A technical guide to Shell tactic emv

A technical guide to Shell Tactic EMV

TABLE OF CONTENTS SECTION PAGES Introduction 3 Benefits of Short Re-Lubrication Intervals 5 Contamination Prevention Strategies 6 Workplace Safety and Efficiency Gains 9 Shell Tactic EMV Product Overview 10 Remote Installation Guidelines 12 Shell Tactic EMV Remote s 14 Electric Motor Lubrication Solutions 16 Slurry Pump Lubrication Solutions 17 Conveyor Pulley Lubrication Solutions 18 Fan Lubrication Solutions 19 Contact Shell 20 The information provided in this guide is of a general nature only. Potential users of Shell Tactic EMV s should seek advice tailored to their particular circumstances and, for this purpose, are welcome to contact Shell on the contact number provided. Shell is not liable for any costs, losses or damages, whether direct or indirect, arising from any reliance upon this document. 2

Shell Tactic EMV s AN Introduction to Shell Tactic EMV Lubrication Programs Shell understands that successful businesses use preventative maintenance programs to help reduce operational costs and plant stoppages. Shell Tactic EMV automated lubrication system is designed to extend the service life of bearings and deliver superior reliability results compared to manual lubrication. A reliable supply of clean lubricant is vital for optimal bearing service. If bearings are not sufficiently lubricated, the result can be premature failure. The flow on being maintenance cost increases and equipment downtime. In response to this, Shell delivers Shell Tactic EMV lubrication solutions to help maintain critical equipment. As the demand for increased production output grows, so too does the investment in preventative maintenance strategies. As a result investment in technically superior maintenance methods such as the automated lubrication of fixed plant equipment also increases. However, automatic lubrication systems alone do not provide complete lubrication solutions. Systems such as the Shell Tactic EMV must be combined with straightforward implementation methods and realistic management plans in order to help establish practical and sustainable solutions. This technical guide has been written to help users of Shell Tactic EMV lubricators to develop robust and practical lubrication programs. 3

4

Benefits of Short Re-Lubrication Intervals The optimal method of grease delivery to rolling elements bearings is generally via the addition of small amounts at short time intervals. This optimal form of lubrication is achieved using automated delivery systems and cannot be practically achieved via manual methods. Bearings which operate in harsh environments demand the shortest re-lubrication intervals. Under such conditions manual lubrication becomes very labour intensive and often impractical. When manual lubrication programs fail to regularly lubricate due to lack of available resources or lack of opportunities to safely access equipment, the absence of fresh grease can lead to lubrication starvation and contaminant entry. This will eventually result in premature bearing failure. Manual greasing Advantages of automated lubrication Volume of grease Manual greasing Manual greasing Over-lubrication Adequate lubrication Under-lubrication The risks associated with over-lubrication and lubricant starvation varies based on a range of factors such as bearing size, bearing type, speed, temperature, vibration and conditions associated with the operating environment. Automated delivery systems inject small amounts of grease at short time intervals which helps to ensure that sufficient fresh grease is consistently available for bearing re-lubrication and for the purging of seals. This method of grease delivery reduces the likelihood of lubricant starvation or over-lubrication from occurring while reducing the workload demand on maintenance personnel. Time Irregular greasing intervals Volume of grease Shell Tactic EMV greasing Routine inspections Time Very regular greasing intervals The graphical representation is for illustration purposes only. Over-lubrication Adequate lubrication Under-lubrication How the Shell Tactic EMV lubricator works The Shell Tactic EMV dispenses grease in small amounts at short time intervals. The time interval between each injection of grease varies depending on the time settings of each lubricator. The shortest time interval between injections is 1 hour and 30 minutes while the longest time interval is 18 hours and 12 minutes. (Refer to page 11 for further information). time settings are selected based on factors such as bearing size, bearing type, speed, temperature, vibration and conditions associated with the operating environment. These factors, along with site specific requirements relating to equipment access opportunities and time based maintenance cycles are used to establish practical programs for the management of groups of individual lubricators. 5

SHELL TACTIC EMV LUBRICATION PROGRAMS CONTAMINATION PREVENTION STRATEGIES THE CONSISTENT AND REGULAR PURGE OF FRESH GREASE THROUGH SEALS HELPS TO PREVENT THE ENTRY OF DAMAGING CONTAMINANTS. 6

