March / April 2015 NLGI Spokesman

NLGI

SPOKESMAN

Serving the Grease Industry Since 1933 – VOL. 79, NO. 1, MAR/APR 2015

In this issue . . .

18

S teel Mill Lubrication - Boosting the Grease Performance for Longer Bearing Service Life

30

Lubrication in Mining Equipment

38 Super Additive Packages: The Next Generation of Lubrication Performance Enhancing Additives

NLGI 82nd Annual Meeting June 6-9, 2015 Coeur d’Alene, Idaho

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Registered and pending trademarks appearing in these materials are those of R.T. Vanderbilt Holding Company, Inc. or its respective wholly owned subsidiaries. For complete listings, please visit this location for trademarks, www.rtvanderbiltholding.com.

PRESIDENT:

VICE-PRESIDENT:

Bruce M. Urban FMC-Lithium Division 2801 Yorkmont Rd., Ste. 300 Charlotte, NC 28208

David Como Dow Corning Corp.

P.O. Box 0994 Midland, MI 48686

SECRETARY:

TREASURER:

Kim Smallwood Citgo Petroleum Corp.

1293 Eldridge Pkwy.

Houston, TX 77077

Joe Kaperick Afton Chemical Corporation 500 Spring St. Richmond, VA 23218-2158

PAST-PRES./ADVISORY:

EXECUTIVE DIRECTOR:

Chuck Coe Grease Technology Solutions LLC 7010 Bruin Ct. Manassas, VA 20111

Kimberly Hartley NLGI Inter­national Headquarters 249 SW Noel, Suite 249 Lee’s Summit, MO 64063

DIRECTORS Barbara Bellanti Battenfeld Grease & Oil Corp. of NY P.O. Box 728 • 1174 Erie Ave. N. Tonawanda, NY 14120-0728 Richard Burkhalter Covenant Engineering Services 140 Corporate Place Branson, MO 65616 Gian L. Fagan Chevron Lubricants 100 Chevron Way Room 71-7338 Richmond, CA 94802-0627 Paul Grives Exxon Mobil Corporation 3225 Gallows Road Room 7C1906 Fairfax, VA 22037 Jim Hunt Tiarco Chemical 1300 Tiarco Drive Dalton, GA 30720 Tyler Jark Lubricating Specialties Co. 8015 Paramount Blvd.

Pico Rivera, CA 90660 Dr. Anoop Kumar Royal Manufacturing Co., LP 516 S, 25th West Ave. Tulsa, Oklahoma 74127 Wayne Mackwood Chemtura 199 Benson Rd. Middlebury, CT 06749 Dwaine (Greg) Morris Shell Lubricants 526 S. Johnson Drive Odessa, MO 64076

Dennis Parks Texas Refinery Corp.

One Refinery Place Ft. Worth, TX 76101 Tom Schroeder Axel Americas, LLC P.O. Box 12337 Kansas City, MO 64116 Raj Shah Koehler Instrument Co. 85 Corporate Dr. Holtsville, NY 11716-1796 Dr. Huafeng “Bill” Shen Bel-Ray Co. P.O. Box 526 Farmingdale, NJ 07727 Terry Smith Lubrication Engineers, Inc. P.O. Box 16447 Wichita, KS 67216 Thomas W. Steib The Elco Corporation 1000 Belt Line Street Cleveland, OH 44109 Lisa Tocci Lubes ’n’ Greases 6105 Arlington Blvd., Suite G Falls Church, VA 22044 William (Bill) Ward The Lubrizol ­Corpo­ration 29400 ­Lakeland Blvd.

Mail Drop 051E Wickliffe, OH 44092 Ruiming “Ray” Zhang R.T. Vanderbilt Company, Inc. 30 Winfield St. Norwalk, CT 06855

Thomas J. Pane King Industries, Inc. Science Road Norwalk, CT 06852

TECHNICAL COMMITTEE CO-CHAIRS:

CHAIR, SESSION PLANNING:

J oe Kaperick Afton Chemical Corporation 500 Spring St. Richmond, VA 23218-2158

Joe Kaperick Afton Chemical Corporation 500 Spring St. Richmond, VA 23218-2158

David Turner 22110 Stone Cross Court Katy, TX 77450

SERVICE INDUSTRY ASSISTANCE COMMITTEE CHAIR: J im Hunt Tiarco Chemical 1300 Tiarco Drive Dalton, GA 30720

EDITORIAL REVIEW COMMITTEE CHAIR: Joe Kaperick Afton Chemical Corporation 500 Spring St. Richmond, VA 23218-2158

SPOKESMAN

NLGI

OFFICERS

Serving the Grease Industry Since 1933 – VOL. 79, NO. 1, MAR/APR 2015

5 NLGI President’s Podium 6 8

NLGI Sponsorship Benefits & Opportunities

NLGI 82nd Annual Meeting Preliminary Program

18 Steel Mill Lubrication - Boosting the Grease

Performance for Longer Bearing Service Life

Hocine Faci, Philip Booker, Martin Maass, Marcus Totten, Castrol Industrial

30 LAshok ubrication in Mining Equipment Kumar Goyal, Rohit Agarwal, Balaram Ghosh and Abhijit Roy Balmer Lawrie & Co. Ltd., Applications Research Laboratory, P-43, Hide Road Extn, Kolkata, India – 700 088.

38 Super Additive Packages: The Next Generation

of Lubrication Performance Enhancing Additives Ajay P. Malshea, Wenyang Zhanga, Melanie Murphya, and Greg Schwartzb a nGlide Division, NanoMech, Inc., 2447 Technology Way, Springdale, AR 72764 • b NanoMech Energy, 100 Crescent Court, Suite 440, Dallas, TX 75201

59 Advertiser’s Index ON THE COVER

Registration is open for the NLGI 82nd Annual Meeting, June 6-9, 2015, Coeur d’Alene, Idaho! Preliminary program details begin on page 8.

Published bi-monthly by NLGI. (ISSN 0027-6782) KIMBERLY HARTLEY, Editor NLGI International Headquarters 249 SW Noel, Suite 249, Lee’s Summit, MO 64063 USA Phone (816) 524-2500, FAX: (816) 524-2504 Web site: http://www.nlgi.org — E-mail: nlgi@nlgi.org One-year subscriptions: U.S.A. $65.00; Canada $80.00; International $109.00; Airmail $147.00. Claims for missing issues must be made within six months for foreign subscribers and three months for domestic. Periodicals postage paid at Kansas City, MO. The NLGI Spokesman is indexed by INIST for the PASCAL database, plus by Engineering Index and Chemical Abstracts Service. Microfilm copies are available through University Microfilms, Ann Arbor, MI. The NLGI assumes no responsibility for the statements and opinions advanced by contributors to its publications. Views expressed in the editorials are those of the editors and do not n­ ecessarily represent the official position of NLGI. Copyright 2015, NLGI. Postmaster: Send address corrections to the above address.

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PRESIDENT’S PODIUM

President’s Podium Bruce Urban

President Bruce Urban Welcomes the Technical Committee to this month’s Podium For the first time since NLGI’s founding in 1933, we’re tailoring our meeting to a specific industry…..MINING! Almost half of our 20 technical presentations have direct relevance to the mining industry, such as “Open Gear Lubricants for Mining Equipment: Exploring the Depths of a Technology in Constant Evolution” and “Rust Never Sleeps: An Investigation of Corrosion in Grease Lubrication”.

The NLGI Annual Meeting is the premier event for technical information, education, networking and the latest developments in manufacturing and innovation in the lubricating grease industry!

Our three outstanding grease courses: Basic (for those with little background in grease), Advanced (for those who attended Basic and/or has a working knowledge of grease) and Application & Maintenance (for those involved with grease selection and maintenance), will again be offered during the NLGI 82nd Annual Meeting.

The course schedules are Monday, June 8, 10:00 a.m. – 5:00 p.m., and Tuesday, June 9, 8:30 a.m. – 12:30 p.m.

All meeting functions and activities are included with your course fee.

Test your knowledge and improve your professional credentials by becoming a Certified Lubricating Grease Specialist (CLGS™). The examination will be offered Tuesday, June 9 at 2:00 p.m. For more information, visit the NLGI website, https://www.nlgi.org/certefications/ professional/.

The joint ELGI/NLGI Working Groups will follow up discussions from the ELGI 27th AGM, Barcelona, Spain, April 2015. The groups will meet Sunday afternoon, June 7, beginning at 1:45 p.m., and will encompass the following: • NLGI GC-LB – evaluation of specifications •B io-Based Greases – concerned with all facets of greases in which bio-based fluids are used •G rease Particle Evaluation – continued work to develop a standard to measure and quantify the cleanliness of lubricating greases •F ood Grade Lubricants – concerned with the use and certification of greases in food processing applications Be sure to attend the Monday morning session at 8:30 a.m., where you will hear a dynamic presentation from Mr. Ron Nilson, President and CEO of Ground Force Worldwide, producer of mine support equipment for both open pit and underground mines.

We hope you will join us for this once-a-year event, and take advantage of all the technical expertise our presenters, instructors and participants have to share!

David Turner, Joe Kaperick Technical Committee Co-Chairs

-5NLGI SPOKESMAN, MARCH/APRIL 2015

NLGI 2015 SPONSOR BENEFITS

82nd Annual Meeting • Coeur d’Alene, ID • June 6th - 9th, 2015

PLATINUM • • • • • • •

$4,000 and up

Company Name listed in The Spokesman Company Name displayed during Closing Festival Company Name displayed on banner throughout meeting Company Name & Logo displayed in Event Program Company Logo hotlink on NLGI Website Company Logo hotlink on NLGI Mobile Meeting App 1 Complimentary Upgrade to an Education Course

PLUS • Photo with signage published in The Spokesman • Tabletop Display in Meeting Central Or • 1 Month complimentary banner ad on the NLGI website

SILVER • • • • •

$1,000 - $1,999

Company Name listed in The Spokesman Company Name displayed during Closing Festival Company Name displayed on banner throughout meeting Company Name displayed in Event Program Company Name listed on NLGI Website

PLUS • Company Name on NLGI Mobile Meeting App

GOLD • • • • • •

$2,000 - $3,999

Company Name listed in The Spokesman Company Name displayed during Closing Festival Company Name displayed on banner throughout meeting Company Name displayed in Event Program Company Logo with hotlink on NLGI Website Company Logo hotlink on NLGI Mobile Meeting App

PLUS • 1 Complimentary Upgrade to an Education Course

BRONZE • • • • •

$650 - $999

Company Name listed in The Spokesman Company Name displayed during Closing Festival Company Name displayed on banner throughout meeting Company Name displayed in Event Program Company Name listed on NLGI Website

PLUS • Company Name on NLGI Mobile Meeting App

SPONSORSHIP OPPORTUNITIES Yes! Count on our company as an 82ndAnnual Meeting Sponsor for items/functions marked below.

PLATINUM $4,000 and up

No. of Sponsors Amount Final Program Guide (one) $4,000 __________ Refreshment Breaks (two) $4,500 __________ Audio Visual (multiple) $6,500 __________ Closing Festival Entertainment (two) $4,500 __________ *Fun Run (FMC) (one) $5,000 __________ *Golf Tournament (CITGO) (one) $4,000 __________ Keynote Speaker (three) $4,500 __________ Mobile Meeting App (one) $4,000 __________

GOLD

$2,000 - $3,999

Flash Drive (Meeting Proceedings) (one) $3,500 Meeting Central (multiple) $2,000 Golf Four Caddy (one) $3,000 Monday Continental Breakfast (four) $2,500 Closing Festival Cocktails (three) $3,000 Photographer (two) $2,000 Preliminary Program (two) $2,000 Instructor Thank You Gifts (one) $2,500 Conference Bags (two) $2,000 Education Course Binders (one) $2,000

SILVER

$1,000 - $1,999

BRONZE

$650 - $999

Saturday Evening Reception (multiple) $1,000 First Time Attendee Reception (three) $1,000 Board of Directors Breakfast (one) $1,500 Industry Speaker (one) $1,500 Closing Festival Dinner (multiple) $1,000 Golf Breakfast (three) $1,500 Tuesday Continental Breakfast (multiple) $1,500 Ed. Course Student Luncheon (four) $1,500

__________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________ __________

Welcoming Reception (multiple) $800 Closing Festival Reception (multiple) $800 Spouse/Guest Program (multiple) $800 Opening Entertainment (three) $800 Closing Festival Décor (multiple) $800 General Meeting Sponsor (multiple) $650 Shipping of Supplies (multiple) $650

__________ __________ __________ __________ __________ __________ __________

TOTAL AMOUNT COMMITTED:

__________

$

*Please note: NLGI has sponsor commitments for all categories marked with an X. If you have any questions, please contact Marilyn Brohm, Manager, Membership & Marketing at 816-524-2500 or email: Marilyn@nlgi.org

___________________________________ _________________________________ _________________ Company Contact Signature Date

PLATINUM SPONSORS

Afton Chemical Corporation Monday Continental Breakfast Co-Sponsor Closing Festival Decor Co-Sponsor Industry Speaker Sponsor Welcoming Reception Co-Sponsor Axel Americas, LLC Final Program Guide Sponsor Battenfeld Grease and Oil Corp. of NY Keynote Speaker Co-Sponsor Saturday Evening Reception Co-Sponsor CITGO Petroleum Corporation Golf Tournament Sponsor

SPONSORS

Daubert Chemical Company Closing Festival Entertainment Co-Sponsor Emery Oleochemicals LLC Photographer Co-Sponsor Saturday Evening Reception Co-Sponsor Closing Festival Dinner Co-Sponsor ExxonMobil Fuels, Lubricants & Specialties Marketing Company Audio Visual Co-Sponsor Education Course Binders Sponsor FMC-Lithium Division Fun Run Sponsor Welcoming Reception Co-Sponsor Saturday Evening Reception Co-Sponsor Lubes’n’Greases Monday Continental Breakfast Co-Sponsor Saturday Evening Reception Co-Sponsor Lubrizol Corporation Saturday Evening Reception Co-Sponsor Closing Festival Dinner Co-Sponsor Mobile Meeting App Sponsor Martin Lubricants Refreshments Breaks Co-Sponsor

Tiarco Chemical Saturday Evening Reception Co-Sponsor Golf Four Caddy Co-Sponsor Golf Breakfast Co-Sponsor Vanderbilt Chemicals, LLC Saturday Evening Reception Co-Sponsor Closing Festival Dinner Co-Sponsor Opening Entertainment Co-Sponsor Welcoming Reception Co-Sponsor

SILVER SPONSORS Calumet Packaging Meeting Central Co-Sponsor Calumet Specialty Products Partners, L.P. Meeting Central Co-Sponsor Chemtura Closing Festival Dinner Co-Sponsor

Royal Mfg. Co., LP Awards Banquet Dinner Co-Sponsor NLGI Author Award- Development Sponsor Soltex Inc. Saturday Evening Reception Co-Sponsor Texas Refinery Corp.

