ludwig - methods of application of open gear lubricants-stle

Methods of Application of Open Gear

Lubricants

Lawrence G. Ludwig Jr. CLS, OMA, CMFS

Schaeffer Mfg

Open Gear Lubricant Product Types

Presently Used

Current Open Gear Lubricant Product Types Being

Used By Different Operations On Type 1 and 2

Open Gears Include:

- Asphaltic Type (aka Residual Type)

- Semi-Fluid Greases (aka Paste Type)

- Semi-Fluid Grease Cut Backs

- Gel/Polymer Thickened Lubricants

- High Viscosity Synthetic Oils

OGL Types

Asphaltic

– Formulated from high viscosity mineral oils or residual

compounds that contain a high level of asphalt or

bitumen and a volatile solvent diluent

– Viscosity can be as high as 3,000 SUS @ 100°C

Semi-Fluid Greases (Paste Type)

– Medium to high viscosity petroleum oil which can contain

some asphalt or bitumen or a synthetic oil, a gelling

agent or thickener system, solid lubricants, rust inhibitors,

and extreme pressure agents

– Solvent cut-back versions contain a volatile solvent for

ease of application

– NLGI Grades 00 to 1

OGL Types

Gel/Polymer Thickened

– Contain a medium to high viscosity petroleum or

synthetic base oils, a polymeric thickener, E.P. agents

and solid lubricants

– Some formulations may contain VI Improvers to boost

Viscosity

– May contain a solvent diluent for ease of pumpability

– NLGI Grade 000 to 0

High Viscosity Synthetic Oils

– High viscosity PAO or PAO/Ester blends

– ISO 1000 or greater

– Conform in viscosity to old 14R or 15R AGMA viscosity

classification

Methods OF Application Used

Spray/Atomization Systems Traditional Type

Airless Spray

Gravity Feed or Drip Feed

Continuous Lubrication Oil Bath (Splash/Sump)

Idler Immersion (aka Transfer)

Continuous Pressure Lubrication

Hand Brush

Pour it on

Application Methods

The OGL must be fluid enough to be applied by any of these methods

During operation the OGL must be viscous enough and have the proper consistency to resist squeeze out and fling off Resist channeling (dripping into splash pan or oil bath

Consistency or grade used must permit easy application under the prevailing ambient conditions

Spray/Atomization Systems

Most common type used is intermittent mechanical spray system

Usage depends on OGL remaining on the gear teeth through several revolutions

Pump Selection

OGL being used should be

applied using a minimum

pump ratio of 50:1

Ideal pump to use is a 75:1

ratio pump

Preferred type of pump to

use is a positive

displacement double acting

shovel pump

Spray Time and Amounts

Spraying time should equal the amount of time it

takes for 1 or 2 revolutions of the pinion

AGMA 9005 E-02 recommends a maximum interval

of 2 hours per application

Amount used depends upon:

Open gear application

Pitchline velocity

Rated electrical power draw on the motor

Type of gearing

Type of OGL used

Application Rates and Spray Pattern

Application rates are expressed in grams per centimeter face width per hour AGMA 9005-D94 and AGMA 9005-E02

Lubricant supplier

A spray pattern without any gaps should be maintained

OGL should be distributed over the entire height and width of the tooth flank on the loaded side of the gear

Lubricant Quantity Guidelines for Intermittent Methods of Application

Gear

diameter in

meters (feet)

¼ Hour 1

Face Width in meters (inches)

0.2 0.4 0.6 0.8 1.0

(8) (16) (24) (32) (40)

1 Hour 1


0.2 0.4 0.6 0.8 1.0

(8) (16) (24) (32) (40)

2 Hours1, 2


0.2 0.4 0.6 0.8 1.0

(8) (16) (24) (32) (40)

3.0 (10)

5.9 8.9 11.8 14.8 17.8

23.7 35.5 47.3 59.2 71

59.1 88.8 118 148 178

3.7 (12)

