GREASES FOR MINING EQUIPMENTS

Transcription

1 GREASES FOR MINING EQUIPMENTS Augusto Fernandes Product Application Specialist 1

2 Introducing Shell Lubricants Major global lubricants supplier 3,000 + employees across the global supply chain R&D centres on four continents Customers in over 70 countries 370 technical field staff and 30 product specialists Grease specialists in the field worldwide 18 grease manufacturing plants Expert advice, practical tools and training 2

3 SHELL GADUS S4 OG A HIGH-PERFORMANCE OPEN-GEAR GREASE 3

4 What Drives the Mining Equipments Market? Extended Service Intervals Energy Efficiency Market Influence: Market Influence: Technology Extended Equipment Life Reduced Emissions Legislation Increased Power Output 4

5 Evolution of Mining Equipments and Components > 2020 Near Future 50s 70s 90s Komatsu 190 ton 2,000 hp Nowadays Caterpillar 400 ton 4,000 hp Belaz 450 ton 4,600 hp Concept 560 ton 6,800 hp 30s Euclid 10 ton <200 hp Walter 20 ton 300 hp Komatsu 50 ton 600 hp Contamination Sensitivity Va n e Pu m p Pisto n Pu m p 5 Gea r Pu m p

6 Shell Gadus S4 OG Designed to Improve Profitability At Shell Lubricants we appreciate that, in tough conditions and in remote areas, you are constantly striving to: Maximise machine availability Drive down production costs Cut maintenance costs 6

7 Working With the Mining Industry Shell Lubricants is a leading supplier of oils, greases and fluids to the mining industry, providing: Pioneering research centres and innovative technical partnerships to help our lubricants deliver excellent component protection. On-the-ground experts to help analyse your needs and solve your lubrication problems, thereby unlocking your mining potential. International resources offering security of supply and consistently high-quality products and services. A comprehensive range of lubricants and services for mining operations. Experience working with leading mining companies, including Anglo American, Barrick Gold, BHP Billiton, Rio Tinto, Thiess, Vale and Xstrata. Over 4,000 equipment manufacturer approvals across the product range. 7

8 Shell Gadus S4 OG Outstanding Protection Our newly extended open-gear grease range offers outstanding protection across all seasons and climates: Shell Gadus S4 OGT for warm climates and extreme hot weather Shell Gadus S4 OGXK for cold climates and sub-arctic winters Shell Gadus S4 OG Multi-Season our universal mid-range temperatures product. These products are suitable for open gears on mobile mining equipment such as shovels, excavators and hoists. They meet equipment manufacturer specifications including CAT SD4713, P&H 520 and P&H

9 Shell Gadus S4 OG Wide Temperature Range Shell Gadus S4 OG is fully compatible with aluminium complex greases. Shell Gadus S4 OGXK Shell Gadus S4 OG MS Shell Gadus S4 OGT Temperature range, C -45 C to +10 C -20 C to +40 C -7 C to +50 C NLGI 00/000 0/00 0 Base Fluid Viscosity, cst* 4,000 4,000 5,500 *1cSt = 1mm 2 /sec Temperature Range, C Shell Gadus S4 OGXK Shell Gadus S4 OG MS Shell Gadus S4 OGT 9

10 Shell Gadus S4 OG Meeting Tough Challenges The Shell Gadus S4 OG product range offers protection during: Extreme heavy-duty applications, sustained heavy loads and shock loads. Severe environmental conditions. A wide range of ambient temperatures and significant daily and seasonal temperature variations. Long operating hours with a focus on productivity and minimum, planned downtime for maintenance. It meets increasingly challenging equipment manufacturers lubricant performance requirements. 10

11 Shell Gadus S4 OG Exceeds Load-Carrying Needs The Shell Gadus S4 OG product range helps to prevent damage to gear teeth from shock loading, for reduced downtime and maintenance costs and extended equipment life. It incorporates: A specially designed anti-wear, extreme-pressure (EP) additive package*: >15% solid additives, including 5% MoS 2. Optimised for use with the aluminium complex thickener. Ultra-high-viscosity base oils that: Far exceed equipment manufacturers requirements. Offer heavy-duty protection. Synthetic technology, which: Maintains excellent flow properties across the operational temperature range. Has flow properties that are achieved without viscosity modifiers. Our products meet the essential 800-kg four-ball weld load specification. 11

