Welcome to Lubrica/on Engineers SA
Who are we ?
Producer of high performance industrial lubricants, oil analysis services & reliability solu/ons
Expert in maintenance cost reduc/on
Who are we ?
Based in more than 60 countries
State of the art plant based in Kansas USA
Interna/onal Headquarters based in UK
Who are we?
What is the main differences of LE, compared with other lubricant
producers ?
Studies shows that the lubricant
cost, represents only 2-3 % of the total maintenanc
e cost
LE uses 100 % Paraffinic base oil
Synthe/c Base oil
LE adds unique-proprietary addi/ves to reduce fric/on, heat, wear, increase water separa/on, tachiness, heat resistance etc.
Almasol Monolec Duolec Quinplex
DUOLEC is the newest LE proprietary additive incorporating revolutionary technology designed specifically for use in LE gear lubricants. It is a temperature activated, dual acting, liquid additive that imparts special properties and synergies to the LE Products in which it is used. DUOLEC increases lubricant film strength and protects metal surfaces outperforming at
Under normal to light conditions of speed and load, two metal surfaces are effectively separated by a lubricant film. This is known as hydrodynamic lubrication. An increase in load or a decrease in speed reduces the lubricant film allowing metal to metal contact and raising the temperature of the contact zone due to frictional heat. As a result, the EHD and mixed film antiwear components of DUOLEC
Solid Additive
Almasol
Maximum Service
Temperature
1,038C (1,900F) 400,000 psi(28,123 kgf/cm)
Inert None
MolybdenumDisulfide
343C (650F) 400,000 psi(28,123 kgf/cm)
Some Oxidizes in air above 343C (650F), forming abrasive molybdenum trioxide. Tendency to build up on itself, affecting machinery with close tolerances. Cannot tolerate hydrochloric and nitric acid, especially when heat, water and air are present.
Graphite 426C (800F) 80,000 psi(5,625 kgf/cm)
Some Known to exhibit galvanic corrosion problems. Tendency to build up on itself, affecting machinery with close tolerances.
Fluorocarbon (PTFE)
260C (500F) 5,000 psi (352 kgf/cm)
Inert No load-carrying capability. Tendency to build up on itself, affecting machinery with close tolerances.
Load Carrying Capacity
Acid Resistance
Drawbacks When Used in Industrial Lubricants
A
B
C
DEMO
Quinplex
1
2
3
4
5
Water Resistance
Tackiness
Cohesion
Mechanical Stability
Corrosion Resistance
BEFORE AFTER
Quinplex Demonstra/on
Impact Tester Water Separa/on
Gear Box Demonstra/on
Gear Box Live Opera/on
Gear Lubrica/on
Duolec 1601-1609 strong advantages Highest FZG A/8,3/90 Stage passed 14 Great lubricant supply to the lubrica/on
film, wider film width, less fric/on Increased gear box life Possible gear healing Opera/onal temperature reduc/on Much longer oil change intervals No foaming
Oil Analysis Services ''''''Lubrica@on'Engineers'Hellas
Lubrica(on+Engineers+Leaders+in+lubricants
www.le9greece.gr++30+210+5152+040
''''''''':'
1)######2)######3)###.
':+:++(Fe),+M+(Pb)+X+(Cu)+,++(Cr),++(Mo)+,++(l),++(Ni)+,++(Ag),++(Sn)+..+
+++++++++.+++++++++++++.+H++++++++,+++++++++++.
'(P),''(n),''(Ca),''(),''(Mg):++++++++++++++++++++++++.++++++++++++,+++,+++++++++++.++++++++++,+++++++++++++++.+++++++++++++++++++.
'()',''(),''():+++++++++++.++++++++++++++++++++++.+++,+,++++++++++++.
'(Si'b'Silica):++,++,++++++++++++"".++++++++++++.+++(silicone)++++++++.
