SHELL OPEN GEAR LUBRICANTS WEBINAR SERIES: · PDF fileSHELL OPEN GEAR LUBRICANTS ... is...

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SHELL OPEN GEAR LUBRICANTS WEBINAR SERIES: PART 1 OF 3

Greg Paluska Greg Morris Technical Advisor – Mining Product Application Specialist - Greases


BEFORE WE GET STARTED…

We respect your time – we will not run more than 55 minutes.

Questions are encouraged during this webinar. Use the “Question” link in the bottom of your screen. We’ll answer all your questions! If we can’t answer them all live, we will have a direct follow-up with you.

An interactive webinar – you’ll be able to participate in several live polling questions. Click your answers onscreen.

A recorded version of this presentation will be sent to all webinar registrants within the next few days.


SPEAKERS

Greg Paluska

Technical Lead – Fleets & Mining

Leads a team of Lube Service Experts – onboard lubrication and lubrication system support for key mining machinery – Shovels, draglines, mills and kilns

Shell Technical Advisor since 2011

Avid cyclist, enjoys “golfing” and is a sports car enthusiast


SPEAKERS

Greg Morris

Product Application Specialist – Greases

Part of Global team with the task of integrating field level support and feedback to RD projects

Validation of product performance

Working with OEMs and end users on product performance inquiries

24 years of industry experience -17 years with Shell


AGENDA

Basics of Gearing and Open Gearing

Types of Open Gear Lubricants

Shell Gadus Open Gear Portfolio


BASICS OF OPEN GEARING 1.0


GEAR MANUFACTURING

Pre-forming

Gear turning

Cutting

Gear hobbing

Gear shaping

Quenching/ Hardening

Finishing

Gear shaving

Gear grinding

Gear Honing/ grinding

Final operations

Broaching

Gearbox machining

Gear Quenching Nitriding

Induction or Flame

hardening

Gear milling

Forming

Gear forging

Gear sintering

http://shyiming.en.alibaba.com/product/50042399/50192248/Gearboxes/Gearbox_Assembly.html


Outside diameter

Pitch diameter

Whole depth

Root diameter

Root diameter

Base diameter

Pitch diameter

Line of centers

Driven Pitch Point

Pressure Angle

Driver Dedendum

Addendum

Clearance

GEAR GEOMETRY


REVIEW – FILM THICKNESS AND COEFFICIENT OF FRICTION

Separating surfaces is critical!

Film thickness is dependent on:

Lubricant Viscosity

Temperature

Load

Size and Speed of Gears

Coe

f of F

rictio

n

ZN/P

Boundary Lubrication

Hydrodynamic Lubrication

Mixed Film Lubrication


GEAR LUBRICATION REGIMES

Very lightly loaded gears, operating at high speed, are effectively lubricated under the conditions of hydrodynamic or thick-film lubrication

Elasto-hydrodynamic lubrication is the lubrication condition which exist in most gears, but usually NOT open gears.

Heavily loaded gears, especially those operating at low speed, are lubricated under the conditions of mixed film & boundary lubrication. The lubricant film is very thin and there is significant metal-to-metal contact between gear teeth.

Boundary Lubrication

Hydrodynamic Lubrication

Mixed Film Lubrication

Wear Scuffing

Type of Gear failure

Lubrication Condition

Pitting, Micro-pitting


Mixed Lubrication

High Circumferential Velocity

Low Circumferential Velocity

Courtesy of STLE Lubrication Engineering, May 1990, Page 322 (with permission)

Open Gearing operates under mixed lubrication conditions where linear speeds are low

Pitch line…

LUBRICATION AT GEAR FACE


GEAR FINISH MAY BE ROUGHER THAN BEFORE

Tooth of a new girth gear Tooth of a new pinion


LAMBDA RATIO

Mean Oil Film

Thickness (h)

RMS Surface

Roughness

s1

s2

Combined Surface Roughness s = (s12 + s2

2)0.5 { ≈ Ra1 + Ra2 }

l ratio = h s

1, for the case shown

above

RMS (root mean square) – a measure of surface roughness of a surface relating to the centreline average between peaks and valleys of asperities

The l Ratio can provide clues to the prevailing

Lubrication Regime and hence the likelihood of Wear.