12 Shell Gadus S4 OG Exceeds Load-Carrying Needs Shell Gadus S4 OG lubricants all comfortably exceed the minimum threshold of 120 in the load wear index*, which measures the ability of a lubricant to prevent wear under applied loads. Better Protection Cold Weather Products (-20 C or lower) Warm Weather Products (-20 C or higher) Shell Competitors Load wear index, kg *Calculated from data obtained from the Four-Ball EP method according to ASTM D

13 Shell Gadus S4 OG Outstanding Adhesiveness in Harsh Conditions To protect effectively, open-gear lubricants must prevent metal-to-metal gear tooth contact, even under sustained and shock loads, in the presence of water and other contaminants. Adhesiveness is critical. Shell Gadus S4 OG lubricants offer: Minimal wash-off, fling-off or squeeze out (displacement under load). A highly persistent lubricant film on gear teeth. Outstanding protection, even in challenging wet or dusty environments. In water spray-off tests, Shell Gadus S4 OGT showed negligible loss.* * Based on ASTM D4049 water spray-off test 0 Better Water-Wash-Off Resistance Shell Competitors Water spray off, % 13

14 Shell Gadus S4 OG Outstanding Adhesiveness in Harsh Conditions Shell Gadus S4 OG is formulated with: A special aluminium complex thickener modified for adhesiveness. High-quality, high-viscosity base oils to deliver good film thickness, even under high pressure. Anti-rust additives to enhance corrosion protection for components. Caterpillar shovel showing good product film adherence with Shell Gadus S4 OG TZ shovel at the same site showing poor lubricant adherence (competitor product) 14

15 Helping You Add Value SHELL GADUS S4 OG Meets the specifications of leading equipment manufacturers, including Caterpillar and P&H. Shell s optimised aluminium complex thickener formulation. Ultra-high viscosity base oil, with synthetic or semisynthetic components. Specially formulated additive package, including 5% moly, and overall >15% solids. Formulated without solvents or bitumen. NEXT LEVEL OF PERFORMANCE Provides the high level of protection required by equipment manufacturers. Outstanding adhesiveness. Persistent lubricant film. Long effective lubricant lifetime. Reliable pumpability and sprayability. Environmentally considerate. DESIGNED TO HELP MINING OPERATORS Maintains high productivity across long working hours with limited downtime for servicing and maintenance. Extends component life and reduces component failure caused by wear or corrosion. Simplifies lubricant inventory. 15

16 Shell Gadus S4 OG Clear Oil Advanced Open Gear Lubricant Shell Gadus S4 OG Clear Oil is advanced part-synthetic non-bitumastic viscous lubricant specifically developed to satisfy the demands of heavily loaded open gearing. This product was primarily designed for fixed plant (mills, kilns) for gears in vertical orientation. Shell Gadus S4 OG Clear is approved and recommended for the main Mills & Kilns OEMs as Metso, FLSmidth and Ferry Capitain. 16

17 Shell Gadus S4 OG Clear Oil Exceeds Load-Carrying Needs The Shell Gadus S4 OG Clear Oil helps to prevent damage to gear teeth heavily loaded, for reduced downtime and maintenance costs and extended equipment life. It incorporates: Extreme pressure performance: The high viscosity base oils are combined with extreme pressure additives to give the lubricant very high film strength and extreme load carrying capability needed for the protection or heavily loaded open gearing. Ultra-high-viscosity base oils The use of synthetic oil with thickening has produced a lubricant with high viscosity index, which provides good pumpability at low temperatures while maintaining high viscosity at elevated temperatures. Easier gear inspections: Static and dynamic inspections are much easier to view the gear condition without cleaning off the grease or oil, as the lube film is clear, can inspect the gearing through the lube film Shell Gadus S4 OG Clear Oil meets the essential 800-kg four-ball weld load specification. 17

18 Shell Gadus S4 OG Clear Oil Easier Gear Inspections Open gear with Shell Gadus S4 OG Clear Oil (much easier to view the gear condition) Open gear with a typical OGL (much harder to view the gear condition) 18

19 Complete Range of Open-Gear Lubricants Products Shell Gadus S4 OG Shell Gadus S2 OG Shell Gadus S2 S4 OG Clear Oils Shell Gadus S3 Repair Applications Advanced protection for mobile mining equipment that meets the latest specifications from leading equipment manufacturers. A comprehensive, versatile range with a long service history and established reputation for use in mobile and fixed plant applications, including gears and journal bearings on mills and kilns, as well as on wire ropes. Lubricants for fixed plant, including mills and kilns, whatever the lubricant delivery system, offering easier gear inspections because of the clear lubricant film. A sprayable running-in and repair grease for open gears. Smoothes surface roughness, increases contact area for loading and helps to reduce maintenance requirements. 19