''''''Lubrica@on'Engineers'Hellas
Lubrica(on+Engineers+Leaders+in+lubricants
www.le9greece.gr++30+210+5152+040
Ball & Rod Mill Lubrica/on
LE Interna9onal European Sales Mee9ng Oct13| 21
Targe9ng improvements & cost effec9veness Open gear systems
Pyroshield 9011 strong advantages Highest oil viscosity, 36.070 cSt @ 40oC Highest FZG A/8,3/90 Stage passed 14 Big lubricant decrease, usually by 50%-80% Possible gear healing Pinion temperature reduc/on Transparent use
G. SteinbergerTU MnchenB.-R. Hhn standard FZG back-to-back test rig 1/144.21.36
Standard FZG back to back rig test
www.le-inc.com
PYROSHIELD OEM Approvals
Audits & Inspec/ons
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13/03/13 12:22 46 49 42 43 40 44 43 48 43 31 110
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&:&:&:&:&:&:
&&&&
LubricaRon&Engineers&Hellas&Leaders&in&lubricants
www.le/greece.gr&+30&210&5152&040
:&Kluber&CF&3
&&
LubricaRon&Engineers&Hellas&Leaders&in&lubricants
www.le/greece.gr&+30&210&5152&040
38,0
39,3
40,7
42,0
43,3
44,7
46,0
3 4 5 6 7
LE Interna9onal European Sales Mee9ng Oct13| 24
Targe9ng improvements & cost effec9veness Open gear systems
Pyroshield 9011 results in Kiln Daily consump/on with previous
lubricant: 3 Kg
Daily consump/on with Pyroshield 9011: 660 gr
87% reduc/on
8oC pinion temperature reduc/on
LE Interna9onal European Sales Mee9ng Oct13| 25
Targe9ng improvements & cost effec9veness Open gear systems
Kilns pinion with common semi-fluid grease, with graphite & MoS2
LE Interna9onal European Sales Mee9ng Oct13| 26
Targe9ng improvements & cost effec9veness Open gear systems
Kilns pinion with common semi-fluid grease, with graphite & MoS2
LE Interna9onal European Sales Mee9ng Oct13| 27
Targe9ng improvements & cost effec9veness Open gear systems
Kilns pinion withPyroshield 9011
LE Interna9onal European Sales Mee9ng Oct13| 28
Targe9ng improvements & cost effec9veness Open gear systems
Kilns pinion withPyroshield 9011
www.le-inc.com
PT. HOLCIM INDONESIA
NAROGONG CEMENT PLANT
www.le-inc.com
PT. HOLCIM INDONESIA
Holcim Indonesia, known previously as PT. Semen Cibinong, became a LE customer since 1994.
In Indonesia, there are two plants: Narogong Plant (West Java) Cilacap Plant (Central Java)
Narogong Plant operates 2 kilns
Kiln No. 3 (NG3)
Kiln No. 4 (NG4)
www.le-inc.com
KILN NG4 Girth-gear heavily loaded on the kiln. Kilns previously lubricated with: Fuchs Ceplattyn KG-10 via an automatic spray system & Shell Albida EP NLGI 2 as the gear coupling lubricants. Kiln No. 4 converted to LE 9000 PYROSHIELD on 19/11/99 During 2006, LE launched the updated product Pyroshield XH
9011 & Holcim agreed to replace LE 9000 with LE 9011
Pyroshield XH in Dec. 2006.
Kiln No. 4 (NG4) Monthly Monitoring on Gear Surface condition
www.le-inc.com
Wear Particle Flushing on NG4 - August 2007
August 2007 Automatic Lubrication System failure on girth-gear, resulted in
gear surface temperatures rising to 95oC. Lack of lubricant meant that extensive pitting appeared on the
girth-gear & large amounts of wear created. LE offered a flushing service to remove gear wear particles
using LE 5250 ALMAGEAR gear oil (ISO 1000) as a flushing lubricant.
This flushing successfully removed 90% of wear particles and helped to reduce the amount of pitting generated.
www.le-inc.com
LE Indonesia Technical Support Our technical team helps Holcims
maintenance team to monitor and
evaluate their equipment uses LE
lubricants Particular attention is paid to the
kilns
www.le-inc.com
Kiln No. 3 (NG3) Monthly Monitoring on Gear Surface conditionKILN NG3 Kiln No. 3 converted to LE 9000 Pyroshield 12 July 2002 December 2006 converted to LE 9011 Pyroshield XH ALMAGARD 3752 replaced Shell Albida EP NLGI 2 for gear coupling lubrication. Global Crisis February 2009 lubricant consumption reduced from 5 Kg per day to 3.4 Kg per day with no negative effects on production or operations. ALMAGARD 3752 now used for all gear couplings. Couplings include: Rawmill, Crusher, HRC, Finish mill. Quantity of application depend on size of coupling.