The specific film thickness of the chosen lubricant

should be above the 5% line on the graph to insure maximum performance and gear protection

REDUCE THE PROBABILITY OF SCUFFING AND GEAR DAMAGE


OPEN GEAR LUBRICATION – SOLID LUBRICANTS

When the oil film is of a comparable thickness to the surface roughness, the condition of boundary lubrication exists.

Under these conditions and also during sliding motion, the addition of solid lubricants in the lubricant can provide additional protection against gear wear.

Friday,

Metal to metal contact due to insufficient lube film thickness

Solid additives act as barrier to the gear surfaces

Covalent

Van

der

Waa

l

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OPEN GEAR LUBRICANT REQUIREMENTS

New gear manufacturing technologies have added increased load and stress on to gears utilized today.

The following are key requirements of open gear lubricants

Adhesiveness to gears

Water wash and spray resistance

Load carrying capability

Protection against wear and corrosion

Health and safety concerns

Resistance to centripetal acceleration – cannot “fling” off the gears

Capability of easy removal – slumpable into drains


AGMA SPECIFICATIONS FOR OPEN GEARS

Ambient Temperature °C

Intermittent Spray Gravity Feed of Force Dripped Non-residual

lubricant Residual type lubricant

-10 to +5 4140 cSt at 40°C 428.5 cSt at 100°C 4140 cSt at 40°C

+5 to +20 6120 cSt at 40°C 857 cSt at 100°C 6120 cSt at 40°C

+20 to 50 190 cSt at 100°C 857 cSt at 100°C 190 cSt at 100°C

Above is taken from AGMA 9005-E02

Pitchline velocity: V t <7.5 m/s Quantities dictated by gearing size and timing (subject of future webinar)


OEM SPECIFICATIONS

BE OGL SD 4713 P&H Rev 464 Metso OG

Viscosity -50 to 10 C – min 680 -20 to 40C – min 1860 10 to 50C – min 3600

- 3,300 SSU @100C (Asphaltic) 870 SSU @100C (All others)

Four Ball Wear Scar 0.7 1.0 .75 mm

Four Ball Weld Point Load Wear Index

800 (w/out diluents)

120

400

250

250 kg

45

Lincoln Ventmeter 600 400

Viscosity is key property to consider as it does most of the work Four Ball Weld Point is great indicator of shock loading capability Lincoln ventmeter critical for lubrication systems where venting is necessary


OPEN GEAR COMPONENTS AND CHOICES

2.0


KEY COMPONENTS OF OPEN GEAR LUBRICANTS

Base Oils – High base oil viscosity Asphaltic base

Thickeners (same as typical greases)

Additives Extreme pressure, Solids,

Antioxidants, Tackifier

Solvents


ASPHALTIC OPEN GEAR LUBRICANTS

Also known as “Crater Lube,” residual compounds and black oils

Older technology that has been proven and is widely accepted in the mining industry

Formulated with high viscosity base oil, bitumen or asphaltic base, and low flash point diluent

Use the principle of oil separating mating surfaces – thus no solids required

Typically applied via spray systems


ADVANTAGES/LIMITATIONS OF ASPHALTIC LUBRICANTS

ADVANTAGES

Asphaltic base provides high viscosity characteristic to provide separation of mating tooth surfaces