20 Gadus S3 V460XD Premium Multipurpose Grease for Mining Equipments Shell Gadus S3 V460XD Greases are premium heavy-duty greases designed for use in a wide range of mining applications with shock loaded, heavy-duty slow moving bearings Approvals and non-bearing and Recommendations applications Shell in Gadus Shovels, S3 Excavators, Haul Trucks, Tractor V460XD and industrial meets equipments. following OEM specifications: Komatsu Shell Gadus S3 Komatsu V460XD Trucks Greases help improve the life of moving bearings and non-bearings heavily Terex loaded, reducing downtime and maintenance costs: Wide Operating Temperature Range: Prolonged Grease Service Life Excellent Mechanical Stability For Shock Loaded Conditions Enhance Extreme Pressure and Antiwear Properties Low Water Wash-Out Liebherr Trucks P&H BE (certified) Caterpillar (exceeds specification) Effective Corrosions Protection 20

21 Shell Gadus Product Chart for Mining 21

22 SHELL LUBEEXPERT 22

23 Shell LubeExpert 1994 Australia deep knowledge in mining equipment wide expertise in lubrication Experts Team Critical Assets 23

24 Shell LubeExpert Components Life Identify Premature Failures Unscheduled Downtime MTTR MTBS 24

25 Shell LubeExpert Focus in Critical Assets Draglines Mills Reclaimers Shovels Haul Trucks Excavators 25

26 Shell LubeExpert Management Operational Support Help them stay in control Extending best practices Total Productivity Maintenance (TPM) and Reliability Centered Maintenance (RCM) Only successful with proactive personnel like LSE s Productivity Availability Reliability + Safety 26

27 Shell LubeExpert: Developing LSE Capability Lubrication Audits Setting Performance Standards Three years to fully train a LSE to be competent in all aspects of the role Three increasing levels of competency development Five years of experience assembling and rebuilding critical equipment Shell s comprehensive training and field coaching 27

28 Shell LubeExpert Services Overview Operational inspections Visual, Temperature, and Strobe-O-Scope Thermal Imaging Vibration analysis Shut Down Inspections Visual inspections, Lubrication system audit, and spray pattern monitoring Tooth profiling Hardness testing Deflection checks Specialty product conversion 28

29 Shell LubeExpert Operational Inspections Mills, kilns and draglines don t shut down often Visual, temperature and strobe-o-scope Inspected for: Blockages Correct spray patterns Leaking seals Identify gear teeth misalignment 29

30 Shell LubeExpert Operational Inspections Quality Inspection Reports Checklist of inspection points Comprehensive review and issue report Also provide advice on required repairs Assessment of open gear and bearing lubrication Complete report using ipad/tablet Should be conducted monthly 30

31 Shell LubeExpert Advanced Operational Inspections Thermal Imaging Video Video 02

32 Shell LubeExpert Advanced Operational Inspections Vibration Monitoring Temperature Tags Used while in operation Accelerometers and Tachometers Compared over time, detecting possible wear All rotating equipment vibrates to some degree Older bearings and components vibrate more dramatically Monitoring identifies this before it becomes a problem LSE s with level 2 or above certification Correlating vibration with oil analysis can be provided 32

33 Shell LubeExpert Basic Shut down Inspections Equipment is switched off and isolated for maintenance It s the only time LSE s can access the isolated machine Reveal hidden facts How often and how much Check gearing alignment and lubricant s evenness View the gears condition See any damage or fatigue Involve detailed work that can be time consuming Every lubricant injector is operated and examined Should be conducted at least twice a year 33

34 Shell LubeExpert Basic Shut down Inspections Routine spray pattern checks Too much air pressure Not enough air pressure 34

35 Shell LubeExpert Shut Down Inspections Tooth Tape Carbon Impressions (used to monitor fatigue, pitting, spalling) Tooth Measuring Hardness Testing 35

36 Shell LubeExpert Support Focus Troubleshooting Bull Gear New Pinion 38

37 Shell LubeExpert Support Focus Failure Diagnostics Understanding how it failed The root cause of failure, has to be know to prevent it from occurring again in the future 39

38 Shell LubeExpert Support Focus Training Skills and competences Safe working procedures (SWP) Job Safety Analysis (JSA) 40

