INDUSTRIAL GEAR OILS

FUNCTION OF GEARSALMOST ALL MODERN MACHINERY MAKE SOME USE OF GEARS AS A MEDIUM FOR TRANSMITTING POWER WITHCHANGE IN SPEEDCHANGE IN DIRECTIONCHANGE IN LOAD / TORQUEPRIME MOVERGEARSOUTPUT

TYPES OF GEARSSPUR GEARSBEVEL GEARSHELICAL AND HERRING BONEWORM GEARSHYPOID GEARS

REASONS FOR STRESS ON GEAR LUBRICANTS VELOCITY OF ROLLING / SLIDING GEARS

MESHING TOOTH EXPERIENCE SHOCK LOADS STRESS ON THE FLANK

HIGH TOOTH FLANK TEMPERATURE

FUNCTIONS INDUSTRIAL GEAR OILS PERFORMLUBRICATION TO REDUCE WEAR FRICTION & PREVENT DISTRESSHEAT REMOVAL FROM THE HIGH FRICTION POINTS TO THE SUMPCUSHIONING AGAINST VIBRATION, SHOCK & SONIC ENERGY LOSSESPROTECTION FROM RUST AND OTHER CORROSION OF THE EQUIPMENT CLEANING CONTAMINANTS, DEBRIS OR SLUDGE THE SYSTEM SHOW INERTNESS TOWARDS ALL NONMETALLIC PARTS OF THE SYSTEM

EVOLUTION OF INDUSTRIAL GEAR OILS

PROPERTIES OF GEAR OILSGEAR OILS SHOULD HAVE : -SATISFACTORY ADHESION COMPATIBILITY WITH METALLURGY & RUBBER COMPONENTSWATER AND AIR SEPERATION PROPERTYOXIDATION STABILITYSURFACES CLEANING PROPERTYSATISFCATORY FILM STRENGTHSSHEAR STABILITYSATISFACTORY VISCOSITY - TEMPERATURE PROPERTY REASONABLE COSTLONG DRAIN PERIODS

GEAR LUBRICANTS (THE CRITICAL PROPERTIES) PHYSICAL PROPERTIES (i.e. Viscosity - kV ) CHEMICAL PROPERTIES (i.e. Pour Point, Flash Point , Cu corrosion, S, P etc) PERFORMANCE PROPERTIES (i.e.AW / EP, AO, RI etc)

TYPES OF INDUSTRIAL GEAR OILS

1) BASED ON S-P CHEMISTRY . IOCL SERVO MESH SP Series ( 68 / 100 / 150 / 220 / 320 / 460 / 680)

2) ENERGY EFFICIENT GEAR OILS. IOCL SERVO MESH EE Series ( 220 / 320 / 460 / 680 )

3) ANTI - MICRO PITTING GEAR OILS. IOCL SERVO MESH PLUS Series ( 220 / 320 / 460 / 680 )

4) SYNTHETIC GEAR OILS.IOCL SERVO SYNGEAR Series ( 68 / 100 / 150 / 220 / 320 / 460 / 680 )

SULPHUR PHOSPHOROUS CHEMISTRY INDUSTRIAL GEAR OILS

S - P CHEMISTRY BASED GEAR OILSMost of todays industrial gear oils are based on S-P CHEMISTRY and meets USS 224 / AGMA, IS / DAVID BROWN Gear Industries Ltd.. (UK) specs etc.IOCL SERVO MESH SP Series ( ISO VG 68 / 100 / 150 / 220 / 320 / 460 / 680 etc.)These are Extreme Pressure type industrial gear oils. PERFORMANCE BENEFITS:Have high load carrying abilityLow Foaming tendencyProtect gear tooth metals against Rust & Corrosion.Ensures excellent wear protectionEnsure long service life - as they have good oxidation & thermal stabilityGood DemulsivityMinimize formation of sludge even at high bulk temperature

APPLICATION : All Heavy Duty Enclosed Gear Drives with Circulation / Splash Lubrication system - Operating under Heavy Load / Shock Load conditions , With Bulk Oil Temperature of upto 100 deg C.Can be applied in Gears involving Plain / Roller Bearings / Sliding Surfaces.