Contamination Prevention Strategies Bearings operating in industries such as minerals processing and mining are inevitably subjected to sources of contamination by solid particulates and moisture. If these contaminants are allowed to enter bearings via poorly maintained seals or poor lubricant handling practices they can cause accelerated wear and the early onset of fatigue. For solid contaminants, the rate of wear increases as the size, concentration and hardness of the contaminants increases. Smaller particles lead to abrasive wear, while larger particles can cause indentations to bearing raceways which can then become initiation points for fatigue wear. Shell Tactic EMV lubrication programs use greasing practices to help prevent the introduction of contaminants. Consequently there can be a long term financial return because equipment experiences a longer bearing service life and reduced downtime. Different bearing configurations and operating environments lead to different re-lubrication requirements and therefore different Shell Tactic EMV configurations. Listed below are three of the commonly accepted methods to help reduce contamination of rolling element bearings with taconite or labyrinth type seals. 1. Where the threat of contaminant entry is high and for larger bearings the use of individual, dedicated Shell Tactic EMV lubricators for the bearing re-lubrication point and the seal purge point(s) is most common refer to the example image opposite. 2. For smaller sized bearings running at relatively low speeds the application of a single lubricator to the bearing re-lubrication point only, set to dispense at an elevated rate, can provide sufficient fresh grease for bearing relubrication and seal purging. 3. As an alternative strategy manual and automated lubrication programs can be combined by utilising Shell Tactic EMV to help achieve a constant purge of fresh grease through seals while maintaining periodic manual lubrication for the bearing point re-lubrication. Taconite seal purging example: Automatic lubrication of taconite seals help to provide a constant protection against the ingress of contaminants. The image below demonstrates the grease entry point and seal purge point for a typical taconite seal arrangement. Regular lubrication of this point creates a positive purge of grease which passes through the seal and exits the bearing housing, thereby preventing the entry of contaminants. The photograph below shows the result of a successfully purged seal using Shell Tactic EMV. The ring of grease around the exit point of the taconite seal provides evidence that while the grease is exiting the bearing housing, ingress of contaminants is prevented. 7

8

Workplace Safety and Efficiency Gains Using Shell Tactic EMV Shell Tactic EMV automatic lubricators are maintenance tools which can make a positive contribution to work place safety and efficiency. In harsh climates this is particularly important especially for large sites where the physical demands of performing regular manual greasing in hot weather can increase the risk of heat exhaustion to workers. However, it is important to note that the implementation of automatic lubrication systems does not mean that the frequency of equipment inspections should be reduced. In fact, the proper use of automated systems can liberate time. This can then be invested into other preventative maintenance tasks such as routine equipment inspections, filter and breather maintenance and oil cleanliness management activities. Here are 3 ways to HELP improve workplace safety and save time: Maintenance Challenge Shell Tactic EMV Solution Assessment criteria for improvements Access to lubrication points located behind safety cages or guards Access to lubrication points located at heights or in confined spaces Minimisation of repetitive manual tasks Remote mounting of Shell Tactic EMV lubricators at safe to access locations makes inspection and servicing possible while equipment is operating. This helps to remove reliance on valuable time during maintenance shuts which would otherwise be required to access such points. Shell Tactic EMV lubricators can be used to lubricate points which would otherwise demand more frequent working at heights and confined space entry. Converting manual greasing tasks to automated grease delivery using Shell Tactic EMV will help to minimise the highly repetitious use of manual grease guns. In addition it can save time by automating an otherwise laborious manual task. Efficiency Gains: Time is liberated from shutdowns by servicing lubricators while equipment is operating. Time is saved by not having to complete isolations to access lubricators. Time is saved by eliminating the need to remove and re-instate cages and guards. Safety Improvements: Elimination of tool work required to remove guards and cages. Elimination of the manual handling of cages and guards. Efficiency Gains: Time is saved by reducing the frequency of demand to gain working at heights or confined space permits and access. Reduced requirement for equipment such as elevated work platforms. Reduced demand on personnel and equipment associated with confined space entry. Safety Improvements: Reduced risks associated with working at heights and confined space entry by reducing the frequency of the activity. Efficiency Gains: Automated delivery of grease via a mechanised system in place of manually applied strokes of a grease gun. Safety Improvements: Reduced manual work load and reduced physical demand. 9

