Trackless Support Services
Proposal to address 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.
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
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
Nμ
Relief from the Egyptian tomb of Jehutihotip approx. 1800 B.C.
Basic Theory• Boundary lubrication: 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)
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.
Different Applications on the mine• Rolling Bearings: Include Plummer Blocks
• White metal bearings: Winders, Main Fans, Compressors, Mills, etc.
Different Applications on the mine• Diesel Engines: Diesel Loco’s
• Open gear Lubrication: Mill Girth-gear and pinion
Different Applications on the mine• Closed Gear Lubrication: Splash Lubrication
• Closed Gear Lubrication: Oil pressure Circulation
Different Applications on the mine
• Transfer energy: hydraulic systems
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)
Additives – Oil Soluble• 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)
Additives – Oil Soluble• 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
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
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
Types and grading
Viscosity – Measure of the internal shear friction or resistance to flowAbsolute Viscosity – Force necessary to move a 1cm² plane at 1m/s (poise = grams/cm²)Kinematic Viscosity – The accepted standard viscosity measurement throughout the world. ()
Types and grading
Types and grading
Condition Monitoring• Continuous Monitoring – 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)
Typical Mill lubrication circuit1. Trunion Bearings2. Girth-Gear3. Pinion4. Pinion Bearings5. Gearbox6. Motor Bearing7. Motor
SAG Mill2 11
3 445
7 66
In-Line Return Sediment Vessel
Oil Tank
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
In-Line Return Sediment Vessel
Typical use : ball mill returnLine and crusher return line.
CIRCULATING REFINER SYSTEM
For cleaning dirty hydraulic/gearbox oil to specifications of new oil in hydraulic and winder brake systems, crusher oil tank, ball mill reservoirs and industrial gearboxes.
ONBOARD REFINER SYSTEMMaintains oil 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.
BULK OIL REFINER PLANTS
For cleaning dirty/ dispensing hydraulic/gearbox oil to specifications of new oil.
GIRTH AND PINION LUBRICATION 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.)
BREATHERA high performance Breather.Transparent casing indicates outward breathing, absorbs and drain moisture , prevents solid and semi-solid particles above 5 micron to form ingress in gearboxes and reservoirs/tanks.
Conclusion• Oil is the 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
CONTACT INFORMATION
Brian Wood Lambert le RouxOwner Sales / [email protected] [email protected] 336 9002 083 381 1600
Terence [email protected] 338 3536