Saturday Evening Reception Co-Sponsor

GOLD SPONSORS

Chevron Global Lubricants Saturday Evening Reception Co-Sponsor NLGI Author AwardApplication Sponsor

Castrol Industrial North America Inc. Photography Co-Sponsor

Cross Oil Refining & Marketing, Inc. Saturday Evening Reception Co-Sponsor

Climax Molybdenum Marketing Corp.

Welcoming Reception Co-Sponsor

Grease Technology Solutions LLC Saturday Evening Reception Co-Sponsor

Elementis Specialties Closing Festival Reception Co-Sponsor

Acme-Hardesty Company Meeting Central Co-Sponsor

Covenant Engineering Services, LLC Preliminary Program Sponsor Dow Corning Corporation Education Course Student Luncheon Co-Sponsor Welcoming Reception Co-Sponsor Elco Corporation Golf Breakfast Co-Sponsor Education Course Student Luncheon Co-Sponsor Ergon, Inc. Flash Drive (Meeting Proceedings) Sponsor Exploiter Molybdenum Co., Ltd Conference Bag Co-Sponsor Lubricating Specialties Company Saturday Evening Reception Co-Sponsor Closing Festival Dinner Co-Sponsor

Ivanhoe Industries, Inc. Closing Festival Dinner Co-Sponsor King Industries, Inc. Golf Four Caddy Co-Sponsor Welcoming Reception Co-Sponsor

Axxess Chemicals, LLC General Meeting Co-Sponsor

FedChem LLC General Meeting Co-Sponsor H.L. Blachford Ltd. General Meeting Co-Sponsor Harrison Manufacturing Co. Pty Ltd. General Meeting Co-Sponsor

Koehler Instrument Co., Inc. First Time Attendee Reception Co-Sponsor

Lubriplate Lubricants Company General Meeting Co-Sponsor

Loadmaster Lubricants Saturday Evening Reception Co-Sponsor

Lucas Oil Products Opening Entertainment Co-Sponsor

NSF International Board of Directors Breakfast Sponsor

Petro-Canada Lubricants Welcoming Reception Co-Sponsor

NYCO America LLC Tuesday Morning Continental Breakfast Co-Sponsor

Primrose Oil Company General Meeting Co-Sponsor

Lubrication Engineers, Inc. Golf Breakfast Co-Sponsor Conference Bags Co-Sponsor

Nynas USA Closing Festival Dinner Co-Sponsor

Rockwood Lithium Closing Festival Cocktails Co-Sponsor Clarence E. Earle Memorial Award Sponsor

Palmer Holland, Inc. Closing Festival Dinner Co-Sponsor

Shell Canada Products Meeting Central Co-Sponsor Shell Lubricants Award

BRONZE SPONSORS

Patterson Industries Canada, A Division of All-Weld Company Ltd. Saturday Evening Reception Co-Sponsor

Sea-Land Chemical Company Welcoming Reception Co-Sponsor Shamrock Technologies Welcoming Reception Co-Sponsor SQM North America Corp.

Lanyards Sponsor Summit Lubricants, Inc. Welcoming Reception Co-Sponsor

TECHNICAL PRESENTATIONS PAPER 1502

PAPER 1515

PAPER 1504

PAPER 1516

Determination of Synthetic Grease Pumpability Using the Lincoln Ventmeter Paul Conley, SKF Industrial Market, Strategic Industries The Effect of Composition of a CSC Grease on the Key Parameters for Electric Motor Bearing Grease Solongo Wilson, Chemtura Canada Company

PAPER 1505

Lubricating Behavior of PTFE Powders in Lithium Greases and Liquid Dispersions Mary Moon, Presque Isle Innovations, LLC The Development of a New Betonite Grease Xiaochuan Guo, Logistical Engineering University

PAPER 1518

High Temperature Grease Utilizing New Silicone Based Fluids Manfred Jungk, Dow Corning GmbH

Development of Next Generation Electrical Motor Greases Offering Improved Frictional Characteristics John Lorimor, Axel Americas, LLC

PAPER 1507

COMMERCIAL PRESENTATION

Effect of MoDTC and MoDTP on Frictional and Anti-wear Properties of Overbased Calcium Sulfonate Complex Greases Mihir Patel, Vanderbilt Chemicals LLC

PAPER 1508

Calcium Sulfonate Complex Greases Using Calcium Hydroxyapatite as a Hydroxide-Containing Basic Reactant J. Andrew Waynick, NCH Corporation

The Lubrizol Corporation

PAPER 1520

Optimizing Heat Distribution in Grease Manufacturing Process – A Critical Parameter for Quality Assurance Anoop Kumar, Royal Manufacturing Co. LP

PAPER 1522

COMMERCIAL PRESENTATION NanoMech, Inc.

Evaluation of Boron Esters in Lithium Complex Greases Prepared with Hydrogenated Castor Oil Vijay Deshmukh, Standard Greases & Specialities Pvt. Ltd.

PAPER 1509

PAPER 1524

PAPER 1511

COMMERCIAL PRESENTATION

Rust Never Sleeps: An Investigation of Corrosion in Grease Lubrication Joseph P. Kaperick, Afton Chemical Corporation The Effect of Polymer Additives on Grease Flow Properties Daniel Vargo, Functional Products, Inc.

PAPER 1512

Investigation into the Dynamic Particle Generation of Lubricating Greases Jason Galary, Nye Lubricants, Inc. Afton Chemical Corporation

PAPER 1525

The Development of More Environmentally Considerate Greases Gareth Fish, The Lubrizol Corporation

Assessment of Bearing Grease Anti-Corrosion Performance Using the Emcor Washout Test Rig Ajay Kumar, Indian Oil Corporation Ltd.

PAPER 1513

PAPER 1526

COMMERCIAL PRESENTATION

PAPER 1527

Grease Lubrication for Longer Service Life in Angular Contact Ball Bearings Ryosuke Ichimura, Kyodo Yushi Co., Ltd.

Energy Efficiency Dwaine (Greg) Morris, Shell Lubricants

Matrica Spa/Novamont Spa

PAPER 1514

Open Gear Lubricants for Mining Equipment - Exploring the Depths of a Technology in a Constant Evolution Hocine Faci, BP (Castrol Industrial North America, Inc.)

The Effects of Thickeners on the Low Temperature Properties of Open Gear Greases Huafeng (Bill) Shen, Bel-Ray Company, LLC (a Division Of Calumet Specialty Products)

PAPER 1528

Reducing Fire Hazards in the Underground Mining Industry with Fire Resistant Greases Joel Garrett Sc.D., Summit Lubricants

-9NLGI SPOKESMAN, MARCH/APRIL 2015

IF YOU SEE ME, PAY ATTENTION!

EDUCATIONAL OPPORTUNITIES NLGI GREASE EDUCATION PROGRAM NLGI has promoted technical training for the grease industry for many years through its Grease Education Program. Courses are offered annually at the NLGI Annual Meeting in June and provide instruction at both basic and advanced levels. Course contents cover a broad spectrum of subjects and are designed to familiarize the student with all aspects of the grease industry, including manufacturing, chemistry, application, product characteristics and marketing. Course instructors are experienced specialists in their respective topics of discussion and course participants are supplied with an extensive study manual for later reference. Below are descriptions of the courses offered at the 2015 NLGI 82ND Annual Meeting.

All courses are one and one-half day programs.

Monday, June 8, 2015 10:00 am – 5:00 pm Tuesday, June 9, 2015 8:00 am – 12:30 pm (Lunch is provided Monday) • The courses run concurrently, attendance at more than one during the meeting is not possible.

• Course fees are $675 (NLGI Members) or $950 (Nonmembers).

• An additional late registration fee of $50 applies to those registering after May 8th.

BASIC GREASE EDUCATION COURSE With more than 1200 alumni, NLGI’s Basic Grease Education Course is the world’s foremost foundational training class for the global grease industry. This course provides an excellent overview of the types of greases, thickeners, base oils and additives. The methods of manufacturing, testing methodology and their use in bearings and in industrial and automotive applications are also covered.

ADVANCED GREASE EDUCATION COURSE

Advanced instruction regarding specific types of greases, chemistry and specialized application will be offered in this course. There is an increased focus on high-value, specialty greases and their manufacture and usage.

APPLICATION & MAINTENANCE GREASE EDUCATION COURSE

Stretch your lubrication dollars and sharpen your skill in selecting, maintaining and trouble-shooting lubricating greases, and refining your in plant maintenance procedures.

Taught by the industry’s experts, this course is especially useful for lubricant buyers, maintenance personnel and lube suppliers and/or their customers who need practical instruction.

TUESDAY, JUNE 9, 2015 NLGI CLGS EXAM INFORMATION

NLGI will offer the certification examination to the public on Tuesday, June 9, 2015 at the NLGI Annual Meeting in Coeur D’Alene, ID. Exam participation is open to any individual who is experienced in the field of grease and has achieved a high level of expertise in this field.

Details regarding the topics covered on the exam, application procedures and fees are detailed on the NLGI website at www.nlgi.org. You are NOT required to register for the annual meeting to sit for the exam.

NLGI exam fee is $225 (re-take: $125) for individuals employed by a member company, and $275 (re-take: $175) for those not employed by a member company.

PROGRAM HIGHLIGHTS

SATURDAY, JUNE 6, 2015 5:00 pm – 6:00 pm First-Time Attendee Reception 6:00 pm – 7:30 pm Networking Reception

SUNDAY, JUNE 7, 2015

8:00 am Golf Tournament sponsored by CITGO Petroleum Corporation

The Coeur d’Alene Resort golf course is simply sublime. Nothing is spared to deliver the ultimate golfing experience, once described as America’s Most Beautiful Resort Golf Course by Golf Digest. Golfers will be transferred to the course via the Mish-an-Nock Boat where breakfast will be served.

With the attention of your personal forecaddie, the comfort of your luxury custom cart, gorgeous Lake Coeur d’Alene views on every hole, and every item expertly attended to, you’re in for the golf game of your life. It’s quite simply, golf at its finest...

or two about creating Human Synergy – “that magic that allows groups of ordinary people to accomplish extraordinary things together.”

Her New York Times best-selling book How Winning Works, published by Harlequin has been reviewed as “an excellent resource for all business owners on approaching challenges with a team mentality.”

It is through these harrowing, life affirming and often hilarious experiences in the world’s most grueling challenges that she has emerged with her refreshing and truly unique perspective on what it takes to build the kind of World Class Teams that succeed against all odds, that triumph in the face of adversity and that win as one in times of great challenge and change. Whether you’re trying to beat the competition to market, scale a looming mountain of a project or simply get your team all marching in the same direction, Robyn’s 8 Essential Elements of Human Synergy will coach you to the finish line of success.

6:15 pm – 7:15 pm Welcome Reception

MONDAY, JUNE 8, 2015

6:15 am Sign-up 7:00 am Start 31st Annual NLGI Fun Run and Volkswalk sponsored by FMC Lithium

Join us for this always fun and invigorating event! Grab your running/walking shoes and join FMC again at 6:15 am to sign-in.

Official starting time for the event is 7:00 am. In keeping with long-time tradition, we will walk together to the 5:00 pm – 6:15 pm starting area the morning of the race.

Opening General Session Teams consist of three Fun Runners and/ Awards Presentation – New time & place or Volkswalkers each. Lots of water, fun, and a tee shirt to commemorate the event Keynote Address will be provided by FMC.

Robyn Benincasa

- Robyn is the founder of World Class Teams, a world champion adventure racer, a CNN Hero, former corporate sales expert and a full time firefighter who advises organizations on building World Class Teams of their own. World Champion Eco-Challenge Adventure Racer, Founder of the Project Athena Foundation (Survivors to Athletes!), three time Guinness World Record Distance Paddler and proud owner of 2 metal ‘bionic hips’, Robyn definitely knows a thing

products, employs 200 people in the USA and is the leading manufacturer in the industry.

Currently, GFW has (3) factories in the USA, (1) in Europe and (1) in Peru, with plans for another in Australia in 2016. Ron has spent over 30 years working directly with the CATERPILLAR® dealers worldwide and has built a reputation for quality and commitment to his customers.

Ron serves on several boards across North Idaho including; Kootenai Technical Education Campus (KTEC), Boys and Girls Club of Kootenai County, North Idaho Manufacturing Consortium, and has served as President at PF Chamber. Ron also serves on the NIC Board of Trustees and was appointed by Governor Otter to the PNWER Board. In 2007, Ron was awarded Citizen of the Year; 2008, Ron was awarded the Inland Northwest Partners “Hall of Fame” award; 2009, GFW was awarded “Company of the Year” by the Post Falls Chamber of Commerce and also received the Governors Choice Award – Lifetime Achievement Award. In 2013, Ron was awarded the “Idaho Businessman of the Year” Award.

8:30 am – 10:00 am Annual Business Meeting Industry Speaker Ron Nilson, President

and CEO of Ground Force Worldwide (GFW)

Ron has over 42 years in the manufacturing industry, and has owned several companies over the years. GFW builds mine support equipment for both open pit and underground mines and currently exports 75% of their

TUESDAY, JUNE 9, 2015 NEW THIS YEAR!

The Tuesday Evening Reception and Dinner will be very different from years past. First, it will be CASUAL! The reception will be held on two large vessels from the Coeur d’Alene Resort, transferring attendees across the lake to the beautiful Hagadone Event Center. Walk up to the Pavilion from the dock and join us for our Closing Street Festival featuring international food stations, interactive entertainment, magic and more surprises! At 10:00pm, the boats will begin transferring you back to the Resort.

