Open Gear Lubrication:

Reducing wear with improved lubrication methods

OC 40

A cement mill was experiencing extreme wear due to an open gear working out of the specification recommended by the open gear manufacturer.

This customer was looking for a solution to reduce or remove completely wear in their equipment, therefore they contacted our open gear experts to look for the causes.

The mill was currently using a competitor’s product without any method to control and measure the status of the lubricant and the open gear. Quaker Houghton experts suggested to perform a full analysis and they found:

• Vibration measurements: RMS (Root Mean Square) extremely above specification. Equipment used Adash Vibrio 4900.
• Temperature measurements noted with infrared Thermometer to evaluate potential mechanical issues (misalignment, wobbling, …).
• Contact surface: it was expected a bad contact surface considering the vibrations and temperature values.
• Spray pattern:

1. the nozzles were orientated upward blocking them with the grease.
2. the tooth flank was not completely covered by the grease.
3. Pulverization cycle was too long.

The Quaker Houghton Solution

Quaker Houghton experts recommend OC 40 to lubricate the open gear, a high-quality product that when using in the right conditions will reduce wear. This product recommendation was followed by a series of methods to improve the lubrication. After 3 years the status of the gear is:

• Vibration measurements: Considering the kind of equipment any RMS measurement below 2,3 mm/s is considered as if the equipment would be working as a new conditions.
• Temperature measurements noted with infrared Thermometer. Temperature profile is stable (≤ 3°C), and it does not show any significant variation. A variation of temperature along the teeth flank ≤ 3°C is not considered significant.
• Contact surface: a very good contact surface (it must always be > 80%) as it was expected considering the good vibrations and temperature values.
• Spray pattern:

1. Our experts recommended to fix the nozzles horizontally or downwards. Improving lubrication.
2. The tooth flank was completely covered by the grease.
3. Pulverization cycle was adjusted to be as short as possible, achieving better lubrication and reduction in consumption.

The Product

OC 40 is a special fluid for in-service lubrication of large crown-and-pinion open gears as in SAG mills, ball mills, kilns and agglomeration drums used mainly in large-scale mining and in the cement industry.

The lubricating film on the tooth flanks becomes visible under a UV lamp.

The Benefits

The maintenance department observed several benefits since using the Quaker Houghton solution, including:

• Vibrations values are very low, matching expected values for a new girth gear.
• Temperature profile is stable along the teeth width in both pinion and girth gear.
• Reduction of the wear in the open gear.
• The solution offers excellent corrosion protection.
• It can handle heavier loads more effectively.
• The overall consumption has decreased 20%.

For additional information or questions contact:

Guillermo Díaz del Pino

Business Development Manager Operating Solutions Europe

[email protected]

https://home.quakerhoughton.com/