8.9 8.9 11.8 14.8 17.8

35.5 41.4 53.3 65.1 76.9

88.8 104 133 163 192

4.3 (14)

8.9 11.8 14.8 17.8 20.7

41.4 47.3 59.2 71.0 82.8

104 118 148 178 207

4.9 (16)

11.8 14.8 17.8 20.7 23.7

47.3 59.2 71.0 82.8 94.7

118 148 163 207 237

5.5 (18)

14.8 17.8 20.7 23.7 26.6

59.2 71.0 82.8 94.7 107

148 178 207 237 266

6.1 (20)

17.7 20.7 23.7 26.6 29.6

71.0 82.8 94.7 107 130

178 207 237 266 325

6.7 (22)

20.7 23.7 26.6 29.6 32.5

82.8 94.7 107 118 142

207 237 266 296 355

7.3 (24)

23.7 26.6 29.6 32.5 35.5

94.7 107 118 130 154

237 266 296 325 385

7.9 (26)

26.6 29.6 32.5 35.5 38.5

107 118 130 142 166

266 296 325 355 414

8.5 (28)

29.6 32.5 35.5 8.5 41.4

118 130 142 154 178

296 325 355 385 444

AGMA 9005-E02 Recommendations

Application Rate To Use – Lube Supplier Formulation for applying #200 Silver StreakXYZ OGL

Pinion Width X 2.5 (3) grams per operating hour2.5 grams per hour

Pinion Size Amount per size Amount of product

17" = 43.18 cm X 2.5 grams = 108 grams per hour

18" = 45.72 cm X 2.5 grams = 114.3 grams per hour


20" = 50.80 cm X 2.5 grams = 127 grams per hour




24" = 60.96cm X 2.5 grams = 152.4 grams per hour

Application Rate – OEM (FFE Minerals)

The recommended total quantity of lubricant (all

nozzles) is given by the following:

Q = [(0.6 x D) + (0.15 x F) – 4.8] x T

• Q = total quantity of lubricant per application ounces

• D = gear diameter, feet. If D <10 feet, then set D=10 feet

• F = gear face width, inches. If F<8 inches then set F=8 inches

• T = time interval between applications, hours

• Suggested time interval between applications is 0.25 hours 1

hour is maximum interval permitted

Example

Q = [(0.6 x 12) + (0.15 x 4) – 4.8] x 0.25 = 0.75 ounces

Spray Nozzles and Placement

Number of spray nozzles to

use for a given application is

determined by the gear

width

Should be properly spaced

to provide adequate

coverage across the entire

face of the gear teeth

Overlap of at least 25mm

25 to 50mm overlap

Gear Width

375 mm

Spray Nozzle Placement

Slow speed open gearing operating up to 10

meters per second (2000 ft./min)

End nozzle placement 50 to 65 mm (2 to 2.5 inches) from

the gear face edge

Remaining nozzles spaced 130 to 180 mm (5 to 7

inches) of center

Nozzle location is a function of spray pattern

Spray Pattern

Correct spray pattern covers the entire gear face

overlapping each other

Position spray nozzles to direct OGL at loaded

profile of the gear teeth

Maximum distance of 150 to 200 mm (6 to 8 inches) from

the gear teeth

Spray Pattern

Air Pressure Settings Air pressure to the spray bar must be properly set

To low of an air pressure will result in splattering, while to

high of an air pressure will blow the OGL off the gear.

Air pressure settings – minimum of 517 kPa (75 psi) and

maximum of 620.5 kPa (90 psi)

Air supply allowed to blow 5 to 10 seconds after OGL is

dispensed to keep nozzles clean

Spray Pattern Checks

Checks of spray patterns are recommended

Spray bars have different designs and some do not allow

easy access to check spray patterns.

