Petron 2003 Distributor Meeting: by Chad Tennant

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Petron 2003 Distributor Meetingby Chad Tennant

• Power Generation Case Histories

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Coal Fired Power Generation

• General Information
• Four Case Histories
• First Energy
• Progress Energy (Carolina Power)
• Tampa Electric
• Sunbury Generation

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General Information

• Estimated 20 of coal fired stations have ball
  mills
• Newest large station in my area was built in 1982
  - Carolina Power, Roxboro, NC.
• Have had success, but typically three years from
  first call to total conversion. Extensive sales
  cost.
• Competitors are Whitmore, Kluber, Lubrication
  Engineers, Tribol, and Shaeffer.
• Most stations have 20-30 years experience with
  their mills. Quite old
• No station I have visited is eager to change.
  Operations personnel do not want to change
  anything.
• Sales volume is 3,000 to 5,000 per mill per
  year. Three nozzle system is 3,000 and five
  nozzle 5,000.
• The negatives work in your favor after plant
  conversion.

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First Energy 1 of 2

• Plant Size 2,400 megawatts (3 units _at_ 800 MW ea)
• Mills 24 Foster Wheeler D-9. Mill age 25-30
  years.
• Lube Systems Farval 3,000 series measuring
  blocks. 3 nozzles per mill.
• Current Supplier Whitmore Surtac 2000HD. Have
  had business for 20 plus years.
• Annual Lubricant Usage 30,000-40,000 pounds.
  Supplied in 120 pound kegs.
• Status Gear Shield NC NCW on mills 2A since
  November 2002. Gear Shield NC NCW on mill 2F
  since May 2002. Mills using Gear Shield NC NCW
  are running well.

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First Energy 2 of 2

• Observed Differences Between Surtac 2000HD and
  Gear Shield NC NCW
• 20 minute interval for Surtac and 15 minute for
  Gear Shield
• Surtac builds up on guards and in roots. Gear
  Shield NC NCW drains.
• Gears with Gear Shield have heavier, more
  adherent coating. Mills appear to run smoother.
• Temperatures about the same with both products.
• Gear Shield NC NCW mills have slightly lower
  vibration levels.
• Surtac gears have pits, marks, high gradients.
  Gear Shield has none of these problems.
• No gear replacement data available.

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Progress Energy 1 of 2

• Plant Size 800 megawatts (1 unit _at_ 800 MW)
• Mills 8 Foster Wheeler D-9. Mills started in
  1982.
• Lube Systems Farval 3,000 series measuring
  blocks. 4 nozzles per mill. BOMAC on 8 minute
  application cycle and Gear Shield NCW on 20
  minute.
• Current Supplier BOMAC. Have had business for 5
  plus years. Price is 1.54 per pound. Includes
  freight in and waste removal.
• Annual Lubricant Usage 27,000-70,000 pounds.
  Supplied in bulk.
• Status Gear Shield NCW on mill 2B since March
  2003.

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Progess Energy 2 of 2

• Observed differences between BOMAC and Gear
  Shield NCW.
• 8 minute interval for BOMAC and 20 minute for
  Gear Shield NCW.
• BOMAC builds up on guards and in roots. Gear
  Shield NCW drains better.
• Gears with Gear Shield NCW have heavier more
  adherent coating.
• Temperatures about the same with both products.
• No lube throw off when gear inspection door
  opened.
• Gears lubed with BOMAC have pits, marks, high
  gradients.
• No gear replacement data available. None in 2002
  or 2003.
• Deliveries and waste disposal are concerns.

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Tampa Electric 1 of 2

• Plant Size 1200 megawatts (3 units _at_ 400 MW)
• Mills 9 Foster Wheeler D-9. Mills started in
  1970s.
• Lube Systems Lincoln. 4 nozzles per mill. 15-20
  minutes lube cycles.
• Current Supplier Gear Shield NCW. Have had
  business for 7 months. Replaced local lube
  company grease.
• Annual Lubricant Usage 27,000 pounds. Supplied
  in bulk. Delivered by Highlands Oil. Highlands
  services the Lincoln systems.

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Tampa Electric 2 of 2

• Observed Differences Between Columbia and Gear
  Shield NCW
• Columbia Lube builds up on guards and in roots.
  Gear Shield NCW drains. Drain pans not serviced.
• Gears with Gear Shield NCW have heavier more
  adherent coating.
• Temperatures about the same with both products.
• No lube throw off when gear inspection door
  opened.
• Gears lubed with Columbia have pits, marks, high
  gradients.
• No gear replacement data available. None in 2003.

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Sunbury Generation 1 of 2

• Plant Size 450 megawatts (3 units _at_ 150 MW)
• Mills 13 Foster Wheeler D-7. Mills started in
  1960s.
• Lube Systems Lincoln. 4-5 nozzles per mill. 15
  minutes lube cycles.
• Current Supplier Gear Shield NC. Have had
  business for five years. Replaced Whitmore
  Surtac, Envirolube. Exxon Surrett 6K
• Annual Lubricant Usage 23,000 pounds. Supplied
  in 120 pound kegs.

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Sunbury Generation 2 of 2

• Observed Differences Using Gear Shield NC
• Gear failures have stopped, none in five years.
• Temperatures about the same with both products.
• No lube throw off when gear inspection door
  opened.
• Gears lubed with Whitmore have pits, marks, wear.

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Service Reports

• Viewed on overhead