates which are transverse to the pearlite.
The Magna slag blanket holds the heat and retards the cooling to permit the complete precipitation of the ferrite in the grain boundaries in such a way that the ferrite surrounds the pearlite grains. The Magna protective slag blanket effectively retards the cooling rate and promotes a more refined and more desirable grain structure.
- Hydrogen gas inclusion (commonly referred to as "fish-eyes") is a major problem in maintenance welding. Hydrogen's main threat to welding comes from the chemically combined water which is present in the coatings of many production welding electrodes. This water decomposes into hydrogen and oxygen in the arc transfer process. Iron has a high solubility for hydrogen even at moderate temperatures, so considerable amounts of hydrogen enter weld deposits. The hydrogen which enters the weld when production welding electrodes are used can be completely removed by heating the weld to 482oF (250oC) and holding the part at this heat for 15 hours.
This procedure can be carried out in production factories as another step in manufacture. However, it is totally impractical in maintenance welding. This is why the Magna Research Department has given consideration to the problem of hydrogen inclusion in maintenance welds.
It has repeatedly been demonstrated that hydrogen contamination of welds causes cracking and underbead cracking (this is a type of cracking in the heat affected zone adjacent to or under the weld, caused by the hydrogen contamination during welding). Hydrogenous welds cause a pronounced reduction in ductility and elongation and are crack sensitive.
Magna has built into the special coatings a resistance to hydrogen transfer across the arc. Electrodes such as Magna 305, Magna 303 Gold and many others are based on all mineral coatings with special additives that tend to repel hydrogen. These coatings, in manufacture, are baked at high temperatures to remove even the last traces of hydrogen. These special coatings are another reason Magna electrodes result in more reliable maintenance welds.
Magna coatings are not mere simple cellulose or rutile formulations. They contain many supplements and special features. Some of these are:
(1) Higher purity, higher quality binders.
(2) Higher purity, higher quality chemicals. There are many grades of chemicals available to electrode manufacturers including the lower quality technical grades, U.S. pure, Pharmaceutical grades, etc. Magna quality requires unusually high grades of chemicals.
(3) Magna coatings are produced with special mixing equipment, using a variety of mixers to attain different results with different chemicals. The particle size of chemicals is carefully studied. The mixing of the coatings is carefully monitored so that every batch is identical.
(4) Magna introduces many additional metals such as strontium, sodium, aluminium, graphite, as well as stabilizing compounds and various other additives such as fluorides, carbonates and calcium, through the unique coatings to improve both maintenance weld quality and weldability.
(5) Magna upgrades the quality of the deposit by adding finely ground metal to the coating. Such metals as molybdenum, chromium, cobalt, nickel and many others enrich the weld deposit.
(6) The concentricity of all Magna Maintenance Welding Electrodes is controlled with such surgical preciseness that the maximum core-plus-one-covering dimension by more than 5 per cent of the minimum core-plus-one-covering dimension. This precise concentricity control prevents "finger-nailing", uneven burn-off, erratic performance and spatter which occurs with so many welding electrodes because of poor concentricity.
(7) Magna employs carefully controlled amounts of ferrite formers in the coatings in order to enable the Magna deposits to resist hot-cracking. Magna electrode coatings are highly sophisticated coatings, many containing more than 20 ingredients. They are the result of specific research to design coatings especially engineered for the special problems of maintenance welding. It is believed that they represent the highest state of the art today for the purpose for which they have been designed. They supply weld deposit additions that provide increased physical properties and increased resistance to cracking or costly weld failures. The coatings are so rich in extra metals and supplements that the final alloying process is actually only completely finished at the tip of the electrode.
For more information on Magna Welding Alloys, click the button below.
Corium Industrial Chemicals
The engineering and research that goes into the development of each individual Corium product encompasses, as its first objective, ways to make the product easier and safer to use. Wherever possible, potentially dangerous or harmful elements are eliminated or rendered as safe as possible.
Where potentially damaging ingredients cannot be avoided in the chemical composition of a Corium product, extensive safety guidelines and warnings are prominently displayed. Corium are extremely proud of its enviable international safety record and its active support and participation in developing safer, yet equally effective replacements for dangerous compounds.
However, as in all trades and industrial activities, some commonsense safety precautions must always be observed. The Corium Chemical Division also firmly recommends that proper safety practices and approved safety equipment be used to ensure maximum worker well-being and safety.