There will not be assigned seating as in years past. If you indicated you would be attending the Closing Festival on your registration form, an Event map and 2-drink tickets per person for the dinner will be included in your registration packet.

SPOUSE/GUEST PROGRAM

NLGI welcomes all spouses and guests to the stunning Coeur d’Alene Resort!

The NLGI Spouse/Guest registration includes the Saturday networking reception, Sunday Keynote Session and Welcoming Reception, participation in the Fun Run and Volkswalk, Golf Tournament (additional fee), continental breakfast Monday and Tuesday, plus the Tuesday evening Closing Festival.

NLGI has created a unique, special program just for registered spouses and guests, which is available for a small additional fee of $50.00. However, advance reservations for this program are required. Refunds are not available for cancellations received less than 7 days prior to this event.

MONDAY, JUNE 8 11:00 am – 2:00 pm

Lake Coeur d’Alene Cruise & Lunch Enjoy a three-hour guided tour of one of the world’s most beautiful lakes. Learn the history of Coeur d’Alene, with an emphasis on the steamships/ cruise boats, and the impact they had on the people and the economy of the Inland Northwest. Enjoy a fantastic slideshow of photos and listen to stories as Captain Carl takes you back in time, all while you have the opportunity to take in the sights from the waters of Lake Coeur d’Alene.

Lunch and refreshments will be served.

- 12 VOLUME 79, NUMBER 1

COEUR D’ALENE RESORT & SPA COEUR D’ALENE, ID

MAKE YOUR RESERVATION BEFORE THE CUT-OFF DATE OF APRIL 21ST! NLGI’s room rate at the Coeur d’Alene Resort is $189.00 per night (Deluxe/Park Tower) or $229.00 per night (Premier/Lake Tower), plus applicable taxes (currently 8%).

NLGI expects to sell out the reserved guest room block, early reservations are strongly encouraged.

Toll Free Reservations: 1-800-688-5253 or fax form to 561-691-9133. You may also confirm your reservation on-line via a link on the NLGI website, https://www.nlgi. org/hotel-information/. If you wish to arrive earlier than the conference start date of June 6, or stay beyond June 10, please contact the hotel directly.

Reservations received after the cut-off date of April 21, 2015 will be confirmed based on room availability and at the prevailing rate. See hotel reservation form for more details.

The Coeur d’Alene Resort offers six wonderful dining options, from gourmet to casual on-the-water dining.

The area offers an amazing amount of activities, too many to list here! Please visit http://www.cdaresort.com/ discover/activities/activity-directory for a list of activities and contact information. You can also contact the concierge at the Coeur d’Alene Resort.

The beautiful lake front, infinity pool located at the Hagadone Event Center is accessible via a short 7 minute boat ride from the resort. Van transportation is available upon request. There is also an indoor pool and exercise facility in the resort.

Coeur d’Alene’s downtown has a small town’s charm and a big city’s excitement and amenities, with coffee shops, art galleries and specialty shops. All walk able from the resort!

Please note: The NLGI Group rate cannot be accessed via the Coeur d’Alene Resort website.

DESTINATION COEUR D’ALENE, IDAHO Airports and Ground Transportation

Coeur d’Alene is located 32 miles from the Spokane International Airport (GEG) Washington. Time zone will be Mountain Daylight Time. Transportation from the Spokane Airport can be arranged through the hotel by calling 800-688-5253, Ext. 7133 or by completing an on-line request form at http://www.cdaresort.com/discover/resort/transportation.

You may also choose to rent a car. Parking rates at the Resort are $17.00 per night (self park) or $22.00 per night (valet).

Clothing and Packing Hints

New! Tuesday night’s Closing Festival will be casual! We will depart the resort via the Coeur d’Alene Cruises two enclosed/open air vessels. Cocktails and hors d’oeurvres will be served on board. Upon arrival at the Hagadone Event Center, we’ll have entertainment, international food stations, quiet conversation areas, strolling magician, and more fun activities. There will be inside and outside seating areas, so please plan your attire accordingly as it will get chilly! And don’t forget your drink tickets!

June in Coeur d’Alene is usually mild, with highs in the mid to high 60’s, and lows in the mid 40’s. The resort is directly on the water, light sweaters and jackets would be advisable. There can be slight chances of rain. All receptions will be outdoors, as well as Tuesday’s Closing Festival. Transportation to the Festival will be via boat, it will be chilly, particularly on the return trip to the resort. Dress for all events is casual.

- 13 NLGI SPOKESMAN, MARCH/APRIL 2015

IF YOU SEE ME, PAY ATTENTION!

PRELIMINARY SCHEDULE SATURDAY, JUNE 6, 2015 12:00 Noon – 2:00 pm

Executive Committee Meeting

12:00 Noon -6:00 pm

MONDAY, JUNE 8, 2015

TUESDAY, JUNE 9, 2015

6:15 am Check-in 7:00 am Start

7:00 am – 8:15am

31st Annual NLGI Fun Run/ Volkswalk

NLGI Meeting Central

7:00 am – 4:00 pm

2:30 pm – 4:30 pm

- Registration - Refreshments - Table Top Displays

- Registration - Refreshments

Board of Directors Meeting

5:00 pm – 6:00 pm

First Time Attendee Reception

NLGI Meeting Central

7:00 am -8:15 am

Continental Breakfast

8:30 am – 9:45 am

6:00 pm – 7:30 pm

Networking Reception

- General Session - Annual Business Meeting - Featured Industry Speaker

SUNDAY, JUNE 7, 2015

10:00 am – 12:30 pm

6:45 am – 8:00 am

Session 1

Golf Continental Breakfast/ Transportation to Course

8:00 am Shotgun Start Golf Tournament

10:00 am – 6:30 pm

NLGI Meeting Central

Technical Presentations

10:00 am – 5:00 pm - Basic Grease Education Course - Advanced Grease Education Course - Application & Maintenance Grease Education Course

7:30 am – 8:30 am

Board of Directors Breakfast Meeting

8:00 am – 2:00 pm

NLGI Meeting Central - Registration - Refreshments - Table Top Displays

8:00 am – 12:30 pm - Basic Grease Education Course - Advanced Grease Education Course - Application & Maintenance Grease Education Course

7:25 am – 12:05 pm

Technical Presentations Session 3

12:05 pm – 1:00 pm Lunch (on your own)

1:00 pm – 5:00 pm

Technical Presentations Session 4

11:00 am – 2:00 pm

2:00 pm – 4:00 pm

12:30 pm -1:45 pm

6:00 pm – 7:00 pm

- Registration - Refreshments - Table Top Displays – Set-Up

Optional Spouse/Guest Tour

1:45 pm – 4:30 pm

(Students and Instructors Only)

Committee/Working Group Meetings

Continental Breakfast

Education Course Luncheon

1:45 pm – NLGI GC-LB Specification 2:00 pm – Biobased Grease Performance 2:45 pm – Grease Particle Evaluation 3:30 pm – Food Grade Lubricants

12:30 pm – 1:45 pm

5:00 pm – 6:15 pm

Session 2

Lunch (on your own)

CLGS Exam

NLGI Floating Reception

7:00 pm – 10:00 pm

NLGI Closing Festival

2:00 pm – 5:35 pm

Technical Presentations

Opening General Session Awards Presentation – New time & place Keynote Speaker

6:15 pm – 7:15 pm

Welcoming Reception

Thank you to Covenant Engineering, LLC Sponsor of the Preliminary Program

NLGI REGISTRATION FORM

NLGI 82ND ANNUAL MEETING – JUNE 6-9, 2015 Coeur d’Alene Resort, Coeur d’Alene, Idaho, USA

Please type or print clearly and use one form per registrant.

First Name:_______________________________Last Name:________________________________Nickname for Badge:______________________ Business Title:________________________________________________________ Company:____________________________________________________________ Address:________________________________________________________City:________________________State:______ Zip:________________ Country:___________________ Phone:_____________________Cell:_____________________ E-mail:____________________________________ Registered Guest/Spouse Name:__________________________________________Nickname for Badge:____________________________________ Please indicate any special disability or dietary needs: ________________________________________________________

PLEASE NOTE: IF YOU ARE REGISTERING MORE THAN (1) GUEST, CONTACT NLGI AT (816) 524-2500

❒ This is my first NLGI Annual Meeting. ❒ I am a new NLGI Member (2015) ❒ I am attending the Tuesday Evening Closing Festival (Casual!)

Please select your business category:

❒ Manufacturing ❒ Supplier ADVANCE REGISTRATION

❒ Marketing ❒ Technical REGISTRATION

Through 5/8/15

❒ Consumer

After 5/8/15 and On-Site

TOTAL

Registration Category

Member

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Member

Non-Member

Annual Meeting Fee

$575

$850

$625

$900

$

Educational Courses* (Advanced registration required) Basic Grease

$675

$950

$725

$1000

$

Advanced Grease

$675

$950

$725

$1000

$

Application & Maintenance

$675

$950

$725

$1000

$

Author/Instructor Fee

$400

$400

$450

$450

$

Spouse/Guest Fee**

$265

$265

$315

$315

$

CLGS Examination

$225

$275

$225

$275

$

* Please note: Annual Meeting Technical Presentations and NLGI Educational Courses are held simultaneously. Attendance at both is not possible. Attendance to the Opening General Session and Business Meeting/Industry Session, three Receptions, two Breakfasts and Tuesday dinner are included in both the Annual Meeting and Educational Course fees. ** Fee includes three Receptions, Two breakfasts, and Tuesday Dinner. Please check below for the Optional Spouse/Guest Tour for the nominal fee of $50:

Spouse/Guest Program ($50 Additional Fee):

Payment Information

______Coeur d’Alene Lake Tour with Lunch, Monday, June 8, 2015 $____________________

❒ Check for fees $ _________________ payable to NLGI, is enclosed.

$_____________________

Signature __________________________________________________

Total fees enclosed or authorized by credit card (USD)

Registration Procedures

❒ Charge for fees $ _________________ to: ❒ VISA ❒ MasterCard ❒ American Express Credit Card Number________________________ Exp. Date ________ Today’s Date ____________________

company. If you do not meet this guideline, please pay the Nonmember fee.

1. To qualify for advance registration, NLGI must receive your payment 4.

To attend any class, session, or event, you must be a registered attendee. and form by May8, 2015. If you register after that date or on-site, there This policy applies to spouses/guests and children; the guest fee would is an additional charge of $50 per person. If you have questions, please apply. Badge monitors will be posted at all sessions and social events. call NLGI at 816-524-2500.

2. Payment in full must accompany your registration form. No registration 5. Cancellations received in NLGI’s office through May 8, 2015 will receive a 100% refund, less a $75 cancellation/processing fee. After the May 8, will be processed without payment. All fees are in US currency.

2015 date, the entire registration fee is forfeited.

3. Membership in NLGI is by company. To qualify for the Member fee, you must either be a full-time employee or part owner of a member Register by Mail: Register by Fax: Mail completed registration form with payment to: Fax your completed registration form with credit Register On-Line: NLGI International Headquarters card information www.nlgi.org/ 249 SW Noel Street, Suite 249 • Lee’s Summit, MO 64063 24 hours a day to 816-524-2504. registration/ Phone: 816-524-2500 • Fax: 816-524-2504 • E-mail: nlgi@nlgi.org COPY THIS FORM FOR YOUR RECORDS.

HOTEL REGISTRATION FORM NLGI 82ND ANNUAL MEETING • JUNE 6-JUNE 9, 2015 COEUR D’ALENE RESORT, COEUR D’ALENE, IDAHO, USA

Name________________________________________________ Firm_________________________________________________ Street Address__________________________________________ City__________________________________________________ State________________Zip Code__________________________ Country______________________________________________ Telephone (_______)____________________________________ E-mail Address_________________________________________

CREDIT CARD INFORMATION

Arrival Date/Time______________________________________

❒ American Express

Departure Date/Time____________________________________

❒ MasterCard

Sharing with___________________________________________

❒ Discover

Please check credit card type and complete the information requested below: ❒ Visa ❒ Diners Club

Card Holder’s Name

ACCOMMODATIONS Single/Double Single/Double

$189.00 (Deluxe/Park Tower) $229.00 (Premier/Lake Tower)

_____ SINGLE (ONE PERSON) NO. OF ROOMS: _____ _____ DOUBLE (TWO PEOPLE) NO. OF ROOMS: _____ SPECIAL ROOM REQUEST(S):

Reservations received after April 21, 2015 will be confirmed based on availability.

Room types and special requests such as bed types and connecting rooms are subject to availability. Please note that check-in time is 4:00PM and checkout time is 12:00 NOON. GUARANTEE All rooms MUST be guaranteed by major credit card. Nonguaranteed reservations will NOT be accepted.

Register On-Line:

www.nlgi.org/hotel-information

Signature

Account Number Expiration Date _______ / _____ / _______ I, , hereby authorize Coeur d’Alene Resort to charge my credit card for a deposit equal to one night’s room rate.

Please Return Form with a Copy of the Front & Back of Your Credit Card Cancellation

Please be advised that a one-night room and tax will be charged for cancellations received less than 72 hours (3) days prior to your scheduled arrival.

Room rates do not include applicable State and Local Taxes, currently at 8%.

PLEASE RESPOND VIA FAX OR CALL: Fax: (208) 664-7279, Phone: (844) 592-2733

NLGI GOLF OUTING & FUN RUN THE 82ND NLGI MEETING GOLF OUTING SIGN-UP FORM Sponsored by CITGO Petroleum Corp.

SUNDAY, JUNE 7, 2015 6:45 am Breakfast 8:00 am Shotgun

*You must arrive at 6:45am for transportation to the course, via boat. Breakfast will be served on board.

http://www.cdaresort.com/discover/golf Registering on line for the golf outing is acceptable, however will not be confirmed until payment is sent and received.

• No reservations will be accepted without advance payment.

• Registration deadline is April 30, 2015.

• No refunds permitted after May 1, 2015.

• Tournament Fee: $800 USD per team. $200 USD per golfer.