39 Success Case (Demonstrated Value Records DVRs) 41

40 Success Case 01 Chaneme (Hitachi Dealer) Shell Gadus S2 OG 85 Pins & Bushes Hitachi Excavators 1 CHALLENGE 2 SOLUTION 3 OUTCOME Chaneme (Hitachi Dealer in Colombia) in coal mine in Calenturitas Colombia maintains 5 excavators Hitachi EX Chaneme wanted to increase the pins & bushes life beyond the current 4,000 hrs. Shell, through Shell LubeExpert, identified the failures causes and proposed the use of a highperformance grease (Shell Gadus S2 OG 85). By identifying the failures causes, implementation of a routine inspection process of lubrication system and critical components, together with the application of high performance grease (Shell Gadus S2 OG 85) the pins and bushes life increased from 4,000 hrs to 16,000 hrs. 4 VALUE Savings of over USD 600, with increase of productivity and with life extension of pins and bushes Increased pins and bushes life from 4,000 hrs to 16,000 hrs The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices. 42

41 Success Case 02 Albian Sands Energy Shell Gadus S4 OGK/OGXK Saddle Block Liners 1 CHALLENGE 2 SOLUTION 3 OUTCOME Albian Sands Energy in Fort McMurray Canada operates 10 Bucyrus 495 HF shovels. The key challenge was cold temperature and the ability of the product to not just pump through the system, but be robust enough that it provided the best lubrication during winter. Shell, through Shell LubeExpert, made a detailed analysis and inspection of the application and proposed the use of a highperformance lubricant for saddle block liners, open gears, boom and revolving frame (Shell Gadus S4 OGK/OGXK). By implementing of a routine inspection process of the lubrication system and the critical components of the shovels, together with the application of high performance grease (Gadus S4 OGK/OGXK) the saddle block liners life achieved over 32,000 hrs against a estimated life of 10,000 hrs. 4 VALUE Savings of over USD 1,800,000.00/year with increase of productivity and with life extension of saddle block liners Increased saddle block liners life from 10,000 hrs to 32,000 hrs The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices. 43

42 Success Case 03 Iron Ore Mining in Brazil Shell Gadus S3 V220C 2 Bearing of the Bucket Wheel 1 CHALLENGE 2 SOLUTION 3 OUTCOME Iron ore mining in Brazil operates a ThyssenKrupp 5PA5A reclaimer. The challenge was increase the bearing of the bucket wheel life beyond the current 4,000 hrs. Shell, through Shell LubeExpert, identified the failures causes and proposed the use of a highperformance grease (Shell Gadus S3 V220C 2). By implementation of a routine inspection process of the lubrication system, resizing of bearings sealing and application of a high performance grease (Gadus S3 V220C 2), the bearing life increased from 4,000 hrs to over 8,600 hrs. 4 VALUE Savings of over USD 2,000,000.00/year with increase of productivity and with life extension of the bucket wheel bearing Increased bucket wheel bearing life from 4,000 hrs to 8,600 hrs Significantly reduction the reclaimer unavailability and therefore increased its productivity The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices. 44

43 Success Case 04 The Lagunas Norte Mine in Peru Shell Tactic EMV Conveyor Belt Bearings 1 CHALLENGE 2 SOLUTION 3 OUTCOME Lagunas Norte was previously using Shell Gadus S2 V220 2 grease for manual lubrication. The greasing schedule was not always completed, and irregular lubrication, together with contamination by dirt, dust and water, was causing the production belt bearings to wear. Consequently, the company experienced unscheduled stoppages and production losses. Shell Lubricants recommended the installation of a Shell Tactic EMV automated grease dispensing unit prefilled with Shell Gadus S3 T220 2 grease, and staff training using the Shell LubeCoach service. Shell Tactic EMV lubricating units were installed at two critical production points to supply precise, reliable and regular amounts of grease to the machines. After implementing the recommended solution, Lagunas Norte experienced: a decrease in manual lubrication time that enabled technical staff to attend previously neglected areas. the elimination of premature bearing failures through reliable and regular lubrication. peace of mind from knowing that the greasing was automated and set specifically for the machines requirements. VALUE By identifying the mine s need for greasing support and a premium grease to perform well in a high-contamination environment, Shell was able to recommend a solution that met both requirements. Lagunas Norte reported a potential annual saving of US$167,417 as a result of implementing the solution. The savings indicated are specific to the calculation date and mentioned site. These calculations may vary from site to site, depending on the application, the operating conditions, the current products being used, the condition of the equipment and maintenance practices. 45

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