DISADVANTAGES

First generation asphaltic lubes typically used chlorine based solvents

Excellent as the flammability was low, and performance was excellent

Chlorine was identified as harmful to the environment, thus was banned

Presence of polycyclic aromatics that are environmentally objectionable

Petroleum based solvents have lower flash points

Poor high and low temp performance

Oxidize and fall off easily at high temps

Tendency to crack and peel off during cold temperatures

Tendency to build up in root of teeth

Tend to attract dust leading to potential for more abrasive wear

Solvent volume is ‘wasted’ as customers pay for mobility component that does not lubricate


Newer technology of open gear lubricants

Same general application, however is typically applied in shorter time quantities in smaller amounts

Formulated just as any other grease would be (Base oil, thickener, additives)

Solvent used for mobility and spray potential in low ambient temperature applications (Gadus S4 OGT is neat, but has limited temperature due to lack of solvent)

SEMI-FLUID GREASE FORMULATIONS


ADVANTAGES/LIMITATIONS OF GREASE FORMULATIONS

ADVANTAGES

Forms a dry, tacky protective film and thus does not attract dirt and dust as much

Improved housekeeping due to better tackiness on the gears

Potential for consolidation by using is various other applications (MPG)

Suitable for mobile equipment and stationary/plant based gearing

DISADVANTAGES

Consumption is sometimes higher


HIGH VISCOSITY SYNTHETIC GEAR OILS

Newest technology of open gear lubricants

Typically formulated with high viscosity synthetic base oils (PAO and POE) along with EP and MoS2

Do not use solvents for mobility – can be developed at lower viscosities


ADVANTAGES/LIMITATIONS OF HEAVY OIL FORMULATIONS

ADVANTAGES

Lower traction coefficient – lower pinion operating temperatures

High viscosity enhances adhesiveness to gears

Allows for gear to operate close to full-film lubricating regime

DISADVANTAGES

Potentially difficult to pump or move in cold temperatures

May require drum heaters and heat tracing

Much higher up-front cost compared to all other OGLs

Modifications to intermittent spray systems may be required to spray these lubricants


SHELL PORTFOLIO OF OPEN GEAR LUBRICANTS

3.0


SHELL OGL PRODUCT DATA POINTS

Several Types (“Families”), Several applications, Many products

Product type Shell Gadus Product Name Solids Base oil type Base oil vis @ 40oC NLGI grade

Bitumastic S1 OG 1600 None Mineral 1,500 000

Bentonite

S2 OG 40

Moly/Graphite

Semi Syn 655 000 S2 OG 50 Semi Syn 870 00 S2 OG 80 Semi Syn 1,625 0 S2 OG 85 Semi Syn 1,625 1

Aluminium complex S4 OGXK

Moly/Graphite Mineral 4,000 00/000

S4 OG MS* Mineral 4,000 0/00 S4 OGT Mineral 5,500 0

Aluminium complex S4 OGH 160 Moly/Graphite Mineral 4,100 00

Aluminium complex S3 Repair Graphite Mineral 550 00

Oil S2 OG Clear Oil 6800

None Semi Syn 6,800 Fluid

S2 OG Clear Oil 20000 Semi Syn 20,000 Fluid


SHELL OPEN GEAR APPLICATION RANGES


SHELL GADUS S4 OGT IN HOIST GEAR OF SOUTH AMERICAN ELECTRIC ROPE SHOVEL (BE 495)

Excellent coverage

Good adhesion to gearing

Little to no severe wear patterns

Max temperature 52C

Ambient closer to 22C


CAT 7495 – USING GADUS S4 OGT

Excellent coverage

Good adhesion to gearing

Swing Rack


CAT 7495 – USING GADUS S4 OGT (CONT’D)

Hoist Crowd

Both gear sets show excellent coverage after many months of use

Gear lubricant is providing the wear protection it needs to

Next steps in open gear optimization is grease delivery!

Contamination control, grease system design


Q & A

Submit questions in the lower right corner of your screen.


CONTACT US

Do you have more questions about how to better your lubrication practices? Greg Paluska [email protected] Greg Morris [email protected]

mailto:[email protected]

mailto:[email protected]

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