www.le-inc.com
FINISHMILL (FM) Due to the enormous cost savings & benefits achieved on their
2 Kilns, Holcim Indonesia decided to apply LE 9011 for all
open gear applications in the cement plant Holcim Narogong Plant has Finishmills. Several are driven by
open gears: Finishmill No. 2 (FM-2) Finishmill No. 3 (FM-3) Finishmill No. 4 (FM-4)
Picture of Finishmill units ( FM-4 , FM-3 , Fm-2 )
www.le-inc.com
Finishmill FM-3 Monthly Monitoring on Gear Surface conditionFINISHMILL (FM) February 2007 - Finishmill FM3 converted to LE 9011 from Mollub-Alloy 8031. Lubricant consumption of LE 9011 = 4 Kg per day versus, 6 Kg per day with Mollub-Alloy. During 2009, lubricant consumption further reduced to = 1.4 Kg per day. With this minimum consumption, this unit is still operating in perfect order with constant low gear surface temperature. (Indication of adequate lubrication, no metal to metal contact creating friction, heat & wear)
www.le-inc.com
www.le-inc.com
FINISHMILL (FM) Finishmill FM-2 & FM-4 converted without flushing conversion
procedure. This equipment started using LE 9011
PYROSHIELD during an overhaul. During the overhaul its the previous lubricant was manually
cleaned from its girth-gear 13 May 2008 - FM-2 converted to LE 9011 LE 9011 PYROSHIELD replaced Mollub-Alloy 8031 Reduced lube consumption from 8 Kg /day to 4.5 Kg/day.
Finishmill FM-2 Monthly Monitoring on Gear Surface condition
www.le-inc.com
www.le-inc.com
FINISHMILL (FM) April 2008 - FM-4 was converted to LE
9011 PYROSHIELD - replacing
Mollub-Alloy 8031 Reduced lubricant consumption from 6
Kg per day to 4 kgs/day During 2009,
consumption was further reduced to
1.5 Kg per day
Finishmill FM-4 Monthly Monitoring on Gear Surface condition
www.le-inc.com
Lubricant Applicat ion Comparison
www.le-inc.com
www.le-inc.com
PT Holcim Indonesia Tbk
Plant Manager: Mr Thomas Elvermann
Telephone: +62 (21) 823 5811
Gear Lubrica/on Live
Gear Lubrica/on Live
Gear Lubrica/on Live
Pyroshield 9011 results Daily consump/on with previous lubricant: 2,8 Kg
Daily consump/on with Pyroshield 9011: 1,2 Kg
57% reduc/on
9oC pinion temperature reduc/on
Ball & Rod Mill Lubrica/on
Ball & Rod Mill Lubrica/on
&
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&:&4.224&mm
&:&480&mm
&:&507&mm
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&:&19&rpm
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&&&&
LubricaNon"Engineers"Hellas"
Leaders"in"lubricantswww.leAgreece.gr"
+30"210"5152"040
:&Pyroshield&9011
&
&
1 2 3 4 5 6 7 8 9 10 11 12*
FL3 24/10/06 11:05 36,0 41,0 41,0 43,0 44,0 42,0 40,0 40,0 42,0 25,0 22,0
FL3 23/10/08 11:00 27,0 28,2 29,5 32,5 30,8 27,2 24,0 22,0 17,0
FL3 16/12/10 10:05 22,5 27,0 26,0 28,0 30,0 30,8 29,3 29,6 35,5 5,0
FL3 15/5/13 11:10 """"""""""""
FL3&d&&&
LubricaNon"Engineers"Hellas"Leaders"in"lubricants
www.leAgreece.gr"+30"210"5152"040
10,0
15,0
20,0
25,0
30,0
35,0
40,0
45,0
50,0
3 4 5 6 7T"oC
2006 2008 2010
Ball & Rod Mill Lubrica/on
Ball & Rod Mill Lubrica/on
Gear Lubrica/on - Healing
Pinion gear prior the use of Pyroshield Pinion gear ajer 21 months with Pyroshield
Gear healing - Pikng reduc/on
Vibra/on reduc/on
87% lubricant reduc/on
LE Interna9onal European Sales Mee9ng Oct13| 52
Targe9ng improvements & cost effec9veness Open gear systems
Gear healing explana9on