• For International Payment: Please add $15 USD for each international golfer. Electronic wire transfer of funds is acceptable, a wire transfer fee is associated with this method of payment. Please contact Kim Smallwood for further instructions.

• Club rentals $62.54 incl. tax. Notify Kim Smallwood if needed, advise right or left hand. Payment due day of tournament

Contact Information:

Kim Smallwood 832-486-4879 • ksmallw@citgo.com

Make check payable to: Kim Smallwood Send the completed Registration Form along with your entry fee to: Kim Smallwood • 4606 Silhouette Drive • Katy, Texas 77493

❒ Yes, sign me up for the NLGI Golf Tournament.

Name: _______________________________________________ Company:_________________________________________________ Address: __________________________________________City:________________________State:________Zip:_________________ Country:_________________ Daytime Phone: ____________________Fax:________________E-mail:___________________________

List names of playing partners, company affiliations and golf handicap.

Names / Foursome: Company: Golf Handicap: Email Address: 1.________________________________

___________________________

______________

_________________________

2.________________________________

___________________________

______________

_________________________

3.________________________________

___________________________

______________

_________________________

4.________________________________

___________________________

______________

_________________________

31ST ANNUAL NLGI FUN RUN AND VOLKSWALK Monday, June 8, 2015 • 6:15 am Sign-up / 7:00 am Start Have you been running with FMC for over 30 years!? Well, grab your running/walking shoes and join FMC again at 6:15 am to sign-in for the always fun, 31st Annual Fun Run and Volkswalk. Official starting time for the event is 7:00 am. In keeping with long-time tradition, we will walk together to the starting area the morning of the race. Teams consist of three Fun Runners and/or Volkswalkers each. Lots of water, fun, and a tee shirt to commemorate the event will be provided by FMC.

Please send completed form by May 15, 2015 to: Bruce Urban FMC-Lithium 2801 Yorkmont Road Suite 300 Charlotte, NC 28208

Via Fax Bruce at 704-426-5387 or E-mail ALL information to bruce_urban@fmc.com

Sponsored by FMC-Lithium

■ Yes, sign me up for NLGI’s 31st Annual Fun Run/Volkswalk.

(Send two or more copies of this form if you and a guest(s) are participating.)

Name: __________________________Company: ___________________ Address: ____________________________________________________ City:___________________________ State: _______ Zip:____________ Daytime Phone: ___________________ Fax: _______________________ E-mail: _____________________________________________________

Steel Mill Lubrication:

Boosting the Grease Performance For Longer Bearing Service Life Hocine Faci Philip Booker Martin Maass Marcus Totten Abstract

Calcium Sulfonate Grease has been in use in the steel mill industry for more than 15 years. Its success in these applications is mainly due to a set of performances associated with the thickening material itself, which provides a decent carrying capacity and wear protection, good water resistance, corrosion resistance and thermal stability. Experience has demonstrated however that this technology as currently offered, does not meet the totality of the end users expectations, namely on load carrying capacity, thermal stability and mobility, crucial properties for long service life of the bearings.

The objective of this project was to build on the existing technology of Calcium Sulfonate greases, a more robust product that would boost the load carrying capacity / antiwar properties to higher levels, while keeping the current corrosion inhibition, water resistance, thermal stability, and grease mobility at least at the current level of performance, if not better.

An extensive benchmarking program that involved over 9 different commercially available products has been conducted in the laboratory testing phase where more simulative tests have been performed. This work has led to the development of a product that has met all the specification requirements. The load carrying capacity has been improved as well as the wear protection, the water resistance (under both the sprayoff and washout test conditions), and mechanical stability in the presence of various still mill process waters.

Since undergoing trial in a steel mill caster section, this product has shown great mobility, outstanding

Castrol Industrial

thermo-oxidation stability, excellent mechanical stability, excellent grease coverage of the bearing, and more importantly all these benefits were achieved with lower grease consumption. The service life of the bearing was extended from 3 to 4 years, and could be extended further. The detailed work will be compiled in this paper.

Introduction

Prior to the introduction of continuous casting in the 1940/1950s, steel was poured in individual molds to form ingots. Since then, the steel manufacturing has improved drastically. Continuous casting became the process of choice in steel, aluminium and copper industry.

Within the steelmaking process, the steel is cooled to form a semi-finished product in the continuous caster area. In a typical installation, molten steel is tapped from ladles on the ladle turret and fills a mold before entering a continuous caster. The mold is cooled externally and an outer skin is formed around the liquid metal core; this will remain liquid until near the end of the casting process (known as the metallurgical length).

The caster consists of rollers that are in contact with the cast steel, and these are generally cooled internally with process water. Bearings are installed to allow the rollers to rotate, and these are also water cooled in most casters. The steel is spray cooled at a determined rate, to maintain the metallurgical length. Bearings and rollers are also water cooled in the runout table directly after the caster; at this stage, the cast steel can still be in the region of 800°C. If the internal water cooling system or pipe work fails,

- 18 VOLUME 79, NUMBER 1

roller and bearing temperatures will rise rapidly. The cast steel is very soft and malleable at this stage, and surface damage can occur that cannot be rectified further downstream in the steelmaking process. This can result in scrap costs, as well as downtime to repair the affected machinery including bearings, rollers and cooling water pipe work.

Specialty greases are available to lubricate high temperature applications in the hot areas of a steel mill, and water resistant greases are available for areas where large volumes of water are used. It is not common to find products that are effective in both high temperatures and extreme conditions such as large volumes of process water.

Balancing the mix of oil, thickener and additives to match the type of application can result in a significant increase in performance compared to conventional greases.

This paper discusses the evaluation, benchmarking and field trial of single grease specifically designed for performing under the harsh and varied conditions found in casting sections in steel mill plants.

Background

The most used greases in the steel industry are those based on aluminium complex, lithium complex and calcium sulfonates. References [1, 2, 3, 4, 5 and 6] cover a comprehensive description of some of the steel mill plants, the typical greases used in these plants and their conditions of application.

Recently a good number of papers have been presented at ELGI and NLGI outlining the benefits of calcium sulfonates or calcium sulfonate complexes; Reference [7] indicates that the calcium sulfonate greases remain the fastest growing grease thickener system, a main reason being that it does not change its characteristics even in the presence of large amounts of water. Reference [8] emphasizes on what makes the calcium sulfonate greases different to the other greases from the structure to the manufacturing process. Reference [9] studies the effect of water on various types of thickening systems, and different types of base oils are evaluated for a good

number of characteristics by various test methods. This reference joins the other papers to confirm that calcium sulfonate greases outperform the other greases under high load and high temperature applications. Reference [10] outlines the impact of other advanced thickening systems on the bearing service life.

This study takes into consideration all the work that has been covered earlier using the calcium sulfonate grease technology, and will identify the key advantages of this technology. The laboratory work as well as the field testing approaches will be covered.

Laboratory Development Work

Definition of required tests The caster section bearings in a steel mill plant as described above require grease with good number of properties in order to withstand the harsh conditions of the application, namely: (1) high load carrying capacity, (2) improved wear protection, (3) excellent mechanical stability, (4) outstanding water resistance, and (5) excellent corrosion inhibition. To evaluate these properties, the following test methods were used: 1. Load Carrying Capacity: One of the most popular tests for determining the load carrying capacity is Four Ball EP (ASTM D 2596, DIN 51350-4). This test consists of 4 balls arranged in the form of an equilateral tetrahedron. The basic elements of the tetrahedron are 3 balls held stationary in a pot to form a cradle in which the fourth upper ball is rotated around a vertical axis under pre-selected conditions of loads. The rotating speed is 1770 +/- 60 rpm. A series of 10-second runs are made at successively higher loads until welding of the 4th ball occurs (Figure 1).

- 19 NLGI SPOKESMAN, MARCH/APRIL 2015

Figure 1: Four Ball EP set up

Wear: Wear protection is measured by Four Ball Wear method. The test (ASTM D 2266, DIN 51350-5) can be run at a specified rotational speed under a prescribed load at a controlled temperature. The test duration standard is 1 hour. The diameters of the wear scars on the stationary balls are measured after completion of the test (Figure 2).

Figure 4: Grease Worker

Roll Stability Test: ASTM D 1831 In the Roll Stability Test, a small sample (50 grams) of grease is rolled at 165 rpm for a specified period of time under a given temperature. The difference in worked penetration measured with ¼ scale penetrometer before and after rolling is reported (Figures 5 and 6).

Figure 2: Four Ball Wear set up

Figure 5: Rolls

Mechanical / Shear Stability: Shear stability is the ability of grease to resist changes in consistency when subjected to mechanical work. The most common laboratory tests used to evaluate shear stability are described below: Worked Penetration (extended worked stability): ASTM D 217, DIN 51804 It consists of subjecting the grease in a standard penetration cup in a grease worker to a number of double strokes (1 k, 10 k, 100 k, etc…). The difference between worked penetration before the test and the worked penetration after the test determines the shear stability and is reported as the change from the original figure (Figures 3 and 4).

Figure 3: Penetrometer

Figure 6: Roll Stability Tester

Water Resistance: This can be evaluated by using three different procedures that complement each other. The following test methods were used in this study: Water Washout Test: ASTM D 1264 Method consists of a standardized bearing with front and rear shields having a specific clearance. The bearing is packed with 4 grams of grease and rotated at 600 rpm

- 20 VOLUME 79, NUMBER 1

under a jet of water at a given temperature for one hour.

At the end of the hour, the bearing is removed, dried and weighed. The weight loss is reported (Figure 7).

Wet Roll Stability: ASTM D 1831 (modified) Method consists of running the roll stability test, but in the presence of water. Process water may be used instead of distilled water. Visual inspection of the grease and its penetration change after the roll, along with the presence of free water and its quantity, are determining factors for the water resistance characteristics of the grease.

Corrosion Resistance: In wet applications such as those in steel mill environments, greases are expected to assure protection against steel rusting. Two tests are considered in this program:

Figure 7: Water Washout Tester Water Spray-off Test: ASTM D 4049 This test method consists of subjecting a layer of grease at a given thickness on a stainless steel panel to water spray off. The grease is sprayed with 40 psi water at a given temperature for 5 minutes. The panel is then dried and weighed. Spray off resistance is reported as the percentage weight of grease removed by the water spray (Figure 8).

Figure 8: Water Sprayoff Tester

Rust Test: ASTM D 1743 Method consists of running a tapered roller bearing packed with 2 grams of the grease. The bearing is rotated under a given thrust load for 60 seconds to distribute the grease uniformly. The bearing is then immersed in distilled water without breaking contact between cup and cone and stored at 52°C and 100% humidity for 48 hours.

At the end of the 48 hours, the bearing is removed, cleaned and inspected for rusting. A corrosion spot of 1.0 mm or longer is an indication of failure. Only pass or fail ratings are used. Run in the presence of process water, this test gives an accurate indication of the corrosion resistance characteristics of lubricating grease (Figure 9).

Figure 9: Bearing Spinner for ASTM D 1743 - 21 NLGI SPOKESMAN, MARCH/APRIL 2015

NLGI Emcor Rust Test: ASTM D 6138, DIN 51802 This test method is used to assess the ability of grease to prevent corrosion in rolling bearings operated in the presence of distilled or process water. It consists of packing a pair of double row ball bearings with grease and mounting them on a shaft in a housing where a specified amount of water is added. The bearings are subject to 8 hours run and 16 hours off for three days and after that they are left for 4 days. The bearings are disassembled and the bearing race is rated for corrosion (0 to 5: no corrosion to highly corroded surface), (Figures 10 and 11)

Figure 11: Emcor Test housing and bearing Figure 10: Emcor Test Unit

Based on field experience and after consultation with a good number of end users and OEMs, the following targets have been selected (Table 1):

Table 1: Initial Specification Target

- 22 VOLUME 79, NUMBER 1

NLGI Evaluation of Commercially Available Products:

Nine commercially available products based on different thickening systems have been subjected to a series of tests including water washout, water spray-off, roll stability in presence of process water and rust test as per ASTM D 1743. Different process waters are considered in this program. The results for the nine greases and calcium sulfonate grease prototype, P5606 are displayed in Table 2 below:

Table 2: Evaluation of commercially available products vs. prototype (Process Waters)

P5606: Prototype CAP 1, 2,…: Commercially Available Product 1, 2, ….

WSO: Water Sprayoff WWO: Water Washout

The graphs of Figures 12, 13 and 14 reproduce the above results, showing the effect of process water on each product. The results showed that none of the commercial greases met all three performance targets set

for measuring water resistance and mechanical stability.

On the other hand, calcium sulfonate prototype easily met the targets and specification limits were made more stringent as shown in Table 3.

- 23 NLGI SPOKESMAN, MARCH/APRIL 2015

Figure 12: Water Sprayoff Data obtained on Commercially Available Products

Figure 13: Water Washout Data obtained on Commercially Available Products:

Figure 14: Wet Roll Stability Data obtained on Commercially Available Products:

Final Specification Target: Based on the data obtained above, a new specification target has been established for the prototype grease in terms of water and corrosion resistance. Table 3 regroups these data as well as the results obtained on the prototype:

Table 3: Final Specification Requirement and Prototype Characteristics

NLGI The above results indicate that the prototype meets all of the revised requirements. It displays outstanding results in terms of load carrying capacity, wear, water resistance, mechanical stability as well as corrosion resistance.

Field trial

A trial has been conducted for 12 months in the process downstream of the curved section of a six strand billet caster. This covers the extractors, straightener section, runout table to cutting torches, runout table to cooling bed, lifters, cooling bed, walking bed pivots and transfer car.

Mechanical Stability & Water Resistance Although the grease consumption has been significantly reduced at the start of the trial, a generous amount of grease still remains in the bearing 12 months later. This indicates excellent mechanical stability, advanced water resistance and extremely good tackiness to keep the grease in place.

Pumpability, Dispensability, and Mobility The above picture as well as the field inspection reports indicate that the grease was present in large amounts in all the bearings inspected, demonstrating a good pumpability through the dispensing systems and mobility in the bearing.

This demonstrates the flexibility of the grease; one product can be used in many areas, consolidating stock and making lubrication tasks a lot simpler.