SHELL TACTIC EMV PRODUCT OVERVIEW General specification & grease types Available products Packaging Shell Tactic EMV drive unit Shell Tactic EMV Gadus S5 T100 2 Shell Tactic EMV Gadus S5 T100 2 Shell Tactic EMV Gadus S3 V460D 2 Shell Tactic EMV Gadus S3 T220 2 Shell Tactic EMV Gadus S3 V220C 2 Products come in boxes of 10 units. 110gm 225gm 225gm 225gm 225gm Time settings Dispensing rates Pressure output Operating temperature Remote installation Product dimensions Accessories and thread type 1, 2, 3,... through to 12 months in monthly increments From 0.3 to 8.2cm³ per day, depending on the time settings and the canister size. 6 bar rising to 8 bar if required 10 to 60 C average ambient temperature for the unit drive. Remote mounting from application can be used to reduce ambient temperature. The dispensing rate is not affected by temperature. Up to 5 metres* of grease line with 10mm internal diameter Individual items Drive unit: diameter (including cover) 75mm; length 102mm 120cm 3 canister: diameter 66mm; length 106.8mm 250cm 3 canister: diameter 66mm; length 156.8mm Mounted units Drive unit + 120cm 3 canister: diameter 75mm; length 178mm Drive unit + 250cm 3 canister: diameter 75mm; length 228mm All canisters have a ¼ inch BSP male thread. All Shell Tactic EMV drive units come with a support flange and wet cap as standard. All canisters include a new set of batteries as standard. * Factors such as low ambient temperatures or difficult to pump grease types may restrict the maximum recommended grease line to less than 5 metres. Components & construction Gear motor LCD-display with push button Shell Tactic EMV Battery pack Protection cap Shell Tactic EMV drive unit reusable LCD-display with push button (Discharge period and function) Reusable Parts The Shell Tactic EMV drive system and push-on protection cap are reusable. The system automatically performs a self test when each new battery set is inserted. The drive should also be inspected for physical damage before each new grease canister is used. Piston Shell Tactic EMV Battery pack Shell Tactic EMV lubricant canister Single Use Parts Shell Tactic EMV grease canisters are factory filled in a controlled environment to help ensure against the inclusion of contaminants. A new battery set is supplied with each grease canister and should be exchanged when a fresh grease canister is applied. 10

SHELL TACTIC EMV DISPENSING RATES AND INSPECTION PROTOCOLS The availability of lubricator time settings in monthly increments means that the Shell Tactic EMV can be adapted to the service scheduling requirements of most operations without the need to compromise on lubricant dispensing rates. The Shell Tactic EMV drive system combines an LCD screen and a set of four light windows to communicate its operational status to maintenance personnel. The table below provides a quick reference to the screen and light combinations. In simplest terms, a flashing red light means that a lubricator requires attention. Setting, months 1 2 3 4 5 6 7 8 9 10 11 12 Canister Size 250cm 3 Canister Size 120cm 3 cm3 per day cm3 per day 8.3 4.2 2.8 2.1 1.7 1.4 1.2 1.0 0.93 0.83 0.76 0.69 4.0 2.0 1.3 1.0 0.80 0.67 0.57 0.50 0.44 0.40 0.36 0.33 Time between cycles Hrs : Mins 1h : 30m 3h : 00m 4h : 36m 6h : 06m 7h : 36m 9h : 06m 10h : 36m 12h : 12m 13h : 42m 15h : 12m 16h : 42m 18h : 12m 0.26cm 3 per cycle 0.53cm 3 per cycle Status Screen Lights Action Dwell is between dispensing cycles Shows the TIME and VOLUME settings Single GREEN flash every 7 seconds Inspect lubricator. Mark and date the position of the piston to confirm inspection. Run is dispensing grease Single GREEN flash every 1 second Inspect lubricator. Mark and date the position of the piston to confirm inspection. Purge Grease is being dispensed Single GREEN flash every 1 second The purge feature has been activated by holding the SET button for 10 seconds. Canister empty Canister expected to be empty Double RED flash every 2 seconds Service the lubricator using a new canister and battery set. Overload Excessive resistance to grease flow Double RED flash every 7 seconds Manually purge the point to clear blockage. Investigate possible causes and rectify. Low Battery Battery set is damaged or depleted Double RED flash every 7 seconds Replace battery set. 11