ENERGY EFFICIENT INDUSTRIAL GEAR OILS

BACKGROUND

STEEL INDUSTRY CONTRIBUTION IN DEVELOPING GEAR OIL SPECIFICATIONS EXTREME CONDITIONS OF # TREMENDOUS PRESSURESOPERATIONS PREVAILING # SEVERE SHOCK LOADING IN STEEL MILL # HIGH SPEED & TEMPERATURE # CONTAMINATION WITH WATER, DIRT, ABRASIVES & MILL SCALE NECESSITATED

STEEL INDUSTRIES TO DESIGN # US STEELSPECIAL LUBRICANT SPECS . # BRITISH STEEL Co.OTHER THAN CONVENTIONAL # HOESCH STEEL Co, GERMANYTYPE # NIPPON STEEL, JAPAN # KOBE STEEL, JAPAN

THUS STEEL INDUSTRY IS ALWAYS A PIONEER FOR INTRODUCING IMPROVED LUBRICANTS

ENERGY CONSUMPTION IN STEEL PRODUCTIONSPECIFIC ENERGY CONSUMPTION GigaCAL/TONNE IN SIX ENERGY INTENSIVE INDIAN INDUSTRIES SOURCE BICP ENERGY AUDIT, INDIA 22 0.916 13.1 8.5 10.67 3.68 WHY STEEL INDUSTRY ?

SERVOMESH EE Series ENERGY EFFICIENT GEAR OILGears actuate machines which in turn exerts tremendous pressures on the gear tooth Gears operate under adverse conditions of shock loading, high speed, high temp. & Contaminations like water, dust, metal scale etc.International specifications - USS 224 , AGMA, IPSS etc. Govern the properties of these oilsThere is no stipulation of energy saving potentials in specificationsBut IOCL developed a unique grade SERVOMESH EE oil meeting all above gear oil specs. with proven energy saving potential - seeing the requirements of the Indian Industry.

SERVOMESH EE ENERGY SAVER FOR INDIAN INDUSTRIES

ENERGY SAVING IN INDUSTRIAL GEAR SYSTEMSAPPROACHES TO REDUCE THE VISCOUS DRAGREDUCING FRICTIONAL LOSSES IN BOUNDARY OR MIXED LUBRICATION REGIMESBY USING A OPTIMUM VISCOSITY OILFRICTION REDUCERS SOLID SOLUBLE

Boundary LubricationhR1R2h=film thickness; R=R1+R2(Combined surface roughness)

Mixed Film LubricationhR1R2h=film thickness; R=R1+R2(Combined surface roughness)

Fluid Film LubricationhR1R2h=film thickness; R=R1+R2(Combined surface roughness)

ENERGY EFFICIENT GEAR OILA new energy efficient formulationBy reducing friction Meeting all national & international industrial gear oil specifications with proven energy saving potential

Servomesh EE series (ISO VG 220 / 320 / 460 / 680)

The performance & energy saving potential of Servomesh EE has been proven in different industry trials # Steel # Cement # Power - NTPC Dadri

SERVOMESH EE Series ENERGY EFFICIENT GEAR OILThis is a significant advancement in gear lubrication technology. It saves energy through reduction in frictional losses - reduces power consumption - to the tune of 4% (approx..).Has outstanding load carrying ability due to superior Extreme pressure property .Provides smooth running through reduced vibration & noise.It improves gear efficiency.It has demonstrated improved thermal stability & oxidation resistance over the conventional S-P gear oils.It also extends oil & gear life and Prevents irregular wear - due to superior anti wear property.Possess better demulsibility , low foaming tendency & provides excellent rust & corrosion protection to metal surfaces.It has lower bulk oil temperature - to the tune of 3 deg C (approx...). - Lower temperature rise signifying better energy efficiency.Minimizes formation of sludge & deposits even at high temperatures.These oils are RECOMMENDED for - all types of Enclosed gear drives , Heavily loaded bearings - Industrial gears running at High speed / High pressures / Under impact loads with Circulation / Splash lubrication systems.

ANTI MICROPITTING INDUSTRIAL GEAR OILS

ANTI - MICROPITTING GEAR OILS SHIFT IS TOWARDS HIGHER UNIT LOAD IN THE GEAR BOXES, WHICH TEND TO RAISE THE TEMPERTURE # OPPORTUNITIES FOR NEW GEAR OIL TECHNOLOGY ALONG WITH : - IMPROVED THERMAL / OXIDATION STABILITY - IMPROVED AW / EP PERFORMANCE - COMPATABILITY WITH GEAR METALLURGY GEAR DAMAGE DUE TO NEW FORM OF TOOTH SURFACE WEAR - MICROPITTING

MICROPITTING CAN RESULTS IN HIGHER NOISE / VIBRATIONS IN THE GEARS --> Leading to:

# LONGER DYNAMIC FORCES

# SHORTEN GEAR LIFE PROBLEMS DUE TO MICROPITTING

WHAT IS MICROPITTING MICROPITTING IS : TYPE OF SURFACE DAMAGE THAT OCCURS PREDOMINANTLY IN ROLLING - SLIDING CONTACTS OF GEAR SURFACES. CHARATERIZED BY THE PRESENCE OF FINE SURFACE PITS , SHOWING FRACTURED LOWER SURFACES LEADS TO SURFACE WEAR AND SURFACE DAMAGE, SUCH AS `SCUFFING AND ULTIMATELY TO GEAR TOOTH FRACTURES

FACTORS - INFLUENING MICROPITTING SURFACE ROUGHNESS

TANGENTIAL SPEED & LOADS etc.

