Large open gear drives

Large open gear drives: Cement & Mining Industry

Lubrilog is specialized in very high quality lubricants for the lubrication of Open Gear Drives in raw material industries (Mining industry, Cement plants, Fertilizer industries, Power stations (coal), Steel, Aluminum, Chemical, Environment, etc.)

Approvals

mareche, lubrilog

References

-Cement industry: Lafarge, Italcementi, Holcim, Vicat, Secil…
-Mining industry: Codelco, Anglo-American, Nicico, Managem…

See PDF Raw Materials Process.

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Grafolog: Graphite Greases for Open Gear Dives

The Grafolog egrease range are designed for the lubrication of open gears of very high power used in the cement, lime, steel, thermal power plants (coal route), ore processing, fertilizers, chemistry, etc. MORE INFO
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Gear Fluid: High Viscosity Oils for Open Gear Drives

Gear Fluid is a range of high viscosity oils for the lubrication of open gears of very high power oils used in the cement, lime, steel, thermal power plants (coal route), ore processing, fertilizer, chemistry, etc. MORE INFO
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Lubriclean EP: Open Gear Cleaner In Service

Lubrilog has also developed an innovative cleaning solution in service: Lubriclean EP. Considering the cost of a production shutdown of an oven or a mill, this solution enables in 1h 30 maximum and without production stop. MORE INFO ·


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Appropriate Lubricant selection according to stage and application system

-Priming
-Running-in
-Service
-Spraying
-Bath
-Circulation
-Cleaning & Repair

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After erection and setting-up of the drive (girth gear and pinions) Lubrilog recommends proceeding in two steps for which specific products were developed.

Priming

Priming is the initial lubrication of the gear set. Immediately after the end of the mechanical settings a thick coat of specific and very sticky lubricant containing graphite is applied manually on the working flanks (with brush, without air inclusion, on the previously cleaned surfaces). All other teeth surfaces have to be covered as well, but in lower quantity.

Main functions of the initial impregnation are:
· Avoiding corrosion. · Obtaining a perfect protection by forming an efficient lubricant film from the first teeth contacts (despite the initial surface states and the medium contact quality). · Assessing the running time loading in order to be able to correct mechanical settings if necessary.

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Running-in

Based on its experience, Lubrilog has developed a running-in process for large open gear drives, providing a maximum security and a long life. The running-in phase is very important and determines the shelf life of the open gear drive. Indeed, damages can appear very quickly after the start-up stage. Even with very good mechanical settings, surface states are not perfect and the initial contact may represent only 50 to 60% due to machining or geometry imperfections. In order to respect the mechanical constrains for which the girth gear was calculated, it is very important to use a running-in lubricant (slow lapping without abrasive particles) to improve the state of working flanks. This is achieved by distributing over a larger surface the transmission and the effective power.

The running-in procedure is different depending on the machine driven by the gear set (mills in cement plants or coal power stations, kilns, etc). Therefore, it is necessary to respect the manufacturer’s instructions concerning the loading steps.

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Service

Selection the appropriate service lubricant will determine the correct operation of the pinion gear and girth gear and extends its life. The top quality lubricants Gear Fluid & Grafolog offer the best solution for different application systems of large gears by spraying, bath or circulation.
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Spraying

The following table shows the range of greases and oils suitable for spray lubrication (spraying of lubricant on the working flanks). LUBRILOG helps you to find the best lubrication parameters (choice of the lubricant, amount to apply and lubrication intervals, preventive maintenance controls to be carried out).

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Bath

According to the circumstances, the following lubricants can be applied either directly on the teeth drive (dipping) or indirectly thanks to the transfer pinion (idler).

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Circulation

The choice of the lubricant (see table below) depends on the following parameters:
· Design of drive housing. · Sealing of drive housing. · Pump’s performances. · Temperatures.

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Cleaning & Repair in Motion

For situations that might be challenging for the good performance of the open gear drives, Lubrilog has developed repair and cleaning solutions. Repair or cleaning operations can be performed while operating, without production loss.

Repair Lubricant in Motion:

The repair lubricant, Grafolog RPR (which has to be applied by a Lubrilog specialist) is intended to eliminate some defects (scuffing, marks of foreign bodies, etc.) and to obtain a satisfying loading surface within a very short time. This operation does not exempt from geometrical setting of the drive and should it be necessary it can be completed by a mechanical intervention at standstill (grinding).

Gear Cleaning in Motion:

The cleaning solvent without VOC’s (Volatile Organic Compounds) Lubriclean EP has been developed for cleaning (in maximum 1 hour) large open gears exposed to very high abrasion (nature of the treated material, poor state of housing’s sealing). Lubriclean EP can be applied as a preventive operation or before a maintenance shutdown.
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