Duolec = Less load per square unit of tooth surface
LE Interna9onal European Sales Mee9ng Oct13| 53
Cement Industry - General Approach Strategy Targe9ng improvements & cost effec9veness
Open gear systems Details on consump9on
Example Open gear system with:
D1 = 6,1 m B2 = 660 mm Single pinion
LE Interna9onal European Sales Mee9ng Oct13| 54
Cement Industry - General Approach Strategy Targe9ng improvements & cost effec9veness
Open gear systems Details on consump9on
According to AGMA 9005-E02
1,44 ml/min or
86,4 ml/hr
LE Interna9onal European Sales Mee9ng Oct13| 55
Cement Industry - General Approach Strategy Targe9ng improvements & cost effec9veness
Open gear systems Details on consump9on
22
Table 2: Specific lubricant consumption quantities for running-in and operational lubrication
Fig. 22: Diagram for determining the specific lubricant consumption quantity required for running-in and operational lubrication
Rotary drum drives(e.g. cooling units)
Single-pinion kiln drives
Single-pinion mill
Large single-pinion mill drives and double-pinion kiln drives
Double-pinion mill drives
4
5
6
7
8
1.0 to 1.5
1.5 to 2.0
2.0 to 2.5
2.5 to 3.0
3.0 to 3.5
1
2
3
4
5
** required specific consumption quantity [g/cm/op.hrs.]
Run
ning
-in
lubr
icat
ion
with
GR
AFL
OS
CO
N B
-SG
00
Ultr
aO
pera
tiona
l lub
rica
tion
with
GR
AFL
OS
CO
N C
-SG
0 U
ltra
1.0
1.5
3
2
2.5
3.5
4
5
6
7[kg/
24 o
p.hr
s.]
Con
sum
ptio
n qu
antit
y
19
18
17
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
0
800
750
700
650
600
550
500
450
400
350
300
250
200
150
100
50
[g/o
p.hr
s.]
Flank width (cm)10090807060504030
= type ofinstallationsee table 2
...
8
Consumption quantities ofGRAFLOSCON B-SG 00 Ultra and C-SG 0 Ultra
Type of installation / driveRequired specific consumption quantities [g/cm*/op.hrs.]
Running-in lubricant Operational lubricant
* width of tooth flanks
1
2
3
4
5
1
1
2
5
3
4
5
**
**
**
**
**
**
**
**
**
**
**
23
Table 2a: Specific lubricant consumption quantities for running-in and operational lubrication
Fig. 22a: Diagram for determining the specific lubricant consumption quantity required for running-in and operational lubrication
Rotary drum drives(e.g. cooling units)
Single-pinion kiln drives
Single-pinion mill drives of average dimensions
Single-pinion mill drives of large dimensions or double-pinion kiln drives
Double-pinion mill drives
0.5 to 0.8
0.8 to 1.0
1.0 to 1.3
1.3 to 1.5
1.5 to 1.8
1
2
3
4
5
** required specific consumption quantity [g/cm/op.hrs.]
0.5**
0.8**
1.5**
1.0**
1.3**
1.8**[kg/
24 o
p.hr
s.]
Con
sum
ptio
n qu
antit
y
5.0
4.5
4.0
3.5
3.0
2.5
2.0
1.5
1.0
0.5
0
200
180
160
140
120
100
80
60
40
20
0
[g/B
h]
Flank width (cm)10090807060504030
= type ofinstallationsee table 2
...
Consumption quantities of the transparent Klberfluid lubricants
Type of installation / drive
Required specific consumption quantities[g/cm*/op.hrs.]
Operational lubricant
* width of tooth flanks
1
1
2
3
4
5
5
Please note:The specific quantity of the running-in lubricant Klberfluid B-F 2 Ultra required is the same as of GRAFLOSCON B-SG 00 Ultra and can be found in Fig. 22. The total recommended lubricant quantity of Klberfluid B-F 2 Ultra is two or three 180 kg drums.The total recommended lubricant quantity of GRAFLOSCON B-SG 00 Ultra is oneor two 180 kg drums.