SHELL TACTIC EMV REMOTE MOUNTING SYSTEMS SIMPLE TO INSTALL USING BASIC HAND TOOLS A. Full length protection covers Covers to help protect lubricators from solid and liquid contaminants. A D. Stainless steel bracket There are two main categories of brackets Standard Duty and Heavy Duty. The example shown here is the Heavy Duty C-section design which provides extra protection to lubricators. E. Stainless steel beam clamps B. Manual purge point D E Simple to use beam clamps supplied with case hardened cup head set screws and stainless steel assembly screws. Used for convenient additions of supplementary grease, line purging and grease blockage clearing. F F. Support flanges Provide support to lubricators to help prevent damage from impacts and vibration. B G. Heavy duty hose 3 Supplied with 8 internal diameter and easy to use pushlock type swivel hose ends. C C. Elbows Elbow fittings are full bore with ¼ BSP threads. G 12

Shell Tactic EMV Systems Remote Installation Guidelines For maximum pressure to the lubrication point, direct mounting is preferred. However, this will not be practical in all circumstances. In many cases remote mounting is required to help provide safe and convenient access or to prevent lubricator damage. Therefore, remote installations are recommended under the following circumstances: 1. When protective guards or safety cages have to be removed to access the lubrication point. 2. Where it is difficult or unsafe to access the lubrication point while equipment is running. 3. When the bearing is subject to high vibration or temperature which may damage the lubricator. 4. When the lubrication point is exposed to excessive amounts of water or impact from solid material. Where remote installation of the Shell Tactic EMV is planned the following guidelines are to be followed: Identify a safe point of access to mount stainless steel bracket 3 Use grease line with 8 internal diameter Restrict grease line length to 5 metres* Use only full bore hose ends and elbow fittings** Route grease lines under or around cages, not through Prime grease lines and fittings with grease Test the grease delivery path to ensure bearing and seal points can receive grease freely Protect lubricators with full length covers to suit operating environment Include manual purge points Protect grease lines from damage using spiral wrap * Factors such as low ambient temperatures or difficult to pump grease types may restrict the maximum recommended grease line to less than 5 metres. **Refer to images above. 13

Shell Tactic EMV Remote s A range of installation kits are available which facilitate quality remote installation of Shell Tactic EMV lubricators. The most common installation kits utilise stainless steel beam clamps and cage hangers to attach to beam sections and square mesh safety cage. Other, less common configurations are available upon request. Standard Duty Beam Clamp Mount s Available in 1, 2, 3 or 4-point configurations which are used where lubricators are to be mounted to beam sections. The 2-point version shown below demonstrates the typical bill of materials. Example Contents SK230 4 1 3 2 9 10 5 SK130 (with 30mm beam clamps) SK165 (with 65mm beam clamps) SK230 (with 30mm beam clamps) SK265 (with 65mm beam clamps) 11 8 6 7 Bill of Materials SK330 (with 30mm beam clamps) SK365 (with 65mm beam clamps) SK430 (with 30mm beam clamps) SK465 (with 65mm beam clamps) 1 1 x 2-point stainless steel bracket 7 4 x Push lock hose tails ¼ BSP M 2 2 x 30mm SS beam clamp 8 2 x 90 degree brass elbows ¼ BSP 3 2 x support flange ¼ BSP 9 2 x adaptor ¼ BSP F to ¼ BSP M 4 2 x PVC covers 250mm long 10 2 x reducer ¼ BSP F to 1 8 BSP M 5 2 x Manual purge kit 11 0.5m spiral wrap 6 4m grease line 3 8 internal diameter Heavy Duty Beam Clamp Mount s Available in 1, 2, 3 or 4-point configurations which are used where heavy duty protection systems are to be mounted to beam sections. The 2-point version shown below demonstrates the typical bill of materials. Example Contents SK230C 4 9 10 1 3 2 SK130C (with 30mm beam clamps) SK165C (with 65mm beam clamps) SK230C (with 30mm beam clamps) SK265C (with 65mm beam clamps) 11 7 8 5 6 Bill of Materials SK330C (with 30mm beam clamps) SK365C (with 65mm beam clamps) SK430C (with 30mm beam clamps) SK465C (with 65mm beam clamps) 1 1 x 2-point C-section SS bracket 7 4m grease line 8 internal diameter 2 2 x 30mm SS beam clamp 8 2 x 90 degree brass elbows ¼ BSP 3 2 x support flange ¼ BSP 9 2 x reducer ¼ BSP F to 8 BSP M 4 2 x PVC covers 250mm long 10 2 x adaptor ¼ BSP F to ¼ BSP M 5 2 x Manual purge kit 11 0.5m spiral wrap 6 4 x Push lock hose tails ¼ BSP M