SPECIFIC FILM THICKNESS

CHEMICAL COMPOSITION OF LUBRICANT ADDITIVES

COEFFICIENT OF FRICTION

OIL TEMPERATURE

SERVO MESH PLUS SERIES GEAR OILS(ISO VG 100 / 150 / 220 / 320 / 460 / 680)

MICROPITTING IS ALSO A FUNCTION OF -GEAR SURFACE ROUGHNESS(LOWER BEING BETTER)

BUT TO MAKE LOWER SURFACE ROUGHNESS - GEAR TOOTH PROFILES -- THE GEAR MAKING COST GOES UP.

HENCE ROLE OF LUBRICANTS --- TO IMPROVE MICROPITTING PERFORMANCE AS A MEANS OF CONTROLLING COST

MICROPITTING RESISTANT TESTS FZG INSTITUTE - GERMANY HAS DEVELOPED A MICROPITTING RESISTANT RIG TEST # PROGRESSIVE LOADING STAGE - GEARS ARE DISMOUNTED AFTER 16 hrs - RATED # ENDURANCE STAGE - AFTER 6 X 80 hrs - TOOTH FLANKS / DEVIATION i.e. GEAR PROFILE & TOOTH GEOMATRY ARE OBSERVED FLENDER AG - GERMANY HAVE ALSO DEVELOPED THEIR OWN RIG TEST TO ASSESS MICROPITTING RESISTANCE # MICROPITTING RESISTANT TEST - 100 hrs. - TOOTH PROFILE & GEOMATRY.

SERVOMESH PLUS Series ANTI MICROPITTING GEAR OILThis is a significant advancement in gear lubrication technology. It provides improved protection from Micropitting Failure - leading to extended component life.

These are advanced Extreme pressure type industrial gear oilDemonstrate improved thermal stability & improved oxidation resistance over S-P technology gear oil.Good demulsibility characteristics & low foaming tendency.Provides rust & corrosion protection to metal surfaces - extended wear protection also.Excellent cleanliness by preventing sludge formation

These oils are recommended for -gear oils which are subject to micro-pitting - heavily loaded industrial gear boxes subjected to heavy & shock loads.

Approved by M/s Flender India - Already in Use in ACC LTD.

SYNTHETIC INDUSTRIAL GEAR OILS

SERVOSYNGEAR Series SYNTHETIC GEAR OILSThis are industrial gear oils formulated from synthesized hydrocarbon based fluids combined with suitable additive package. They meet US Steel 224 specificationsGrades are available in ISO VG - 32 / 46 / 68 / 100 / 150 / 220 / 320 / 460 / 680

PERFORMANCE BENEFITSExcellent resistance to oxidation & agingIts use leads to extended component life.Increased Oil LifeReduced wear due to high load carrying capacityLow Maintenance CostExcellent viscosity temperature behaviorWide temperature applications

SERVOSYNGEAR Series SYNTHETIC GEAR OILSThese oils are recommended for -lubrication of spur / helical / bevel / worm & hypoid gears which are used in all manufacturing industries.

Successful Trial has been conducted at NTPC - Ramagundam over a period of 18 months in their Cooling Tower Gear Boxes in place of in use - Servosystem 320 & Servomesh SP 320 - Huge savings were obtained in terms of equipment availability / thermal capability & reduction in worm gear failures.

LUBRICANT TRENDS IN 21st CENTURYTHIS WILL BE GOVERNED BY FOLLOWING FACTORS:

INDUSTRY SPECIFICATIONS, LONGER DRAIN INTERVALSLOWER OIL CONSUMPTION/ FUEL ECONOMYENVIRONMENTAL ISSUES,EMISSIONS &LOWER BASE OIL VOLATILITYBIODEGRADABILITY, RECYCLABILITYENERGY EFFICIENCY

LATEST INDUSTRY TRENDS(In Summary - For Gear Oils)ANTI MICRO PITTING GEAR OILS - IOCL HAVE DEVELOPED :- SERVO MESH PLUS SeriesENERGY EFFICIENCY CHARACTERISTICS REALIZED THROUGH FRICTION REDUCERS SUCH AS GRAPHITE, MoS2, SOLUBLE FRICTION REDUCERS - IOCL HAVE DEVELOPED : - SERVO MESH EE Series.USE OF SYNTHETIC BASE MATERIALS FOR OBTAINING HIGHER THERMAL STABILITY / VERY LONG DRAIN PERIODS -- IOCL HAVE DEVELOPED SYNTHETIC GEAR OILS :- SERVO SYNGEAR Series.

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