It is generally recommended to check the spray pattern

while the machine is operational

If spray bar does not swing out or open outwards check

the spray pattern when the machine is not operational

Spray Pattern Check

Recommended procedure:

Follow isolation procedures. Open inspection door

Use clean piece of cardboard or flat metal piece in front of

the gear set. Mark the width of the gear set on the test

piece

Operate the lube system and check the lubricant

coverage

Check pattern after one cycle

Coverage should overlap. No gaps

Adjust air pressure, spray angle and spray cap if gaps are

found

Spray Bar

If the spray bar requires

changing alter the spray

bar design so the spray

pattern can be checked

during operation

Spray bars should be set

at a 30° angle onto the

drive or loaded side of the

pinion or girth gear

This achieves good

distribution in an upward or

downward direction

Spray Nozzles

Spray nozzles should be set back appropriately depending on the air pressure and the tooth height Maximum distance of 150 to 200 mm (6 to 8 inches) from

the gear teeth

Width of the gear tooth determines the amount of spray nozzles required

Spray nozzles should not be installed to spray upwards onto the pinion or the girth gear Clogging of spray heads

Insufficient spray pattern

Position of Spray Bars & Nozzles Single

Pinion

4

4

4

Solvent cut back paste type,

product should be applied to the

girth gear using spray nozzle

positions 3 or 4 immediately after

mesh to allow evaporation of the

solvent diluent

Position of Spray Bars & Nozzles Dual

Pinion

Outward

turning Pinion

Inward turning

Pinion

Position of Spray Bars & Nozzles Dual

Pinion Spray nozzles for the lifting pinion spray header are

best directed at the girth gear

Nozzles for the second header should direct the

OGL at the lower dedendum of the trailing pinion

pressure flanks as they pass a point approximately

80° to 120° from initial mesh

For lower speed Type 2 drives it is recommended

that the OGL being used be applied to the pressure

flanks of the pinion

Lifting pinion, location of the nozzles should be positioned

in such a way to direct the OGL to the lower dedendum

area of the pinion pressure flanks of the of the second or

third tooth disengaging of the girth gear

Weighing of Expelled OGL from Injectors

Check amount of OGL expelled from each injector

Turn Off Air Line

Cycle system to relieve pressure

Disconnect line before going to nozzle

Use a pre-weighed plastic bag

Catch lube in plastic bag

Weigh the bag after one cycle For example a Lincoln SL-1 expels

1.31 grams (0.046 ounces) per cycle

Timer Settings

Timer settings should be set to shortest frequency depending upon type of OGL used

Asphaltic and High viscosity synthetic – 10 to 20 minutes

Semi-fluid greases and gel/polymer types – 15 to 30 minutes

A strobe light can be used to check the appearance of the gears during operation

Set strobe at the same speed that the gear is turning

OGL Appearance On Gears

A well lubricated gear will

have a dark color to semi-

transparent appearance

and strings of lubricant will

appear as the gear and

pinion teeth separate

An over lubricated gear will

be black in color with

excess lubricant dripping,

fling-off or build up on the

teeth and root zones of the

gears

Temperature and Alignment Checks

Temperature readings across the face of the

pinion gear is recommended during inspection

Use non-contact thermometer

Readings should be taken at least 25mm (~1 inch) from

the end of the gear tooth)

An uneven temperature difference across the gear tooth

may indicate misalignment

Roughly a 10°C (18ºF) difference across the gear

tooth

Check contact patterns while the gear is in

operation or immediately after it has rotated for

one or more cycles

Provides information about gear alignment

Gravity Feed Or Drip Systems

Limited to open gearing

with pitchline velocities of

7.5 meters per second

(1500 fpm) or less

Asphaltic or high viscosity

synthetics primarily used

If grease type or

gel/polymer types are used

the system must contain

pressurized feed lines or

applicator wheels

Drip tubes should be

spaced no farther than

51mm apart (2 inches)

Oil Bath System (Sump/Splash) Simplest method of

lubricating open gears

The pinion gear or an idler is

allowed to dip into the open

gear lubricant carrying it

around to the girth gear

limited to drive systems with

pitchline velocities below 10

meters per second (2000

feet per minute)

Lubricant level should be 1/3

of the vertical tooth in

operation and ½ of it when

the drive is not in operation

Idler Immersion

Primarily used on slow turning Type 2 gear drives

Limited to systems with pitchline velocities below

1.5 meters per second (300fpm)