Standard Duty Cage Mount s Available in 1, 2, 3 or 4-point configurations which are used where lubricators are to be hung on safety cages with square cage mesh down to 25mm x 25mm. The 2-point version shown below demonstrates the typical bill of materials. Example Contents SK2CH 3 1 2 SK1CH SK2CH 9 8 4 10 7 6 5 SK3CH SK4CH Bill of Materials 1 1 x 2-point stainless steel bracket 6 4m grease line 8 internal diameter 2 2 x support flange ¼ BSP 7 2 x 90 degree brass elbows ¼ BSP 3 2 x PVC covers 250mm long 8 2 x adaptor ¼ BSP F to ¼ BSP M 4 2 x Manual purge kit 9 2 x reducer ¼ BSP F to 8 BSP M 5 4 x Push lock hose tails ¼ BSP M 10 0.5m spiral wrap Heavy Duty Cage Mount s Available in 1, 2, 3 or 4-point configurations which are used where a heavy duty protection system is required to be hung on safety cages with square cage mesh down to 25mm x 25mm. The 2-point version shown below demonstrates the typical bill of materials. Example Contents SK2CHC 3 4 1 2 10 9 SK1CHC SK2CHC 5 7 8 6 11 Bill of Materials SK3CHC SK4CHC 1 1 x 2-point C-section SS bracket 7 4 x Push lock hose tails ¼ BSP M 2 2 x cage hanger arms 8 2 x 90 degree brass elbows ¼ BSP 3 2 x support flange ¼ BSP 9 2 x reducer ¼ BSP F to 1 8 BSP M 4 2 x PVC covers 250mm long 10 2 x adaptor ¼ BSP F to ¼ BSP M 5 2 x Manual purge kit 11 0.5m spiral wrap 3 6 4m grease line 8 internal diameter

Electric motor lubrication solutions For electric motor lubrication the following factors are generally relevant to the development of the lubrication solution: Lubrication Assessment Criteria Motor manufacturer s recommendations Motor speed Grease trap / escape port design, access and condition Operating conditions Characteristics of lubricant Bearing types Safe access requirements Desired service schedule (of lubricators) Duty cycle Motor orientation (vertical or horizontal) Installation examples Electric Motor Shell Tactic EMV 110 gram Direct Electric Motor Shell Tactic EMV 225 gram Direct Electric Motor Shell Tactic EMV 110 gram SK230 16

Pump lubrication solutions For pump lubrication the following factors are generally relevant to the development of the lubrication solution: Lubrication Assessment Criteria Pump manufacturer s recommendations Seal types Wash down procedures Operating conditions Characteristics of lubricant Bearing types and grease entry points Safe access requirements Desired service schedule (of lubricators) Duty cycle Typical bearing operating temperatures Installation examples Pump bearings Shell Tactic EMV 225 gram Direct Slurry pump labyrinth seals Shell Tactic EMV 225 gram SK265C Slurry pump bearings & labyrinth seals Shell Tactic EMV 225 gram 2 x SK265C Slurry pump labyrinth seals Shell Tactic EMV 225 gram SK265C 17

Conveyor pulley lubrication solutions For conveyor pulley bearing lubrication the following factors are generally relevant to the development of the Shell Tactic EMV lubrication solution: Lubrication Assessment Criteria Bearing types and speeds Operating conditions Safe access requirements Grease performance characteristics Location of grease entry points on bearing housings Seal types Desired service schedule (of lubricators) Installation examples Conveyor pulley tail bearings Shell Tactic EMV 225 gram SK1CH Head pulley bearing and seal Shell Tactic EMV 225 gram SK230 Drive pulley bearing and seals Shell Tactic EMV 225 gram SK3CH Bend pulley bearing and seal Shell Tactic EMV 225 gram SK2CH 18

Fan lubrication solutions For fan bearing lubrication the following factors are generally relevant to the development of the lubrication solution: Lubrication Assessment Criteria Bearing types and speeds Operating conditions Safe access requirements Grease performance characteristics Grease base oil viscosity Location of grease entry points on bearing housings Seal types Desired service schedule (of lubricators) Bearing temperatures Installation examples Fan jack shaft bearings Shell Tactic EMV 110 gram Direct Fan jack shaft bearings Shell Tactic EMV 110 gram SK230C 19

For more information, please contact: The Shell Company of Australia Limited (ABN 46 004 610 459) 8 Redfern Rd, Hawthorn East, Victoria 3123 Emergency phone number (24 hours) 1800 651 818 Shell Technical Helpdesk 1300 134 205 Shell Customer Service 13 16 18 www.shell.com.au