Open Gear Drive

Lubrication and Servicing

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Types of Open Gear Lubricants

Asphalt Solvent Cutbacks.

Solvent and Solvent Free Greases and Pastes
( European Styled Greases)
High Viscosity Gel
High Viscosity Synthetic, Semi Synthetic, and
Mineral Base Fluids.

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Gear Running With European Style
(Graphite based) Products

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Gear Running With European Style
(Graphite based) Products

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

CASTROL MOLUB ALLOY 8031
OPEN GEAR GEL COMPOUND

– Ultratech Cement

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

High Viscosity Base Oil Gels - Molub-Alloy 8031

• Developed for use in heavily loaded, low speed gears open

gear drives using centralised lubrication systems
• Excellent for various total loss and sump applications that
benefit from the use of a high viscosity, semi-fluid lubricant
• These specialised lubricants are produced from premium EP
mineral base gear oils.
• Fluid viscosities most commonly used for open gear drives are
ISO VG 2200, 3000 & 6000.
• The fluid is gelled to add body, and enhance lubricant film
forming and retention properties.
• These solvent free products are applied in the “as used” state.

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Features of Molub-Alloy 8031
• High viscosity Anti-Scuff gear oil formulation
– Exceeds AGMA requirements for 8A EP, 9 EP, 10 EP and now 12 EP
Gear Oils
• Thixotropic thickener system
– Environmentally less objectionable
• Forms a translucent lubricating film
• Fully miscible in mineral oils
• Superior protection against scuffing and wear
• Easily pumped and sprayed

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Benefits of Molub-Alloy 8031
Non asphaltic- Environmental and disposal friendly
No solvents of any kind- Environment friendly
Self draining from gear guards – Maintenance Friendly
• Requires no heating or solvents to make it drain
Improved housekeeping
Dispose of waste with waste oil
Low spray air pressure- Save air
Short spray purge time – Save air
Lower air consumption- Save Energy- Save Money

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

 Castrol’s OGL
• Advanced Technology
• Brings together High Performance EP gear oil and grease technology
• Blends ISO VG 2200,3000 & 6000 base oils with a unique gel thickener system
• Solvent –free, NLGI 00 consistency yet is semi-fluid
• The gel thickener system adds body, enhances lubricant film forming and
retention properties
• Protects Equipment
• Thixotropic to aid flushing and draining
• Utilises a synergistic blend of EP additives and solid lubricants to minimize
wear
• user friendly - over applying creates no problems
• enhances performance and reliability of most spray systems
• Easy Disposal
• Readily drains from gear guards
• Low disposal costs, excellent TCLP

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

…….Benefits
• Safe to Environment
• Environmentally less objectionable
• Improved equipment reliability
• Flush contaminants……Lesser wear
• Significant reduction in vibration…..High load carrying capacity
• Substantial reduction in temperatures and Delta temperature
• Permits meaningful visual inspections during operation using a strobe light.
• Cost Economical
• Reduced manufacturing cost.
• User Friendly
• Easy change over due to the compatibility with most oils and soap type
thickeners.
• May be applied by most existing intermittent spray systems

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Molub-Alloy 8031

Typical Appearance
Pinion Lubricated With Molub-Alloy 8031/3000 High Viscosity Base Oil Gel

Lifting Pinion with M/A 8031/3000 Pressing Pinion with M/A 8031/3000

STROBE INSPECTION VIEW OF PINION PRESSURE FLANKS WHILE IN SERVICE

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Reference of Some other Customers
• Reliance Energy- BSES Dahanu BHEL( ALSTOM) BBD 4760 Mill
• Giral Lignite Power Ltd.
• Vijayawada thermal power station-Vijayawada(5 ball mills)
• Rayalaseema thermal power plant
• Madras cements Ltd-Jeggiahpet (both the kilns)
• India cements (all 7 on its all the kiln, Cement mill,Rawmill & coal mill)
• Abuja Cements- Rabryawas, Rajasthan(Kiln & Cement Mill)
• Kalyanpur Cement
• Nagarjuna Cements-Andhra(Both kiln & cement mill)
• Rain industries ltd(both the units)-Andhra(Cement mill,Raw mill & Kiln
• BMM Ispat-Hospet(Both the kilns and Grinding mill)
• JSW Steel Bellary
• Hindustan Zinc Agucha and SK Mines
• Bhushan Steel Angul
• Arya Steel Barbil
• Orisa Manganese Tata Nagar.

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

To sum up…
• Castrol is one of the world’s best-known lubricant brands
• Our knowledge and expertise allows us to select and apply the combination of
products and services that most positively impacts productivity, quality and costs
in manufacturing operations
• Our solution includes a wide range of product support services to boost your
performance and profitability
• In our global business…
… we share best practices with our customers
… we understand the challenges of implementing processes across different
locations
… we operate a wide network of sales locations and channels

Back to table YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

of contents
 Value Added Engineering Support

• Safety Issues
• Lubricant Performance
• Lubricant wastage
• Visual strobe of gear teeth
• Mill gearbox operating temperatures
• Casting of gear profiles upon request
• Visual inspection of lubricant coverage
• Thorough inspection of injector and spray function
• Thermographic monitoring during operation - With trending
• Routine vibration analysis with trending

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Waste Lubricant Collection
Castrol Solution

With Competitor

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Vibration Analysis - Open Gear
• Routine vibration analysis with trending
• Gear Mesh Frequency analysis
• Bearing Faults and Foundation related problems
• Tooth Damage
• Misalignment
• Looseness
• Eccentricity
• Visual when not in operation
- Cleaning and inspecting reference teeth
- Obtaining tape pull impressions or castings

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

Standard Equipment
Camera Vibration
Strobe
Light

Infra Red Gear Vernier Thermal Camera

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD
Inspection Reports
• Format contains all relevant
information
- Mill details
- Vibration readings
- Temperature readings
- Spray pattern
- Spray quantity
- On-Off timings
•Trending of report is important
• Tool for discussions with
customer on performance

YOUR ADVANTAGE IN AN INDUSTRIAL WORLD

 Anil Verma
OUR EXPERINCE CASE KEY
Account Manager HPL STUDIES
IN MINING APPLICATIONS
BENCHMARKING

Castrol Industrial Lubricants

Cell-9928848686
YOUR ADVANTAGE Email-
IN AN INDUSTRIAL anil.verma@se1.bp.com
WORLD

19