SHELL TACTIC

DELIVER SAFETY AND

EFFECTIVENESS

Cecep Kurniawan
Shell Technical Advisor

Copyright of Shell Indonesia Feb 2015 1

Bearing Failure Studies
Key Challenge – optimum Lubrication
KEY BENEFITS – BEARING LIFE EXTENSION

 Bearings operating in harsh environments demand the shortest time interval between
additions of fresh grease.
 Operating conditions such as elevated temperatures, vibration and shock load all
contribute to the need for shorter time intervals between re-lubrication.
 The longest bearing service life is achieved when grease is added in small amounts at
regular, short time intervals.
 Extended bearing service life means improved reliability and less downtime.

Manual greasing representation Shell Tactic EMV automation

Copyright of Shell Indonesia
 MANUAL GREASING

Manual Greasing Chart: 1) 2)

 
3)

Potential causes of poor manual greasing practices: 

 Lack of labor resources to do the job on time.
 More urgent maintenance tasks take priority at the detriment of good manual greasing
practices.
 Lack of care to avoid introducing abrasive contaminants and moisture.
 Limited opportunity to access all lubrication points due to access restrictions around
running equipment.
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Automatic Greasing
 Automatic Greasing Chart:


 Advantages of automated lubrication:
 Regular injections of factory filled, fresh grease to bearings while
machinery is running.
 Regular purge of grease past mechanical seals to preclude
contaminants.
 Reduced dependency on labor resources.
LUBRICATION SYSTEM

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 BASIC TECHNICAL DATA

Characteristic Description

Lubricator Type Electro-mechanical with re-useable Drive System

Discharge Periods 1, 3, 6 or 12 months

Lubricant Volume 120cc or 250cc (110 gram or 225 gram)

Canister Material Clear plastic to allow inspection of piston position

Alert System Green and red flashing LED’s

Support Base Glass filled nylon base with integrated ¼” BSP M brass fitting

Battery Pack 3 x AA batteries in series

Remote Lines Limited to 3 meters of 3/8” internal diameter line

Shell Gadus S3 T220 2 in 250cc (225 gram)

Shell Gadus S3 V220C 2 in 250cc (255 gram)
Shell Gadus S3 V460D 2 in 250cc (225 gram) It depens on your working
Grease Types temperature and
Shell Gadus S5 T100 2 in 250cc (225 gram)
environment
Shell Gadus S5 T100 2 in 120cc (110 gram)
Setting and adjustment
SOLUTION EXAMPLE – ELECTRIC MOTOR

Equipment Electric motor

Lubricator Shell Tactic EMV Gadus S5 T100 2 120cc

Lubricator Setting 120cc @ 3 months = 1.3cc per day

Mounting System Direct mount with manual purge kit

Benefits of Solution
Automation delivers injections of 0.26cc of grease every 4 hours and 37
minutes. This form of lubrication will provide optimal bearing service life.
Bearings are protected from abuse from high pressure grease guns thereby
removing the risk of damage due to over greasing.
Lubricators are protected from the site environment by heavy duty covers to
ensure long term, reliable performance in a harsh environment.
Installation includes manual purge kits to provide a quick option for manual
additions of grease if required.
SOLUTION EXAMPLE – WARMAN PUMP

Equipment Warman horizontal slurry pump

Lubricator Shell Tactic EMV S3 V220C 2 250cc

Lubricator Setting 250cc @ 3 months = 2.8cc per day

Mounting System Customer fabricated remote bracket

Benefits of Solution
Automatic purging of the labyrinth seals provides protection to the bearings
from the harsh environment thereby extending bearing service life. The
pump OEM alternatively recommends daily manual greasing of the wet-end
labyrinth.
Demand on manual labour resources is reduced compared to manual
grease. Liberated time can be allocated to other preventative maintenance
tasks.
Automatic purging of expeller gland as an alternative to the recommended
manual turning of a grease cup every 12 hours of operation thereby
reducing demand on labour resources.
Installation includes manual purge kits to provide a quick option for manual
additions of grease if required.
SOLUTION EXAMPLE – METSO PUMP

Equipment Metso horizontal slurry pump

Lubricator Shell Tactic EMV Gadus S3 V220C 250cc

Lubricator Setting 250cc @ 3 months = 2.8cc per day

Mounting System SK330C

Benefits of Solution
Automatic re-lubrication of bearings and impeller gland packings to prevent
lubricant starvation and contaminant entry in harsh operating conditions in
order to extend bearing service life.
Demand on manual labour resources is reduced compared to manual
grease. Liberated time can be allocated to other preventative maintenance
tasks.
Automatic purging of expeller gland as an alternative to the recommended
manual turning of a grease cup every 12 hours of operation thereby
reducing demand on labour resources.
Installation includes manual purge kits to provide a quick option for manual
additions of grease if required.
 KEY BENEFITS – SAFER WORK PRACTICES

Automation of lubrication tasks reduces the

work place dangers associated with manual
greasing by reducing the frequency that
ladders and stairs must be climbed.
Automation reduces exposure by ~80%.

3 stories up via
ladder access
 KEY BENEFITS – SAFER WORK PRACTICES

 SAFETY IMPROVEMENTS

Safe & Easy Access…

Difficult Access…

 
Tactic Application
Benefits Summary

 Bearing Life Extension

 Contamination Prevention
 Reduce Safety Hazard