Following are a few recommendations that the Corium Chemical Division suggests being included in your organizations safety program:
(a) Always wear proper eye protection when handling corrosive products, and avoid skin contact by wearing suitable aprons and gloves (which should be regularly dry- cleaned).
(b) When dealing with highly active or even buffered acid products, avoid prolonged contact with the skin. Hands should be washed after handling such products, and any spillage should be thoroughly rinsed with water. Where fumes are encountered, appropriate respiratory equipment should be used.
(c) Acid products should be handled, stored and applied following the manufacturers’ recommended practice. Avoid contact with skin, eyes or clothing at all time.
(d) Some products contain extremely alkaline material like lye or soda. Avoid prolonged exposure to vapors and always wear safe respiratory equipment and face masks. Keep away from face and eyes. These dangerous materials are deadly if swallowed and can cause eye and skin irritation. Avoid contact with skin, eyes, mucous membranes and clothing.
(e) Solvent based chemicals may cause skin irritation. Avoid contact with eyes, skin and clothing. Do not inhale vapor or spray mist. Do not store or apply near fire or flame. Do not apply to surfaces which may come into contact with food.
(f) Straight muriatic acids are often used in ordinary cleaning chemicals. Prolonged contact with skin is unadvisable, therefore protective gloves should be used to handle.
(g) Avoid smoking while handling any chemical to ensure enhanced safety. Inhaling some chemical fumes accidentally through cigarette smoke may produce a deadly gas mixture.
(h) Chlorinated solvents give off fumes that are dangerous under enclosed or nonventilated conditions.
(i) Cyanoacrylate esters display strong and instant skin tissue adhesion and all skin contact must be avoided. Accidentally bonded skin should be peeled apart and not pulled apart. Hot water also aids separation. Consult physician immediately in cases of internal contact or eye contact. Always use applicator nozzle to avoid skin contact and keep out of reach of children.
(j) Some chemicals or resins may cause rash in some highly allergenic persons. Use rubber gloves when in doubt.
(k) If chemical products are to be used in contact with food, wash the surface thoroughly before use.
(l) For products that are slippery by nature, spread paper on surrounding floor before applying.
(m) Avoid breathing aerosol’s gas vapor for prolonged periods in confined areas.
(n) For products that are toxic in nature, all reasonable precautions should be taken to avoid breathing of vapor and prolonged contact with the skin.
(o) Precautions should be taken when handling inflammable products.
(p) Keep containers tightly closed when not in use.
(q) If chemical products are inadvertently swallowed, consult physician immediately. Strictly observe all safety precautions relevant to the use of such products.
(r) Flammable products should be kept away from open flames. Avoid prolonged contact with the skin and avoid breathing vapor.
(s) Suitable fire-fighting devices must be readily accessible in working or storage places.
(t) Strictly observe all safety precautions relevant to the use of an aerosol product and or printed on the can’s label.
For more information on Corium Industrial Chemicals, click the button below.
Gruetzner Automatic Lubrication
Gruetzner GmbH has been your specialist for automatic lubrication systems and maintenance tools since 1993.
Our user-friendly lubrication solutions are used in almost all areas of maintenance in every industry across the globe. Our offerings also include various maintenance accessories for areas such as bearing mounting.
As an internationally established, family-owned enterprise, we offer particular flexibility and exceptional service. Decades of experience make us a skilled contact for all matters relating to lubrication technology. An individual, custom-built lubrication concept which is adjusted to your machines and constructions will gladly be developed by our experts.
We also take responsibility for the environment with our modern lubrication solutions and maintenance tools. By reducing lubricant and energy consumption as well as extending the service life of wear parts we achieve a significant reduction in CO2 emissions in factories and plants around the world.
The Benefits of Automatic Lubricators
Automatic lubrication systems dispense small, precise amounts of lubricant at short, regular intervals.
The amount of time and personnel required for large plants, and machines located in hazardous areas mean that manual lubrication is often dangerous, impractical and expensive. Automatic lubrication systems as part of maintenance can resolve this issue.
Automatic lubrication:
■ Reduces your costs
■ Saves time
■ Fewer machine breakdowns due to decreased wear
■ Lower lubricant consumption
■ Increased service life of bearings
■ Protects the environment
■ Needs-based lubricant dosage
■ Lowers risk of impurities and contamination
■ Improves work safety
■ Enables monitoring and provides an overview
For more information on Gruetzner Automatic Lubrication, click the button below.