Oil presentation

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 / Installationwoody@lantic.net lambert@trackless.co.za082 336 9002 083 381 1600

Terence WoodSalesterence@trackless.co.za082 338 3536