According to Kluber for Grafloscon B-SG 00 Ultra & C-
SG 0 Ultra
132 - 165 gr/hr (146 - 183 ml/hr)
According to Kluber for transparent lubricants
85,8 - 99 gr/hr (95,3 - 110 ml/hr)
LE Interna9onal European Sales Mee9ng Oct13| 56
Cement Industry - General Approach Strategy Targe9ng improvements & cost effec9veness
Open gear systems Details on consump9on
Pyroshield 9011 typical quan99es
applied
12,78 ml/20 min or
38,34 ml/hr12,78
LE Interna9onal European Sales Mee9ng Oct13| 57
Cement Industry - General Approach Strategy Targe9ng improvements & cost effec9veness
Open gear systems Details on consump9on
Pyroshield 9011
AGMA 9005 - E02Kluber
GraflosconKluber
Transparent
38,34 ml/hr 86,4 ml/hr 146-183 ml/hr 95,3-110 ml/hr
- -56% -74% - -79% -60% - -65%Pyroshield 9011
% reduc9on
Note: Usual consump0on with commercial products, is higher than what AGMA recommends, due to inability of products to stay on gears.
Gear Lubrica/on
Gear Lubrica/on Oil Life
0
12,500
25,000
37,500
50,000
Jan 2006 Jul 2006 Jan 2007 Jun 2007 Dec 2007 Jul 2008 May 2009 Dec 2009 Mar 2013
Oil life (hrs) es9ma9on
Duolec 1606 data from 20 gearboxes Oil analysis (AES) monitoring Con/nuously increasing average life of installed oil More than 7 years oil opera/on in several units
The Lubrication Reliability Source
www.LElubricants.com 800-537-7683 [email protected] Bailey Avenue Fort Worth, TX 76107 Fax: 800-228-1142
LE operates under an ISO 9001 Certified Quality System.
Do More with LEss
LEs Duolec gear oil clings to gears for nonstop protection.
If you would like to experience LEss downtime, visit
www.LElubricants.com to learn more about Duolec
Vari-Purpose Gear Lubricant and LEs reliability solutions.
Say good riddance to inferior oil that robs your gearboxes of performance. Save time and money with LEs superior Duolec Vari-Purpose Gear Lubricant. This proven performer features LEs
proprietary additive technology, which creates a dual layer of anti-wear and EP protection. In high temps,
Duolec remains thermally stable, resists oxidation, and wont create sludge or varnish. It maintains film
strength, clings tenaciously to metal and readily separates from water. To experience more
performance, less wear and less equipment downtime, go with Duolec!
D U O L E C C A N T B E B E AT
F O R 2 4 / 7 G E A R P R O T E C T I O N !
Duolec Vari-Purpose Lubricant
features LEs proprietary
additive technology, the
backbone of the lubricant.
LE is your one-stop shop for
lubrication reliability solutions,
including breathers and sight
glasses.
LEAP oil analysis monitors oil
condition to ensure
long-lasting gearbox reliability.
Thank you!
The Lubrication Reliability Source
www.LElubricants.com 800-537-7683 [email protected] Bailey Avenue Fort Worth, TX 76107 Fax: 800-228-1142LE operates under an ISO 9001 Certified Quality System.
Do More With LEssI N C R E A S E U P T I M E & P R O F I T S W I T H L U B R I C AT I O N R E L I A B I L I T Y P R O G R A M
L U B R I C A N T S
R E L I A B I L I T Y
S U P P O R T & S E R V I C E
Switching to high-performance lubricants can save you time, energy and
money. LE manufactures a full line of industrial oils and greases that are
formulated for the targeted application using highly refined or synthetic base
oils blended with proprietary additives. LE lubricants last longer and protect
equipment far better than ordinary lubricants. This means less equipment
failure, less need for lube changeovers, and less PM activity, all of which adds
up to more uptime and profits for you. | www.LElubricants/lubricants.html
Much more than a lubricant supplier, LE is a one-stop shop offering lubrication
reliability solutions. LE can help you with a custom program including oil
analysis, breathers, sight glasses, filtration carts, lubricant storage and more
whatever you need to keep your lubricants clean and dry. Less contamination
means more reliability. | www.LElubricants.com/reliability-solutions.html
Last but not least, LEs trained and certified consultants are onsite with you to
educate, plan and assist. Our Technical Services team is also available to
help. Short on staff? Lack of knowledge? No worries. You can do more with
LEss. | www.LElubricants.com/implementation.html