Field Trial Results Grease Consumption Using the evaluation data in comparison with the performance of a previous grease in application, it was possible to reduce the grease consumption by 50%. This reduction in consumption resulted mainly from the improved mechanical stability as well as water resistance.

Further reductions were possible, but the centralised grease system was not flexible enough to further optimize grease consumption without risking the damage of critical components lubricated by the system. This level of consumption set up was maintained until the lubrication system constraints are over-hauled.

This reduction in grease consumption has resulted in a lower pumping rate through the lubrication system pipe work, eliminating the risks of blocking the line, and therefore assuring permanently the dispensing of grease to the bearings. Figure 15 shows the condition of the grease inside a bearing housing before cleaning ready for inspection.

Figure 15: Bearing, Pre Inspection Noise Reduction The specificity of the calcium sulfonate greases, which by definition contain a much larger amount of thickening system in comparison with the conventional greases and when also enforced with solid lubricants, this grease will have the capacity of assuring the presence of a strong film between the lubricated surfaces. This film will contribute to the amortization of the shock loading and therefore reducing or eliminating the noise. Effectively the operators have reported that in the walking beam area, where the plain metal bearings of the pivots used to be very noisy, due to metal on metal contact under high temperatures and low speeds, after using the prototype product, no noises were noticed. During the final inspection after 12 months trial, the end user confirmed

- 26 VOLUME 79, NUMBER 1

NLGI that the prototype grease had prevented damage within these critical bearings.

elements, and the grease did not form hard deposits

High Temperature Performance On two occasions during the trial period, pipe work for the internal cooling of the continuous caster roller bearings failed.

This can be quite a common occurrence with flexible pipe work, and failures mean that bearing temperatures will raise very quickly, leading to seized bearings. This causes production quality issues, as the billet surface finish will be affected by sliding instead of rolling over the rollers.

The bearing housing and grease pipe work in the immediate vicinity will also be subjected to extreme heat; some greases will form hard deposits in this situation and will require pipe work and bearing housing replacement as well as a bearing change.

Figure 16: Bearing in normal conditions

During the trial with the prototype grease, the end user reported that cooling water supply to one roller had failed for a period of between 24 and 48 hours. It was not possible to stop production, so the affected bearings had to remain in place after the cooling water system was repaired. Cast product quality was monitored, and no quality issues were reported.

At the next available maintenance opportunity, the bearings were removed from their housings and changed; however, upon further inspection they were found to be in a serviceable condition. Furthermore, grease pipe work did not need to be replaced. Grease within the bearing housings also remained mobile, significantly reducing maintenance time after the cooling water failure.

Pictures of a used bearing running in normal conditions, and one subjected to extreme heat, are shown below (Figures 16, 17).

Discolouration of the brass cage can clearly be seen on the heated bearing, but all roller elements remained free to rotate and clearances were measured and found to be within tolerances defined by the end user.

No scoring marks could be seen on the bearing

Figure 17: Heated Bearing Bearing Life A selection of bearings were inspected jointly with the end user, and the remainder were inspected by the end user’s maintenance team. All bearings were found to be within a specified tolerance and deemed suitable for further use.

Historically, bearings have been replaced every three years as a preventive measure to avoid unplanned downtime. Bearings reaching three year life were also found to be suitable for further use, minimizing bearing replacement costs across the whole of the caster installation. It is fully expected that these three year old bearings will not require replacing during the next 12 monthly maintenance period.

NLGI Even when considering a minimum of 25% life extension then the reduction in spare parts alone is significant, but the end user is confident that bearing life can be extended even further. This will be confirmed after the next 12 month maintenance period.

In addition to the points listed above, the grease did not block pipe work when subjected to extreme heat, giving the added advantage of minimising associated maintenance work.

Corrosion Resistance No staining or corrosion was visible in any of the bearings inspected during the maintenance period, indicating that the grease performs extremely well in being able to resist corrosion from the chemical aggressiveness of process waters in use in the plant

Authors would like to thank Luis Blazquez, Soman Dhar, and the customer for the valued contribution to the product field testing

Conclusion

Key parameters selected to prove the capabilities of the product were high temperature performance, load carrying capability, performance in wet environments and extended component life.

Taking the performance of greases with a similar technology platform, an initial specification was shaped to benchmark a new development product, targeting high load performance, water resistance, corrosion prevention and mechanical stability (also in the presence of process water).

A continuous caster was selected for a field trial. This application is well known to be a critical area requiring high performance in lubrication to avoid costly breakdowns and increased maintenance.

After the 12 month trial period, the performance was evaluated with the end user and the following benefits were observed: • Grease consumption reduced by 50% • Grease still appears to have the same consistency as the new product • No signs of corrosion or surface staining • Bearing tolerances remained within specification • Bearing life extended from three to four years, most likely longer

Acknowledgements

References

1. C. White, Lubrication, Vol. 77, Nr 1, 1991 2. NLGI Lubricating Grease Guide, Second Edition, 1989 3. A.E. Cichelli, Evaluation of Greases For Steel Mill Service, NLGI Spokesman, August 1973 4. A.E. Cichelli, Grease Lubrication in Steel Mills with Emphasis on Roll Neck Bearings, NLGI Spokesman, April 1980 5. J. Schlobohm Sr., H. Faci, B. Cisler, Steel Mill Greases: Evaluation and Analysis, presented at the 71st NLGI annual meeting, Dana Point, CA, 2004 6. P. Booker, H. Faci, M. Totten, M. Maass “Advanced Lubrication of Steel Mill Components. Long term solution for Extreme Conditions”, Presented at the 26th ELGI Meeting, April 26-29, 2014 7. Gareth Fish, William C. Ward, Calcium Sulfonate Answers to Water Issues, presented at the ELGI 25th Annual Meeting, Amsterdam, April 20-23, 2013 8. David Autier and al. Calcium Sulfonate Greases. A solution to Water Resistance, presented at the ELGI 25th Annual Meeting, Amsterdam, April 20-23, 2013 9. Johan Leckner, Water + Grease: Fatal Attraction, presented at the ELGI 25th Annual Meeting, Amsterdam, April 22-23, 2013 10. Hocine Faci, John Haspert, Effect of Water on Grease Performance and Lubrication for life in sealed bearings, presented at the NLGI 80th Annual Meeting, Tucson, AZ, June 15-18, 2013.

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NLGI SPOKESMAN

GOING DIGITAL! The NLGI Spokesman will be offered in print, as well as, digital for the 2015 calendar year. During this year, we will be ensuring that we have correct email addresses for all of our subscribers, to ensure a seamless transition in 2016 to all digital.

If you would like to see the magazine digitally, click below:

https://issuu.com/kim0824/docs/marapr2015 Oh, our apologies, you can’t click!

One of the many advantages of having a digital version of the NLGI Spokesman. If you would like to begin receiving the magazine in digital form only, please let us know at nlgi@nlgi.org

Lubrication in Mining Equipment Ashok Kumar Goyal, Rohit Agarwal, Balaram Ghosh and Abhijit Roy

Balmer Lawrie & Co. Ltd., Applications Research Laboratory, P-43, Hide Road Extn, Kolkata, India – 700 088.

Abstract

Mining industry deploys a large number of heavy earth moving equipment like draglines, shovels, dumpers and dozers for the extraction of minerals and coals via surface or underground mining. Effective lubrication to protect the heavily loaded components of mining equipment is a key responsibility of the users, lubricant manufactures and original equipment manufacturers (OEMs).

The number of breakdown arise due to failure of lubricating components can be reduced by maintaining proper lubrication on production equipment. Dispensing of right lubricant, in right quantity at right time is very crucial to prevent the system failure. Designing of right lubricant for different components of mining equipment viz. enclosed gear drives, open gear drives, different types of bearings, circulating and hydraulic components, is a challenging task for lubricant manufacturers.

Present paper elaborates on various criteria & considerations for the development of appropriate lubricants for different components

of mining equipment especially for draglines and shovels.

Introduction

Maintenance of production equipment in mining industry is very essential to keep the equipment in efficient working condition to increase the productivity by reducing downtime. Maintenance people seek to reduce the maintenance costs, increase equipment utilization and improve equipment reliability. To achieve this, maintenance personal often look to upgrade the lubricants to the latest technology.

Primary function of any lubricant is to reduce the friction which is normally achieved by introducing an ideal film of oil or sufficient amount of grease between two surfaces in relative motion. This lubricant film prevents the two surfaces to come in contact under the conditions of speed and load imposed on the moving parts. In the absence of proper lubrication machine parts develop friction, heat and rapid wear, which may eventually cause machine failure. Improper - 30 VOLUME 79, NUMBER 1

lubrication also results in frequent downtime, higher operating cost due to lower efficiency. Some of the direct costs resulting from improper lubrication include cost of replacement spares and components, labor for replacements and repair, excess lubricant consumption and labour for inefficient manual lubrication practice. Therefore proper lubrication of each lubricating surface of production equipment is very essential for the smooth operation of any industry.

Present paper elaborates about the development of appropriate grease lubricants for different lubricating surfaces of mining draglines and shovels. For the development of suitable grease lubricants mode of application, various tribological aspects and original equipment manufacturers (OEM) recommendations related to lubricants are also taken into consideration.

Mode of Lubrication

Lubricants can be applied on lubricating surfaces by manual or automatic lubrication methods.

The main difference between manual and automatic lubrication is that in the case of manual mode, technicians tend to lubricate on schedule (once a day, week, month, year, etc.) rather than when the lubricating surface needs it. This sets up an over lubrication or an under lubrication scenario (Figure 1). Conversely, automated lubrication provides lubricant constantly at an appropriate amount that allows the lubricating component to operate at its optimum. When the lubricating surface is properly lubricated in this manner, it also helps to seal from contaminants. In addition, there is less downtime compared to the manual lubrication process, as well as substantially reduced man-hours required for the task. It is possible with automated lubrication system to lubricate machine parts while the machine is in operation and also the machine parts which are inaccessible or difficult to access manually can be easily lubricated with automated lubrication system.

However it is very important to maintain the automated lubrication system in proper working condition.

Tribological aspects of lubrication

Lubricants are continuously improved over the years to take care of the modern machines running hotter, faster and longer. Today’s lubricants must satisfy extreme requirements that are specific to each application. Type of motion, speed, temperatures, load and the operating environment are certain tribological aspects which have to be identified before the development of any lubricant. Once these tribological aspects are identified, the lubrication engineer can utilize different lubricant chemistry to design a lubricant that will optimize the performance of the application.

Type of Motion

The first parameter of the tribological aspect involves the type of motion. The motion may be sliding or rolling. Combined sliding and rolling is also a possible form of motion in certain rolling-element bearings including the tapered roller bearing. Protection of machine components under these types of motion can be optimized with specific chemistry. Some specific chemistry is more effective in sliding contacts than in rolling contacts. Combination of synergistic additive system is required for motions which involve both sliding and rolling contacts.

Speed

Speed of moving components can be categorized into the general ranges of fast, moderate and slow. Knowing the speed of the contact, a lubricant can be selected with the optimum physical attributes to minimize friction. In general, for higher speed applications lubricants should be with lower viscosity and for lower or moderate speed applications, lubricant should be designed with medium to higher viscosity.

Temperature

All lubricants have specific temperature ranges for optimal performance. Many lubricants have a broad operational temperature range however, some lubricants are more suited for lower temperatures. For example, there are some greases with low viscosity synthetic hydrocarbon base oil can operate at temperatures as low as -60°C. Other lubricants are designed for high temperature applications, such as greases with high viscosity synthetic hydrocarbon base oil thickened with Calcium Sulphonate Complex soap that can lubricate an oven chain bearing at 220°C. Knowing the application temperature the lubricant manufacturer should develop the lubricants which can provide optimum performance at the application temperature.

Load

Load is an important factor affecting the lubricant requirement. A light load may indicate that application is sensitive to frictional torque and therefore a lubricant with low viscosity should be designed to minimize the fluid friction while still providing adequate protection from friction and wear. For heavily loaded application, a high viscosity lubricant is required with specific extreme pressure additives to protect the machine parts from pitting, galling and extreme wear. Therefore, for heavily loaded applications lubricants should be formulated with high extreme pressure and anti-wear additives.

Operating Environment

If the environment includes moisture or water, the lubricant must provide good anticorrosion properties as well as resistance to water washout. If the application involves the presence of certain chemical liquids or vapors, the lubricant must be resistant to these chemicals.

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Special Requirements

Many applications have special requirements that go beyond the tribological aspects that must be taken into consideration. Lubricant development is also dependent on certain specialized requirements i.e. Lubrication equipment, re-lubrication intervals, cost, special certifications such as DGMS approval, biodegradability etc. Therefore, by identifying various tribological aspects a lubrication engineer (or tribo-engineer) can design proper lubricant for different lubricating surfaces of any machine.

Lubrication in Mining Draglines and Shovels

Big, bigger and biggest are the standards in Mining.

Draglines and Shovels are of prehistoric sizes and their gears and other lubricating parts are amongst the largest applied anywhere. In both closed and open systems a variety of different lubricants are being used.

Extreme pressure protection, reliability, consistency and performance in dusty environment are key factors for the development of correct lubricant for different moving surfaces of the mining equipment.

Lubrication in Swing Gear and Swing Rack Gear system

During the operation of draglines and shovels the whole upper body of the machine can be swing in each direction on lower base body with the help of swing gears (Figure 2). In draglines the swing gear is composed of swing pinion shaft, swing pinions & swing rack gears and swing circle rollers & roller path, which is known as swing rack gear system.

Swing Pinion Shaft: This is a large shaft which is mounted below the swing gear box and at base of which is mounted the swing pinion. The shaft is supported by anti-friction bearings which are lubricated with grease.

Swing Pinions & Rack Gears: These are located in the sub-floor of dragline. Depending on the size and age of machine the no. of these may be between 4 to 8 pinions.

The swing rack is always internally geared & the gear is made up of segments that are bolted to the tub frame.

The swing rack and pinions are lubricated with open gear compounds. Method of lubricant application is normally by spray where grease is delivered via injectors and atomized by air.

