Oil presentation

Oil presentation

• 1.
  Trackless Support Services Proposal toaddress internal wear caused by contamination In hydraulic systems, lube systems and gearboxes. Reduce environmental impact by producing more efficient filtration systems for hydraulic/lube systems and gearboxes and lubricating oils for girth gears, pinions, couplings, etc.
• 2.
  Contents • Lubrication: Background •Lubrication: Basic Theory • Lubrication: Function of lubrication • Lubrication: Applications, types and additives • Lubrication: Systems and maintenance • Lubrication: Condition Monitoring • Lubrication: Oil as a lubricant • Conclusion • Contact info
• 3.
  Background • Tribology –The study of rubbing • F = μN – F = Force required to move the component – μ = Coefficient of friction – N = Force proportional to vertical force F F N μ Relief from the Egyptian tomb of Jehutihotip approx. 1800 B.C.
• 4.
  Basic Theory • Boundarylubrication: Lubrication film is insufficient to separate the contacting surfaces. • Mixed Lubrication: Lubrication film partly separates the contacting surfaces. • Hydro dynamic Lubrication: Lubrication film completely separates the two contacting surfaces. (Jacking oil) • (Insert Steinbeck Diagram with illustrating figures)
• 5.
  Functions of lubrication •Clean: Remove contaminants from components to minimize grinding paste. • Cool moving elements: By reducing friction and transport heat to a place where it can be dissipated from the system • Prevent contamination: Act as a dynamic seal. Pistons, mechanical seal, Seal ring. • Dampen shock: Oil dampers • Transfer Energy: Hydraulic brakes, gear tooth contact, compensating cylinders • Prevent corrosion: Either providing a protective layer between steel and oxidant or chemically neutralizing the corrosive product.
• 6.
  Different Applications onthe mine • Rolling Bearings: Include Plummer Blocks • White metal bearings: Winders, Main Fans, Compressors, Mills, etc.
• 7.
  Different Applications onthe mine • Diesel Engines: Diesel Loco’s • Open gear Lubrication: Mill Girth-gear and pinion
• 8.
  Different Applications onthe mine • Closed Gear Lubrication: Splash Lubrication • Closed Gear Lubrication: Oil pressure Circulation
• 9.
  Different Applications onthe mine • Transfer energy: hydraulic systems
• 10.
  Types of Lubricants •Industrial-type lubricants: – Petroleum based – Above named examples • Synthetic Oils – Hydrocarbon derived, Esters, Chlorinated compounds and Silicones. – Expensive – Used in Refrigeration systems and all type of compressors. • Greases – Semi-fluid product resulting from dispersion of a thickening agent in a liquid lubricant. – Thickened with Metallic soaps (Aluminum), Modified clays (Bentonite) and low friction powders (Silica aerogels)
• 11.
  Additives – OilSoluble • Detergent dispersive: – Prevent coalescing of products of oil oxidation – Alkaline and combat corrosion by acidic residues from Sulfur • Anti-wear additives (EP-additives): – Prevent destructive metal-to-metal contact – Activated by high pressures and high temperatures at points of contact and form compounds with metal to prevent welding (Sulfur and phosphorous) • Viscosity Index (VI) Improvers – Reduces the rate of viscosity decrease with temperature increase – This additives brought about the introduction of multi-grade oils (15W/40)
• 12.
  Additives – OilSoluble • Oiliness Improvers: – Improve the lubricity (Stickiness to steel but lower resistance to shearing) • Adhesion Improvers – Latex and synthetic rubber additives tend to improve the stickiness of the lubricant
• 13.
  Additives – Inhibitors •Oxidation and rust inhibitors: – When a lubricant is subjected to high temperatures oxidation occurs which increases the viscosity, develops acidic contaminants and form carbonaceous matter – Additives such as Zinc-dithiofosfate reduces oxidation and provides a protective layer against rust. • Anti-foam Inhibitor – Foaming or Air entrainment of oils causes problems such as cavitation, reduced load carrying capability and increased temperatures. – Silicone fluids promote air release from the lubricant • Demulsifying Inhibitors – Promotes separation of lubricant from moisture content
• 14.
