SHELL OPEN GEAR LUBRICANTS

WEBINAR SERIES: PART 1 OF 3

Greg Paluska Greg Morris

Technical Advisor Mining Product Application Specialist - Greases

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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.
Well answer all your questions! If we cant answer them
all live, we will have a direct follow-up with you.

An interactive webinar youll 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.

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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

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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

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AGENDA

Basics of Gearing and Open Gearing

Types of Open Gear Lubricants
Shell Gadus Open Gear Portfolio

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 1.0
BASICS OF OPEN GEARING

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GEAR MANUFACTURING

Quenching/ Final
Pre-forming Cutting Finishing
Hardening operations

Gear Gear Gear Gear

Broaching
turning hobbing Quenching shaving
Nitriding
Induction or
Flame
hardening

Gear
Gear grinding Gearbox
Forming shaping machining

Gear
forging

Gear
Honing/ grinding
Gear
milling
Gear
sintering

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 GEAR GEOMETRY

Driver Dedendum

Addendum Root
diameter

Base
diameter
Outside Pitch
diameter diameter

Pitch
diameter

Whole Clearance
depth
Pressure
Angle
Driven Pitch
Point
Root
diameter

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Line of centers
 REVIEW FILM THICKNESS AND COEFFICIENT OF FRICTION

Boundary Mixed Film Hydrodynamic

Separating surfaces is critical! Lubrication Lubrication Lubrication

Film thickness is dependent on:

Lubricant Viscosity
Temperature Coef of Friction

Load
Size and Speed of Gears

ZN/P

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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.

Hydrodynamic Mixed Film Boundary Lubrication

Lubrication Lubrication Lubrication Condition

Pitting, Micro-pitting
Type of
Wear
Scuffing Gear failure
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LUBRICATION AT GEAR FACE

Mixed Lubrication
Open Gearing
operates under
mixed lubrication
conditions where
linear speeds
are low
Pitch line

Low Circumferential Velocity

High Circumferential Velocity

Courtesy of STLE Lubrication Engineering, May 1990, Page 322 (with permission)
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 GEAR FINISH MAY BE ROUGHER THAN BEFORE

Tooth of a new pinion

Tooth of a new girth gear

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

s1
Mean Oil Film RMS Surface
Thickness (h) Roughness
s2

Combined Surface Roughness s = (s12 + s22)0.5 { Ra1 + Ra2 }

l ratio = h 1, for the case shown

s above
The l Ratio can provide clues to the prevailing
Lubrication Regime and hence the likelihood of Wear.
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REDUCE THE PROBABILITY OF SCUFFING AND GEAR DAMAGE

The specific film

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

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OPEN GEAR LUBRICATION SOLID LUBRICANTS

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

Metal to metal contact

due to insufficient lube

Van der Waal

film thickness

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

Solid additives act as

barrier to the gear
surfaces

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Friday,
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

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AGMA SPECIFICATIONS FOR OPEN GEARS

Intermittent Spray
Ambient Gravity Feed of
Temperature C Non-residual Residual type Force Dripped
lubricant lubricant

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

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

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

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)

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 OEM SPECIFICATIONS

BE OGL SD 4713 P&H Rev 464 Metso OG

-50 to 10 C min 680

3,300 SSU @100C (Asphaltic)
Viscosity -20 to 40C min 1860 -
870 SSU @100C (All others)
10 to 50C min 3600
Four Ball Wear Scar
0.7 1.0 .75 mm

Four Ball Weld Point 800 (w/out diluents) 400 250 kg

Load Wear Index 120 250 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

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 2.0
OPEN GEAR COMPONENTS AND
CHOICES

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KEY COMPONENTS OF OPEN GEAR LUBRICANTS

Base Oils High base oil

Asphaltic base
viscosity

Additives
Thickeners (same as typical
greases) Extreme pressure, Solids,
Antioxidants, Tackifier

Solvents

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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

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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
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SEMI-FLUID GREASE FORMULATIONS

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)
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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

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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

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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

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 3.0
SHELL PORTFOLIO OF OPEN GEAR
LUBRICANTS

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SHELL OGL PRODUCT DATA POINTS

Several Types (Families), Several applications, Many products

Base oil vis @

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

Bitumastic S1 OG 1600 None Mineral 1,500 000

S2 OG 40 Semi Syn 655 000

S2 OG 50 Semi Syn 870 00
Bentonite Moly/Graphite
S2 OG 80 Semi Syn 1,625 0
S2 OG 85 Semi Syn 1,625 1

S4 OGXK Mineral 4,000 00/000

Aluminium complex S4 OG MS* Moly/Graphite 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

S2 OG Clear Oil 6800 Semi Syn 6,800 Fluid

Oil None
S2 OG Clear Oil 20000 Semi Syn 20,000 Fluid

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SHELL OPEN GEAR APPLICATION RANGES

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

Excellent coverage
Max temperature 52C
Good adhesion to gearing
Ambient closer to 22C
Little to no severe wear patterns

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CAT 7495 USING GADUS S4 OGT

Excellent coverage
Good adhesion to gearing

Swing Rack

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CAT 7495 USING GADUS S4 OGT (CONTD)

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

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 Q&A
Submit questions in the lower right
corner of your screen.

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CONTACT US

Do you have more questions about how to better your lubrication practices?

Greg Paluska
G.Paluska@shell.com

Greg Morris
dwaine.morris@shell.com

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