Swing Rollers & Roller Path: At upper rotating deck & lower frame of the machine in between two large bearing raceways (roller paths) a series of parallel face rollers contained within a cage is positioned. The path and outer surface of the rollers are lubricated with open gear compound that is usually applied via drip feed from pipes connected to grease injectors. The rollers have centre bearings to support each roller and these bearings are lubricated with grease, which can be applied manually, or via single point lubricators.

Usually lubrication in swing rollers is provided by automated pumping system and in swing rack gear system by automatic spray system. In case of failure of automated lubrication system, lubrication can be carried out manually by maintaining proper amount and frequency of re-lubrication. Swing rack gear system and swing rollers work under tremendously high load and low speed conditions. The lubricant used for swing rack gear system should create a tenacious / tacky film which resists breakdown and wiping under high load conditions. The lubricant should be based on very high base oil viscosity and fortified with extreme pressure additives, anti-wear additives and solid lubricants, to provide adequate protection to the heavily loaded open gears and extend the component life while reducing consumption. The lubricant should also have water resistance property to prevent the lubricant from being washed off in rainy season.

Development of Grease Compound 1

By considering the mode of applications, working conditions and environmental effects along with OEM specifications of swing gear lubricants for shovels and draglines, grease compound 1 has been developed. This grease is suitable for lubrication of all types of large and small open gears working under heavy loads and prone to excessive pitting, scaling or abrasive wear. This compound is right lubricant for typical applications including swing rack gear and pinion, swing rollers, hoist and drag gear system of draglines, swing gear and pinion and hoist gear system of shovels. This compound is highly water resistance even in rainy season and easily can be applied on lubricating surfaces either by automatic lubrication system or by manual method. Grease compound 1 can easily be applied even in cold season as compared to bituminous lubricants which becomes

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very stiff in cold climatic conditions.

The performance of this grease compound was found excellent in terms of easy application, less consumption and less maintenance requirement. The properties of Grease Compound 1 are given in Table 1.

Lubrication in Hoist and Drag gear & pinion

The conventional dragline hoist drum has two hoist ropes that run in unison and are both connected to the bucket rigging at the same attachment point (Figure 3). Hoist and drag drum run independently to each other in both direction and speed up by enclosed gearpinions. Lubrication of these enclosed gear-pinions is carried out by manual or automated lubricant pumping system. Heavy duty grease compound 1 developed for swing rack gear system and swing gears also gives excellent performance when used in hoist and drag gear pinions of draglines.

Lubrication on Hoist, Drag and Dump Wire Ropes

The ropes are made up of many strands and configurations to cope with continuous movement as load is applied & released and also as the rope bends over sheaves during use. Wire ropes are made of high carbon steel wires that have been cold drawn, producing very ductile, fatigue resistance properties, as well as very high strength. The rope life can be reduced from 40-50 % if the ropes are not lubricated beyond what was applied during rope making. Inadequate lubrication could also seriously impact on the

wear of the sheaves and drums. The type of lubricant used and means of lubricant application can also have a significant impact on the rope life.

Therefore, hoist, drag and dump wire ropes should be lubricated properly to extend their service life.

Ropes are lubricated as they pass over deflection rollers and through sheaves. The most common method of rope lubrication is drip tubes or spray nozzles, through some sites use pressurised applicators that straddle the rope as it passes through the application. Rope lubricant should be designed with low viscosity oils to adequately penetrate the strands (wires) of rope which can prevent internal wear as well as higher viscosity base fluids are required to prevent the external wear. For lubrication at external surfaces, oil thickened with soaps or non-metallic thickeners are beneficial. Rope lubricants are usually fortified with extreme pressure additives and may contain plus a low percentage (typically 3 %) of lubricating solid additives.

Development of Grease Compound 2

Taking in consideration both internal and external wear of wire ropes grease compound 2 has been developed which is based on moderate base oil viscosity along with highly water resistance soap thickener. Grease compound 2 is semi-fluid, tacky and specially suited for in-service lubrication of wire ropes under varying services. It contains a performance enhancing additive combination to offer protection of individual wire strands - 33 NLGI SPOKESMAN, MARCH/APRIL 2015

against friction, wear, and corrosion.

It gives excellent performance for in-service lubrication and corrosion protection of wire ropes continuously exposed to atmosphere and for wire ropes requiring protection against varying climatic and environmental conditions.

Grease compound 2 contains a highly water resistant soap base to provide excellent corrosion/ rust preventive characteristics. It is extremely tacky. Hence it does not sag out of the surfaces, adheres well on the surface of the wire ropes and resists throw-off during the service of the wire rope to offer extended protection. Its semi-fluid nature makes it easy to apply on the wire rope by drip tubes or by brush. Due to its moderate base oil viscosity it has the ability to penetrate between the individual strands and the inner core of the wire rope and also provide better lubrication at outer surface because of tacky and water resistance soap. Due to the presence of anti-corrosion additive it protects the wire strands and wire core as a whole against varying climatic conditions from rusting. Its operating temperature range is -10° C to + 80° C. Properties of grease compound 2 are shown in Table 2.

Lubrication in Eccentric Cam and Ball of walking boot

Most of the draglines have a walking mechanism which consists of an eccentric articulated arm, which is supported by a shaft and bearings on both sides (Figure 4).

A link between the walking arm and the main frame stabilizes the eccentric motion. Lubrication of these parts can be carried out by

using greases with extreme pressure properties along with very good mechanical shear stability and water resistance properties.

Development of Grease Compound 3

Grease compound 3 especially designed for walking cam which has high base oil viscosity and fulfils the boundary film lubrication conditions under the harshest loads found on a dragline. This is suitable lubricant for this type of application which is formulated with extreme pressure additives for lubrication under severe mechanical conditions and for extension of lubrication frequency. Lubrication by these grease results in significant reduction in wear and coefficient of friction of mating surfaces. This grease is fortified with solid lubricants and has good surface adherence property to give excellent protection against rust, corrosion, water washout and has excellent film strength. This grease is also recommended for all types of bearings operating under heavy loads, shock loads or under excessively wet/ damp conditions. Properties of Grease compound 3 are shown in Table 3.

Conclusions

Grease compounds developed for different lubricating parts of draglines and shovels are found to be appropriate lubricants in terms of ease of application, less

Table 1: Properties of grease compound 1

consumption and less maintenance requirements. Grease compound 1 gives a perfect solution for any type of swing gears which works under tremendously high load conditions by moving with low speed. Grease compound 2 is provides excellent performance by preventing both internal and external wear of wire ropes. Grease compound 3 gives better lubrication in eccentric cam & walking boot along with all types of bearings positioned in the machine.

References

1. “Open Gear Lubricants for Cat Electric Rope Shovels and Draglines”, www.cat.com.

2. M. Ian, “Dragline Lubrication”, Dragline Mining: Prospectus & Challenges, 217-230, 2013.

3. K. Sherwood and W. Scott, “Improved Lubrication of Dragline Components”, 1996.

4. B. T. Jones, “Dragline Maintenance Engineering”, 2007.

5. D. Lauer, “Tribology: the Key to Proper Lubricant Selection”, Machienary Lubrication, 3, 2008.

Acknowledgements

The authors are sincerely thankful to the Management of M/s. Balmer Lawrie & Co. Ltd. for giving an opportunity to present the above work.

Table 2: Properties of grease compound 2

Table 3: Properties of grease compound 3

- 35 NLGI SPOKESMAN, MARCH/APRIL 2015

NLGI

NLGI

1a

1b

Figure 1: Lubrication Scenario: (1a) Over Lubrication and (1b) Under Lubrication.

2a

2b

Figure 2: Lubrication in swing gear system (a) Internal view of swing Rack gears along with swing rollers of dragline (b) Swing gear of electric rope shovel.

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NLGI

3a

3b

Figure 3: Lubrication in Hoist and Drag gear & Pinions (a) Lubrication in enclosed hoist gear box (b) Open hoist gear of dragline.

4a

4b

Figure 4: Lubrication in (a) Eccentric Cam and in (b) Ball of walking boot of dragline - 37 NLGI SPOKESMAN, MARCH/APRIL 2015

SUPER-ADDITIVE PACKAGES: The Next Generation of Lubrication Performance Enhancing Additives a

Ajay P. Malshea*, Wenyang Zhanga, Melanie Murphya, and Greg Schwartzb nGlide Division, NanoMech, Inc., 2447 Technology Way, Springdale, AR 72764 b NanoMech Energy, 100 Crescent Court, Suite 440, Dallas, TX 75201

*Contacting author- Email: ajay.malshe@nanomech.com; (Dr. Malshe is also a Distinguished Professor and Endowed Chair Professor of Mechanical Engineering at the University of Arkansas, Fayetteville, AR)

Abstract

Traditional additive packages address critical functions including anti-wear, anti-friction, extreme pressure, corrosion resistance, and related others for a wide selection of greases. The tight balance of additive chemistries, with interplay among their chemical compatibility as well as their synergistic response with the mating surfaces, is critical and typically fully exploited when building a well-balanced grease product.

However, over the decades this tight balance has become even tighter as lubricant manufacturers are addressing exponential demands from manufactures of mechanical devices. Mechanical devices such as gear boxes, valves, ball bearings, pin joints, and others are experiencing severe demands for lubrication due to harder and harder materials of construction, tighter and tighter tolerances, extended lubricant changing interval cycles and drastic limitations on pricing for lubrication engineering.

Among all the applications, the critical driving force for expanding this scope of traditional lubricants is boundary lubrication, where direct contact of multiple mechanical surfaces is driving the energy and durability equation.

Super-additive packages are the next generation of additives, capable of working with or without, and above and beyond the established traditional additive packages. These super-additive packages are engineered using fundamentals of material-genomics allowing one to dial-in and enhance the functional performance of selected properties, depending on the end application.

This technical report is presenting a specific case study,

especially for demonstrated performance of superadditives in fully formulated market available greases used for various large market sectors. An atlas of such super-additives to work alongside traditional additives is at the heart of this new platform to be used with a wide selection of off-the-shelf lubricant greases or customized specialty greases.

Introduction

Globally, as population and industrialization are growing, there is an exponential growth in the demand for energy use. The demand for energy is primarily driven by human activities in two types of systems—electrical systems and dynamic mechanical systems. Especially, growth in the population and industrialization, and growth in mechanical devices are almost moving in parallel. In the dynamic mechanical devices, the driving factors for energy losses are due to friction, material losses due to wear, the collective down time, and the cost of maintenance. These issues have become severe across various industry sectors. Another key observation is that many of these energy hungry mechanical components/systems are being rapidly designed and redesigned for better performance with tighter and tighter tolerances under harsher operating conditions, and for extended lubrication maintenance intervals.

These mechanical devices continue to face demanding (quantitatively and qualitatively) boundary lubrication conditions. Lubricating film, also called tribofilm, is the last line of defense under the boundary lubrication

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NLGI [1]. These tribofilms results from thermodynamic metastable conditions due to transient loading and thermal conditions during asperity-to-asperity contact engaging various chemistries in lubricants. Especially, these complex lubrication chemistries and related functions are delivered using greases and oils as media containing state-of-the-art solid and/or liquid lubricants and functional additives (e.g. for anti-wear, anti-friction, extreme pressure, etc.)

Especially in most greases, manufacturers use multiple soap matrix or inorganic thickeners carrying oil and functional additives. Over the time, grease technology has super-matured and been customized to achieve intricate, tighter balance of chemistries and desired functions. Especially, the critical properties of greases for boundary lubrication are application specific for coefficient of friction, wear, load carrying capacity, oxidation/corrosion resistance, water resistance, thermal stability, and last but not the least, for wide operating temperatures and other environmental conditions. This customization of greases, over the years, tailored for specific application conditions have resulted in a range of

products.

For example, one of the major and application specific users of grease lubricants is the gas and oil sector.

Applications range from drilling to fracking, production to transportation, and refining to end-users across the hydrocarbon supply chain. Highly specialized steels and metal alloys such as Inconel, with micron to submicron tolerances and harsh operating conditions (from -70 °F to +700 °F), in on- and off-shore conditions and for the highest desired safety are becoming common to gas and oil components/systems. Many times it has been noted that on one mechanical system, such as a gate valve or a ball valve or others, more than one type of grease lubricant needs to be applied to meet those part specific custom conditions, occasionally resulting in manufacturing errors. At the same time, these products are being challenged as the gas and oil sector is adapting to harsher exploration conditions such as the oil sands project in Canada exposed to extreme abrasive and cold conditions, geothermal exploration in Iceland and Indonesia, and subsea exploration at thousands of feet below the sea level in various parts of the world.

- 39 NLGI SPOKESMAN, MARCH/APRIL 2015

NLGI At this time, for the energy gas and oil boom in the US and the world, there is a critical need for current grease lubrication technology to innovate and adapt rapidly to meet these growing aggressive new performance demands from various mechanical systems/ sectors and bridge the application specific functional gap (Figure 1).

Innovation in additives is one of the most effective ways for desired innovation and adaptation to bridge this functional gap. In fact, the path of innovation in additive technology must address the Holy Grail of the lubrication industry which is to deliver multiple chemistries for multiple functionalities at the tip of every asperity in interacting surfaces. The observed size of these asperities, measured using high magnification microscopes, in boundary lubrication is typically submicron to nanoscale.

So as to address these region specific functional demands, it is apparent that delivery of additives at submicron to nanoscale is imminent. This challenge also presents unique opportunities to discover nano and submicron scale science for understanding novel science, and applying those discoveries to deliver new set of engineering properties at those length scales using multi-component additive packages, and those which could work seamlessly with established current grease platform with state-of-the-art additives and fully formulated lubricants.

This nanoengineered multi-

component additive packages (NOT one element or one compound), and thus nanoengineered grease lubricants are the new class of advanced lubricant materials designed using principles of nanoscience and engineering such as macromolecular delivery, convergent assembly, multi-phase translation, and directed assembly.

This timely progress proposes the next generation of opportunities, such as correcting friction at every asperity, the ability to enhance load carrying capacity by more than 100%, delivering oxidation resistance and corrosion resistance without adding additional corrosion inhibitors, super resistance to water washout at asperity level, and the last but not the least, the ability to seamlessly blend with fully formulated greases of various types with preexisting additives, solids and liquids. This next generation of advanced additive packages due to their following discussed superior functional abilities is called “superadditive” packages from this point onward [2-5]. This paper discusses these opportunities, specifically with a case study, for a gate valve used extensively globally in the gas and oil sector.