Some systems contain re-circulating pumps and

filtration systems

OGL applied via a simple header to the pressure flanks

of the pinion prior to meshing with the girth gear

Splash And Idler Immersion

Asphaltic, high viscosity synthetic oil, semi-fluid grease and gel/polymer type OGL can be used in these type of systems Asphaltic and high viscosity synthetic oil type OGLs are

recommended to have a minimum viscosity of 1000 cSt at 40°C

Semi-fluid grease and gel/polymer type OGLs should be semi-fluid to fluid in consistency

AGMA 9005 D-94 and 9005 E-02 and some OEMs also offer guidelines Use highest viscosity grade over the ambient temperature

range expected

Sump heaters may be needed for low temperature start-up)


Known as circulation lubrication or full pressure

spray

Continuous flow by means of an externally driven

pump that floods OGL onto the pinion and girth

gear pressure flanks prior to mesh

Prior to application OGL is filtered

Some systems contain dual filtration to filter the OGL

from the oil return line

Designed to operate effectively with AGMA 4EP

(ISO 150) to AGMA 10EP (ISO 2200) fluids Asphaltic or High viscosity synthetic oil type

Hand, Brush Or Pour It On

Oldest and most dangerous

method

Limited to asphaltic or high

viscosity synthetic type OGL

Method can result in

improper amounts being

applied and introduction of

contaminants

Considerations to be Taken into Account

The OEM requirements specified

The type of open gear application – mills, kilns, shovels, draglines, etc.

The ambient temperatures encountered in the area the machine operates in

The climate conditions the machine operates in. Ice, snow, wet, dusty

How the lubricant being applied

If applied by a spray or automatic lubrication system, what type of lube system is installed? Farval, Lincoln, Worner, Droppsa

Considerations to be Taken into Account

The type and ratio of the pump utilized on the automatic lube system

The width of the pinion gear

Whether the gearing is a double or single acting pinion

The power rating on the electric motor

Position and number of spray nozzles

New Equipment Procedures

Clean all coatings and debris from the gears

Coat the gear and pinion on the load carrying tooth

flanks with a light film of open gear lubricant by

some sort of spray method

Application by brush or spatula can also be done but this

method is discouraged because of safety considerations

Run equipment slowly under no load to verify that

there is lubricant throughout the entire load zone

New Equipment Procedures – Start Up

Gradually increase speed and load, while turning on

the automatic lube system

Monitor continuously until a proper coating is

maintained

Check the load carrying patterns visually while the

open gear drive is running on the auxiliary motor or

after the drive has been shutdown after it has been

rotated completely several times

If load pattern is poor the drive components can be

realigned or corrected following OEM operational

instructions

Load Carrying Patterns

Spray and Drip Systems

Spray Systems: Prior to startup, purge the lube lines and check spray

patterns for complete coverage

Adjust air pressure and volume as needed

Drip Systems: Most open gear lubricants are designed to adhere where,

they are applied. Drip tubes should be spaced no farther

than 51 mm (2 inches apart)

Procedure For Replacing OGL

Purge the lube lines thoroughly

Start timing settings 50% higher than the

operational settings to ensure all lines are purged

and flushed and have built up a sufficient lubricant

coverage film before reducing the lubricant

consumption rate to the operational settings

Readjust the timer to maintain an adequate

lubricant film

Lubricant quantity should be reduced at 5-minute

intervals of 150 to 200 hours for mills and 100-150 hours

for shovels, draglines and excavators

Procedure For Replacing OGL

Product performance should be monitored

Spray system should be set to ensure the intervals

between spray cycles area are as short as possible

Adjust the air pressure and volume as needed

Inspections of the lubricating systems, tooth flank

conditions and the spray pattern are required to

ensure reliable operation

The spray system should be maintained thoroughly

in accordance with the OEM’s instructions

Questions?

ludwig - methods of application of open gear lubricants-stle

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