  Additives – Solids •Molybdenum Disulfide (MOS2) – Increases the load carrying capacity of the lubricant and is effective at high speeds • Graphite – Has a low coefficient of friction and is effective at low speeds (Often combined with MOS2) • Zinc/Copper/Lead Aluminum Nickel powders – Added to greases to enhance the load carrying and anti-seize properties
• 15.
  Types and grading Viscosity– Measure of the internal shear friction or resistance to flow Absolute Viscosity – Force necessary to move a 1cm² plane at 1m/s (poise = grams/cm²) Kinematic Viscosity – The accepted standard viscosity measurement throughout the world. (𝒌𝒗 = 𝑨𝒃𝒔𝒐𝒍𝒖𝒕𝒆 𝒗𝒊𝒔𝒄𝒐𝒔𝒊𝒕𝒚 𝑫𝒆𝒏𝒔𝒊𝒕𝒚 )
• 16.
  Types and grading
• 17.
  Types and grading
• 18.
  Condition Monitoring • ContinuousMonitoring – Temperature; Flow; Filter delta P; Oil level check; visual inspections. • Open Gear – Visually inspect contact planes; Contaminants in grease; Profile of teeth. • Wear rate Analysis – Material loss – Erosion (Abrasion, Cavitation, wipe) – Corrosion (Oxidation usually in the presence of water) – Cutting (Manufacturing faults, Thrusting) – Pitting (fretting, Fatigue due to overloading)
• 19.
  Typical Mill lubricationcircuit 1. Trunion Bearings 2. Girth-Gear 3. Pinion 4. Pinion Bearings 5. Gearbox 6. Motor Bearing 7. Motor SAG Mill2 11 3 44 5 7 66
• 20.
  In-Line Return Sediment Vessel OilTank Mill Bearing Return Oil Sediment Filter Assembly Filter Bags Non-Solute Water (When an oil-water mixture are under pressure, water “dissolves” into the oil, giving it a milky- contaminated texture. This filter takes out water before that can happen) Water Drain Tap Transparent Lid Bypass Channel Filtered Oil Channel
• 21.
  In-Line Return SedimentVessel Typical use : ball mill return Line and crusher return line.
• 22.
  CIRCULATING REFINER SYSTEM Forcleaning dirty hydraulic/gearbox oil to specifications of new oil in hydraulic and winder brake systems, crusher oil tank, ball mill reservoirs and industrial gearboxes.
• 23.
  ONBOARD REFINER SYSTEM Maintainsoil cleanliness and integrity at all times whilst machine( lhd, drill rigs, excavators, frontend loaders, etc.)operates. Eliminates the replacement of oil and dramatically reduces the wear and failures in hydraulic systems. Saves hydraulic components( hydraulic pumps, valves, valve bank, servos, etc.
• 24.
  BULK OIL REFINERPLANTS For cleaning dirty/ dispensing hydraulic/gearbox oil to specifications of new oil.
• 25.
  GIRTH AND PINIONLUBRICATION UNIT The requirements for a lubricant to meet the demands for large, slow moving girth/pinion gears: • One hundred present synthetic oil. • Totally waterproof. • Impact and shear resistant. • Ability to contract under severe pressure. • Ability to enhance healing in scored/pitted gears. • Tenacious adhesion and sealing qualities. • User friendly and easy to apply. • Transparent (to make inspection of pinion/girth gear easier.)
• 26.
  BREATHER A high performance Breather. Transparentcasing indicates outward breathing, absorbs and drain moisture , prevents solid and semi-solid particles above 5 micron to form ingress in gearboxes and reservoirs/tanks.
• 27.
  Conclusion • Oil isthe blood of our machines and should be cared after • Expenses on proper maintenance is visible costs but account for long term savings Results of filter installation • No oil changes After the installation • No down-time due to blockages in the valve panel • Hydraulic components lasts longer • Lower impact on the environment due fewer oil changes
• 28.
  CONTACT INFORMATION Brian WoodLambert le Roux Owner Sales / Installation woody@lantic.net lambert@trackless.co.za 082 336 9002 083 381 1600 Terence Wood Sales terence@trackless.co.za 082 338 3536