Engineering Problems

In this study, authors have identified a gate valve application for grease lubricant design, development and testing purposes.

This application is one of the most severe applications in gas and oil sector. These valves experience - 40 VOLUME 79, NUMBER 1

direct metal-to-metal contact under high pressure, abrasive and corrosive fracking fluids, wide temp variation, etc. As shown in figure 2a, crosssection of a typical gate valve, and figure 2b, surface wear on a typical gate and a seat during operation, where needs to address such wear and related issues. This excessive sliding wear is caused by (1) high contact pressure (sometimes more than 10,000 psi) in reciprocating sliding motion between a gate and a seat which leads to difficulty of lubricant replenishment and failure of tribofilms, (2) fluids going through the valve removes lubricant applied on valves and hurts lubrication, (3) outside abrasive contaminants from fracking sands, muds, etc. causes excessive wear and (4) extreme temps, e.g. low temperature (-50 ˚F lowest) in northern region of US and Canada negatively affects flow properties of lubricant. An application specific design of nanoengineered superadditive package was developed for a traditional, fully formulated lubricant to address the above discussed chemo-mechanical problems (e.g. wear and extreme pressure protection, harsh operating condition, and low temperature).

This specially designed lubricant solution was intended to deliver formation of a continuous robust tribofilm to avoid sliding wear, as well as survive in the severe operating conditions.

NLGI

Figure 2: (a) Gate valve cross-sectional view [7]; (b) tested gate and seat of a gate valve which show clear sign of abrasive wear

Experimental Procedure

A fully formulated off the shelf grease with wellbalanced additive chemistry was selected as a benchmark, which is widely used extensively for gate valves in gas and oil sector, especially for arctic conditions. Application specific nanoengineered super-additive package was used to advance treat the benchmark grease formulation. This processing could be accomplished as a top-treatment as well as in the typical grease manufacturing process.

This new grease lubricant solution was tested to analyze tribological efficacy using industry standard analytical techniques such as four-ball wear, extreme pressure (EP), coefficient of friction, and grease penetration to study friction/wear reduction, load carrying capacity enhancement, and ability to maintain grease structure.

A series of complementary grease qualification tests including copper corrosion, corrosion preventive, water spray-off, and reciprocating tribological testing, to simulate actual field boundary lubrication conditions, was performed for fully formulated benchmark grease

and super-additive additized benchmark.

Scanning electron microscopy (SEM) and energy dispersive X-ray (EDS) techniques were used to analyze remaining protective layer after water spray-off test and tribo-chemical films formed in testing under boundary lubrication conditions. Following discussion presents details.

Material Selection

Benchmark Grease: fully formulated, commercially available mineral oil based bentonite thickened NGLI #1.5-2 grease (non-drop). This grease was selected for heavy duty gate valve applications especially due to harsh environmental conditions as well as for cost considerations for this open-loop mechanical system, where the grease is pumped in and out during fracking cycles. Product data sheet of fully formulated benchmark grease is shown in below table 1.

- 41 NLGI SPOKESMAN, MARCH/APRIL 2015

NLGI Table 1: Product Data Sheet of Fully Formulated Benchmark Grease

Super-additive Selection: In order to significantly enhance wear resistance, reduction in friction, and load carrying capacity provided by current benchmark grease, authors have selected traditional as well as super-additive multi-component chemistries for top-treatment (table 2), during the screening phase of this research. Following standard grease mixing procedures, a 6% treat rate was chosen due to the severe working conditions of the application.

Table 2: Selection of the State-of-the-art Additives and Nanoengineered Super-additive Systems for Top Treatment of Fully Formulated Benchmark Grease

Testing Program

1. S creening Tests: screening tests were performed for all additive formulations along with benchmark to select best performing formulations for the following analysis and end user application.

Grease penetration (60 strokes worked penetration) was performed for all formulations using ASTM D217 Standard Test Methods for Cone Penetration of

Lubricating Grease [8].

Wear performance was identified using ASTM D2266 Standard Test Method for Wear Preventive Characteristics of Lubricating Grease (Four-Ball Method) by measuring wear scar diameters. Coefficient of friction was also studied and recorded during ASTM D2266 test [9].

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NLGI Load carrying capacity of tested lubricants was determined using ASTM D2596 Standard Test Method for Measurement of Extreme-Pressure Properties of Lubricating Grease (Four-Ball Method) [10].

2. G rease Qualification Tests: after screening tests, the best performance multi-component super-additive 1 (NS1) formulation was selected for grease qualification testing, simulated tribological testing, and surface morphological and chemical analysis.

As the end user application could include bronze parts, copper corrosion was studied using ASTM D4048 Standard Test Method for Detection of Copper Corrosion from Lubricating Grease [11].

Corrosion resistant property was evaluated using ASTM D1743 Standard Test Method for Determining Corrosion Preventive Properties of Lubricating Greases [12].

Water resistant properties, especially spray-off resistance, was analyzed using ASTM D4049 Standard Test Method for Determining the Resistance of Lubricating Grease to Water Spray [13].

3. A pplication Specific Tribological Testing: application specific tribological testing was designed to simulate boundary lubrication conditions of gate valve.

As shown in table 3—section 1, in order to best simulate field conditions in the lab and study friction and wear response of nanoengineered super-additive, testing parameters were carefully chosen for contact mechanics, mating materials, surface finish, load, speed, temperature, and duration of test. Per section 2, similar tribological testing was carried out on steel coupons with grease after water spray-off testing. The purpose of this test is to study thin protecting layer left by multi-component superadditive after tribological testing. Bruker UMT-3 multifunctional tribometer equipped with a high temperature linear reciprocating module was used in this study as shown in figure 3.

Table 3: Tribological Testing Parameters Simulating Field Application Conditions

- 43 NLGI SPOKESMAN, MARCH/APRIL 2015

NLGI Figure 3: Multi-functional Tribometer with Linear Reciprocating Module

4. M orphological and Chemical Analysis: FEI XT Nova Nanolab 200 focused ion beam/scanning electron microscopy (FIB/SEM) and built-in energy dispersive X-ray spectroscopy (EDS) techniques were used for surface morphological and chemical analysis.

Surfaces of stainless steel plates after water sprayoff test were studied for benchmark and selected NS1 grease formulations using SEM and EDS to understand morphology and chemistry of the protective additive film. Wear tracks after tribological testing, using coupons after water spray-off testing, were also analyzed using SEM and EDS to study elemental composition and morphology of tribo-chemical films formed by lubricants. Stainless steel coupons were rinsed with heptane following standard cleaning procedure to remove excessive amount of lubricant left on the surface.

All tests were repeated at least 3 times to establish understanding of error range of each lubricant.

Results and Discussion

Part I. Screening Tests To select best additive formulations, screening tests were performed. As shown in table 4, both CM3 and CM6 showed better friction, wear, and load carrying capacity performance than benchmark grease. Also, CM6 showed slightly better performance than CM3 with addition of 3% weight more in additive concentration.

However, C6 commercially available and recommended additive package showed negative response in wear protection and grease consistency (softened benchmark grease to NLGI grade #1).

For nanoengineered super-additive lubricant packages, NS1 and NS2 showed very promising performance enhancement in every category. At the same time, the additized grease maintained grease consistency.

Although NS3 showed superior performance in friction, wear, and EP (three loading stages over benchmark grease), it did change NLGI # below 1, unlike benchmark grease.

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NLGI Table 4: Screening Testing Results of Various Selected Formulations in Comparison to Benchmark Grease (Note: data in parentheses is for tolerance window of reported testing results)

In a conclusion of screening tests, best performer NS1 and NS2 (highlighted in table 4) were selected for detailed grease qualification tests in the next step. C6 and NS3 were eliminated from contention due to negative performance response.

Furthermore, CM3 and CM6 were eliminated because they did not show comparable results with NS1 and NS2 even under the same dosage rate.

Part II. Grease Qualification Tests To further evaluate key properties such as corrosion and water resistance as required by the end user application, grease qualification tests were designed and carried out for benchmark grease and NS1

and NS2 super-additives additized benchmark formulations. As shown in table 5 (with tolerance window) compared with benchmark, NS1 formulated grease showed more than 20% reduction in wear, 30% reduction in friction, and 2 loading stages increase in weld load. More importantly, it is noteworthy that NS1 also enhanced corrosion and water resistant properties of benchmark grease without intentionally adding corrosion inhibitors and polymers for water resistance. Although there is only 2.6% improvement (table 5) in water spray-off removal of grease over the benchmark, a clear optical difference was observed between benchmark and NS1 formulated - 45 NLGI SPOKESMAN, MARCH/APRIL 2015

greases. As shown in figure 4b, no grease was left on the stainless steel plate for benchmark grease, but a thin layer of network of nanoengineered lubricant could be clearly seen on NS1 plate after water spray-off. This important observation was believed to be a result of well balanced and designed nanoengineered super-additive packages to form a network of surface protecting films among nano and sub-micron scale asperities, which could deliver a barrier for metallic parts from external corrosive and humid environment.

Nanosized multi-component chemistries were demonstrated to form a surface protecting film and tribo-chemical films easier

NLGI than state-of-the-art lubricant additives along with better surface coverage as (1) nanosized chemistries can enter and bond with nano and submicron scale surface asperities; (2) nanoengineered additive packages deliver more surface area and metastable active material phases which contribute to better surface affinity and lucid film formation protecting almost every asperity; and (3) well designed multi-component macromolecular chemistries at nanoscale help efficient delivery and rapid activation of super-additive packages [1]. Morphological and chemical analysis of surface protecting film after water spray-off testing is discussed in Part IV of this paper.

Authors found out that NS2 additized grease formulation showed equally good tribological performance over benchmark and well-maintained corrosion and water resistant properties compared to benchmark. For non-technical reasons, NS1 formulation was recommended for the subsequent tribological testing, chemical analysis of tribo-chemical films, and field evaluation due to its superior tribological performance and corrosion/water resistance.

Table 5: Grease Qualification Testing Results of Benchmark Grease, NS1, and NS2 Chosen after Previous Screening Tests (Note: data in parentheses is for tolerance window of reported testing results)

Figure 4: Pictures of stainless steel plates (coated with benchmark grease and NS1 superadditive additized benchmark) before (4a) and after (4b) ASTM D4049 water spray-off testing

- 46 VOLUME 79, NUMBER 1

NLGI Part III. Application Specific Tribological Tests

Section 1—tribological testing on benchmark grease and NS1 additized benchmark grease As shown in figure 5 and table 6, testing results obtained by simulating actual working conditions for gate valve for gate-ring contact, NS1 showed significant amount of wear reduction and weight loss (wear) reduction (up to 69% reduction) compared with benchmark grease, especially under higher loading condition of 4000 psi. Significant amount of sliding wear

was observed for benchmark grease with deep scratches believed to be due to inability to withstand high-pressure boundary lubrication conditions and inability of traditional grease formulation to penetrate wear interface under severe contact. Very light wear marks were observed for NS1 additized benchmark grease. Moreover, 17% friction reduction was found for NS1 compared to benchmark grease at 2000 psi. This observation is also consistent with four-ball testing results.

Figure 5: Stainless Steel Testing Coupon with Circled Wear Marks after 2000 psi (5a) and 4000 psi (5b) Reciprocating Tribological Testing (see Table 3 for testing parameter details)

Table 6: Friction and Wear Results of Benchmark Grease and NS1 Additized Benchmark Grease under Simulated Boundary Lubrication Conditions for Gate Valve Gate-seat Contact

Note: data in parentheses is for tolerance window of reported testing results.

- 47 NLGI SPOKESMAN, MARCH/APRIL 2015

NLGI Section 2—tribological testing on stainless steel plate after water spray-off testing (testing is based on grease left on the plate) As shown in figure 6 and table 7, NS1 formulated benchmark grease showed significant amount of reduction in friction and reduction in wear (e.g. weight loss reduction up to 70%) compared with benchmark grease. The intent of this was to study tribological performance of surface protecting film left on stainless steel coupon after water spray-off tests and special single coupon was prepared with leftover films after water spray-off from benchmark and NS1 treated benchmark greases. This test was carried out under boundary lubrication conditions for load of 2000 psi and predefined time duration of 10 minutes (see Figure 3 for testing parameter details). Significant amount of sliding wear was observed for benchmark grease with deep scratches due to inability to withstand high pressure

boundary lubrication condition. Very light wear marks were observed for NS1 additized benchmark grease. This observation confirmed the advanced anti-wear (AW) / anti-friction (AF) / extreme pressure (EP) functionality of surface protecting films formed by nanoengineered lubricants. Under harsh operating conditions, the benchmark grease with state-of-the-art additive package failed to protect the surface, but the same grease treated with nanoengineered super-additives is able to form a surface protecting film to continue to provide these advanced functionalities. Surface morphological and chemical analysis of tribo-chemical films formed after reciprocating tribological testing are discussed in Part IV of this paper.

Figure 6: Stainless Steel Testing Coupon with Circled Wear Marks after 2000 psi Reciprocating Tribological Testing on Specimens after Water Spray-off Testing

Table 7: Friction and Wear Results of Benchmark Grease and NS1 under Simulated Boundary Lubrication Conditions after Water Spray-off Testing

Note: data in parentheses is for tolerance window of reported testing results.

- 48 VOLUME 79, NUMBER 1

Part IV. Morphological and Chemical Analysis

Surface morphological and chemical (elemental) evaluation was performed by SEM and EDS techniques to better understand the mechanism of superior performance provided by NS1. Two studies are presented in this section: (1) study of stainless steel plate coated with benchmark grease and NS1 additized benchmark grease after water spray-off testing. As shown in figure 7 and 8—the purpose of this study was to physically and chemically identify surface protecting film formed by benchmark grease, if any left after water-spray off, and NS1 additized benchmark grease; (2) study of tribochemical films on wear tracks for benchmark and NS1 additized greases, after water spray-off testing followed by tested reciprocating tribometer under boundary lubrication regime, as shown in figure 9 and 10—the purpose of this study is to understand delivery of functional nanoengineered multicomponent additive chemistries using NS1 additized benchmark grease and the mechanism for measured better tribological performance.

