LE SA Cement industry

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

&

&

1 2 3 4 5 6 7 8 9 10 11 12*

&

&

1 2 3 4 5 6 7 8 9 10 11 12*

&

13/03/13 12:22 46 49 42 43 40 44 43 48 43 31 110

*&&12&:&&&&::&263/&270&&pitch&line

&

&:&:&:&:&:&:

&&&&

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



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



Kilns pinion with common semi-fluid grease, with graphite & MoS2



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

[email protected]

Telephone: +62 (21) 823 5811

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


&

&

1 2 3 4 5 6 7 8 9 10 11 12*

*""12":""""

::"313"A"320

"&

&:&4.224&mm

&:&480&mm

&:&507&mm

&:&480&mm

&:&19&rpm

&:&158&rpm

&&&&

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

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



Gear healing explana9on

Duolec = Less load per square unit of tooth surface


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




According to AGMA 9005-E02

1,44 ml/min or

86,4 ml/hr




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)




Pyroshield 9011 typical quan99es

applied

12,78 ml/20 min or

38,34 ml/hr12,78




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

Engineering

LE SA Cement industry