I. Chemical and morphological microscopic study of stainless steel plate coated with benchmark grease and NS1 additized benchmark grease after water spray-off testing As shown in figure 7 (a) and (b) SEM micrographs, after water spray off testing, there is no benchmark grease left on the stainless steel coupon except several bentonite particles left on the plate as identified by Al and Si elements as shown in figure 7 (c), elemental mapping EDS results. Surface profile of steel substrate could be clearly seen since there is no protective film formed by benchmark grease. Very little or close to no amount of Al and Si elements were found as shown in figure 7 (d) and (e), EDS spectra and atomic ratio, which is consistent with SEM observation.

From figure 8 (a) and (b) SEM micrographs, clear lubricant coating/distribution was found on stainless steel coupon and texture of substrate (steel surface) could not be observed which also verified that a thin layer of surface protecting film was formed among surface asperities (texture) after water spray-off. Other evidence is that the atomic ratio of Fe element is extremely low as shown in figure 8 (e) which means the steel surface is well covered by a film so that electrons could not

penetrate or escape from substrate for SEM analysis. In figure 8 (c) and (d), signatures of tribo active elements such as Mo, S, and N were found well dispersed in film/ lubricant substrate. Mo and S atomic ratio is closely maintained at 1:2 which partly shows there is no chemical reaction between NS1 and grease structure after water spray-off testing. Interestingly to note that Al and Si elemental concentration from bentonite is also significantly higher than benchmark grease studied in figure 7. It is believed that well dispersed nanoengineered super-additive strengthened the network structure of benchmark bentonite grease avoiding complete washout and at the same time, the strong surface affinity of nanoengineered super-additive chemistries bond and strengthened surface film on steel substrate. This dispersion strengthening effect is under further study to understand the bonding between nanoengineered additives and grease network structure for physical or chemical or hybrid bonding. Above microscopic observations well reconfirm macroscopic findings of water spray-off test with and without nanoengineered additive packages discussed and as shown in figure 4.

II. Chemical and morphological microscopic study of tribo-chemical films on wear tracks for benchmark and NS1 additized greases, after water spray-off testing followed by tested reciprocating tribometer under boundary lubrication regime Wear tracks of benchmark grease after reciprocating tribological testing under boundary lubrication were studied for microscopic morphological and chemical analysis (figure 9). Significant amount of wear debris, sharp edges, and rough surfaces of wear tracks were observed in figure 9 (a) and (b) which are consistent with worse tribological performance observed during prior testing. More importantly, based on elemental analysis in EDS, wear tracks are dominated by Fe element and no tribo-chemical film (protective films) traces were found.

This observation reflects that under harsh operating boundary lubrication gate valve condition, benchmark grease could not form tribo-chemical film to protect the surfaces. Due to no protective film formation, steel debris formed by direct metal-to-metal contact resulting: (1) in scratched surface to create more steel debris; (2) in asperity to asperity welding with surface under high

- 49 NLGI SPOKESMAN, MARCH/APRIL 2015

pressure and peeled off later to create more wear; (3) in welding among steel debris and asperities under high pressure to form larger and harder steel debris because of strain hardening which could significantly damage the surfaces. This explains wear mechanism and inability of surface protection of benchmark grease.

In a clear comparison to results in figure 9, in figure 10 (a) and (b), wear tracks of NS1 additized grease under the same tribological testing conditions showed much smoother wear tracks protected by continuous tribo-chemical film without steel debris. Tribo active elements Mo, S, and N were predominantly observed and found well dispersed in tribo-chemical films as shown in figure 10 (c) EDS elemental mapping results.

In addition, multicomponent additive functional packets were either absorbed or embedded into tribofilms, ready to deliver for tribofilm replenishment and deliver their multi-functionalities for AW, AF, EP and anti-corrosion

[1]. Interestingly, from the EDS quantification results in figure 10 (e), atomic ratio of Mo and S is found to be less than 1:2. This finding demonstrates chemical reaction under severe lubrication condition. It was believed that nanoengineered additive packages reacted with steel substrate to form multi-layer friction-polymer based tribo-chemical films to provide surface protection [1, 6]. Current finding clearly explained the superior performance of NS1 additized benchmark grease during tribological testing and its capability to continuously provide lubrication under harsh environmental conditions, such as after water spray-off testing and in an open loop mechanical system like a gate valve. Further Raman and XPS analyses are in progress to obtain the in-depth understanding of chemical compositions of tribo-chemical films.

Figure 7: (a). SEM image at 350x magnification of stainless steel plate coated with benchmark grease after water spray-off testing; (b). SEM image at 2000x magnification; (c). Elemental mapping results of EDS identified elements for studied surface at 350x SEM image; (d). EDS spectra of studied surface at 350x SEM image; (e). EDS elemental ratio calculated from above EDS spectra

- 50 VOLUME 79, NUMBER 1

Figure 8: (a). SEM image at 350x magnification of stainless steel plate coated with NS1 additized benchmark grease after water spray-off testing; (b). SEM image at 2000x magnification; (c). Elemental mapping results of EDS identified elements for studied surface at 350x SEM image; (d). EDS spectra of studied surface at 350x SEM image; (e). EDS elemental ratio calculated from above EDS spectra

Figure 9: (a). SEM image at 2000x magnification of wear tracks of benchmark grease located at steel coupon (after water spray-off testing) tested by reciprocating tribometer under boundary lubrication; (b).

SEM image at 8000x magnification; (c). Elemental mapping results of EDS identified elements for studied surface at 8000x SEM image; (d). EDS spectra of studied surface at 8000x SEM image; (e). EDS elemental ratio calculated from above EDS spectra

Figure 10: (a). SEM image at 2000x magnification of wear tracks with tribo-chemical films of NS1 additized grease located at steel coupon (after water spray-off testing) tested by reciprocating tribometer under boundary lubrication; (b). SEM image at 8000x magnification; (c). Elemental mapping results of EDS identified elements for studied surface at 8000x SEM image; (d). EDS spectra of studied surface at 8000x SEM image; (e). EDS elemental ratio calculated from above EDS spectra

NLGI Part V. Evaluation Benchmark and NS1 Additized Benchmark Grease for Gate Valves (Assembled for Frac-Tree) Under Fracking Conditions

NS1 additized benchmark grease was recommended for field-testing evaluation after showing excellent lab performance in various perspectives. Benchmark grease was also evaluated for base line control purpose. As shown in figure 11, gate valves filled with benchmark grease and NS1 additized benchmark grease were assembled in two separate frac-trees and tested at the same fracking sites under arctic conditions illustrated in table 8. All field testing work was controlled by the end user by well-established standard operating procedures.

After the end user specified fracking cycles at the site were completed, both frac-trees were shipped back to the factory for disassembly, cleaning, and further part inspection/evaluation following standard operating procedures.

After inspection, for both test valves filled with benchmark grease and NS1 additized benchmark grease (figure 12 and 13): • NS1 additized grease applied parts gave considerable less surface damage (e.g. scratches, pittings, etc.) on hard gates and seats;

•D ensity of scratches for NS1 additized grease applied parts was much less; • S everity of scratches, surface roughness Ra value was an order of magnitude less for NS1 additized grease lubricated valves; •R esistance to water washout was enhanced by NS1 additized grease. Gates and seats after disassembly still showed a thin layer of NS1 additized benchmark grease, which is consistent with previous lab results; •G ates and seats of benchmark grease could not be reused while gates and seats tested with NS1 can still be used again.

In summary, nanoengineered super-additive package, NS1 additized grease in field testing provide up to 90% reduction in wear volume and surface roughness reduction. Cumulative effect of the above functional advancements is that the life of parts in gate valve was extended by 25-50%, based upon field observation.

(Disclaimer- data could partly vary from site-to-site and for operator pattern.)

Figure 11: Testing Frac Tree composed of 7-8 gate valves filled with benchmark grease or NS1 additized benchmark grease; Table 8 Field testing specifications to make sure benchmark grease and NS1 additized grease under the same testing conditions

- 55 NLGI SPOKESMAN, MARCH/APRIL 2015

NLGI

Figure 12: Gate surfaces of gate valves tested with benchmark grease (left picture with much higher Ra values and wear) and NS1 additized benchmark grease (right picture with much lower Ra value).

Figure 13: Seats surfaces of gate valves tested with benchmark grease (left two seats with deep scratches) and NS1 additized benchmark grease (right two seats with almost no wear).

- 56 VOLUME 79, NUMBER 1

NLGI Conclusions and Future Directions

In summary, nanoengineered super-additive package additized benchmark bentonite clay grease provided advanced performance not only over fully formulated well-balanced benchmark bentonite clay grease, but showed the following results as well: • Nanoengineered super-additive package 1 (NS1) showed 30% reduction in friction, 20% reduction in wear, and 2 EP loading stages higher in comparison to benchmark grease.

In another noteworthy finding, NS1 provided better corrosion (without intentionally adding corrosion inhibitors) and water resistant properties. Although better water resistance is not clearly reflected by numbers of traditional ASTM 4049 testing results, consistent network of protecting film was found on stainless steel plate which was formed by nanoengineered super-additive package based on evidence from morphological and chemical analysis using SEM and EDS techniques. This surface protecting film network formed by nanoengineered superadditive packages is believed to be the last line of defense in field application to effectively protect machine surfaces.

• Meanwhile, NS1 showed even better performance in friction and wear reduction, up to 70% reduction in weight loss, under application specific tribological testing to simulate actual boundary lubrication condition.

Smoother wear track and evidence of tribo active elements in wear tracks successfully demonstrated nanoengineered super-additive packages are delivered to mating surfaces to form protective tribo-chemical films even under harsh boundary lubrication conditions. Unlike benchmark grease, it showed no evidence of physical and chemical delivery of functional additives.

•C umulative effect of functional advancements in AW, AF, EP, anti-corrosion, water spray-off resistance for nanoengineered super-additive packages was demonstrated by field testing to provide up to 90% reduction in wear volume and surface roughness.

•F urther chemical composition analysis by Raman and XPS techniques and surface profile analysis by 3D surface profilometer of tribochemical films formed by nanoengineered super-additive packages, low temperature performance (low temperature penetration and torque) of additized grease, and hydrocarbon resistance of studied lubricants are necessary and are in progress, and will be presented at suitable time.

Finally, this technical report has presented patented and patents’ pending breakthrough developments in a new class of lubricant additive packages (unlike nanoparticle component such as friction modifier elements and compounds like carbon, MoS2, WS2, borates, copper, etc.), designed and developed using principles of nanoscience and engineering such as macromolecular delivery, convergent assembly, multi-phase translation, and directed assembly. A new atlas of such multicomponent super-additives is being integrated for various greases based on Li, LiX, calcium sulphonate, bentonite, PFPE, silicone and other base chemistries. This new advancement progresses current scientific and technical understanding and works in complementary and synergistic nature to already established greases and their additive systems to meet the demands of advanced mechanical systems discussed in section on Introduction.

- 57 NLGI SPOKESMAN, MARCH/APRIL 2015

NLGI

Acknowledgements

Special acknowledgements to Cameron International Corporation staff for collaboration. Special thanks to John Bartos, Jim Lovin, Joe Gross, Vasanth Annamalai, Loc Hoang, Muneeb Dogar and all other related Cameron associates for all collaboration work and field testing support. Authors would also like to acknowledge Arkansas Analytical Facility (AAF) and Electron Optics Facility (EOF) for the use of SEM and EDS equipment and Dr. Mourad Benamara for related technical discussions.

References

1. Zhang, W.Y., Jahan, M.P., and Malshe, A.P., 2012, Chemical Understanding of Friction Polymer Based Tribo-chemical Films Derived from Nanolubricant, ASTM Proceedings/Nanotribology, Paper No. IJTC2012-61119, pp. 13-15.

2. Malshe, A. and Verma, A., Nanoparticles Compositions and Methods for Making and Using the Same, Application Serial No. 12/160,758; US Patent and Trademark Office; Filing Date: September 2, 2008. U.S. Patent No. 8,492,319 B1 (issued July 23, 2013) Multiple national and international allowed and pending applications.

3. Malshe, A., multiple national and international allowed and pending patent applications.

4. Zhang, W.Y., Demydov, D., Jahan, M.P., Mistry, K., Erdemir, A., and Malshe, A.P., 2012, Fundamental Understanding of the Tribological and Thermal Behavior of Ag-MoS2 Nanoparticle-based Multicomponent Lubricating System, Wear, 288, pp. 9-16.

5. Verma, A., Jiang, W.P., Abu Safe, H.H., Brown, W.D., and Malshe, A.P., 2008, Tribological Behavior of Deagglomerated Active Inorganic Nanoparticles for Advanced Lubrication, Tribology Transactions, 51(5), pp. 673-678.

6. Hsu, S.M. and Gates, R.S., 2005, Boundary Lubricating Films: Formation and Lubrication Mechanism, Tribology International, 38(3), pp. 305312.

7. www.c-a-m.com 8. ASTM D217 – 10 (2010) Standard Test Methods for Cone Penetration of Lubricating Grease. ASTM International, West Conshohocken, PA. 9. ASTM D2266 – 01 (2008) Standard Test Method for Wear Preventive Characteristics of Lubricating Grease (Four-Ball Method). ASTM International, West Conshohocken, PA. 10. ASTM D2596 - 10e1 (2010) Standard Test Method for Measurement of Extreme-Pressure Properties of Lubricating Grease (Four-Ball Method). ASTM International, West Conshohocken, PA. 11. ASTM D4048 – 10 (2010) Standard Test Method for Detection of Copper Corrosion from Lubricating Grease. ASTM International, West Conshohocken, PA. 12. ASTM D1743 – 13 (2013) Standard Test Method for Determining Corrosion Preventive Properties of Lubricating Greases. ASTM International, West Conshohocken, PA. 13. ASTM D4049 - 06(2011) Standard Test Method for Determining the Resistance of Lubricating Grease to Water Spray. ASTM International, West Conshohocken, PA.

- 58 VOLUME 79, NUMBER 1

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