Lubrication Basics

Specialty Chemicals Business
Major Market Business Units
 Automotive, Appliance,
Assembly & Maintenance
 Advanced Interface Markets
 Construction
 Electronics
 Life Sciences
 Solar
Reference Number: 80-3477-01 1

Automotive, Appliance,
Assembly & Maintenance
Business Overview:
Major Markets, Typical Applications, Products and Functions

Automotive, Appliance, Assembly & Maintenance
Products & Brands
 High-performance lubricants
– Greases, anti-seize pastes, anti-friction coatings,
compounds and oils
 Heat-resistant adhesive/sealants
– Silicone and fluorosilicone
 Engineered elastomers
– LSR, FSR, F-LSR, HCR
 Precured gel grommets and strips
– Electrical connector moisture protection
 Soundproofing foams
– Self-expanding formulations

Major Markets Served
 Automotive
 Assembly
 Maintenance
 Imaging
 Appliances
 Moldmaking
 Aviation

Typical Applications
Assembly
 Industrial equipment
– Lubrication, assembly adhesives/seals
 Wind turbines
– Sealing, lubricating, friction control
 Power and utilities
– Insulation, dielectric coatings
 Oil and gas
– Severe-duty sealing/lubricating,
insulation
 Water purification/filtration
– Water-resistant, food-grade lubricants

Typical Applications
Maintenance
 Oil and gas
– Flange and thread lubrication
 Chemical/petrochemical/refining
– Corrosion protection, lubricating,
solvent-resistant sealing
 Mining and marine
– Severe-duty lubricating/sealing
 Primary metal processing
– High-temperature/load lubrication
 Utilities
– Power generation facilities, turbines
and generators
– Electrical circuit breakers
– Water treatment pumps, filters and
valves
 General MRO
– Lubricating, sealing, bonding

Functions & Benefits
 Lubricating
– Reduced friction, wear, noise, energy usage
 Bonding
– Increased assembly strength, flexibility,
productivity
 Sealing
– Improved durability, reduced failures
 Coating
– Enhanced safety, increased quality
 Fabricating
– Increased productivity, longer life
 Replicating
– Accurate details, fast turnaround

Critical components in Industrial Assembly
and Maintenance
 Gear Box
 Bearings
 Chains
 Wire Ropes
 Couplings
 Hydraulic Systems

Most Prone to Failure component - The
Bearing
 The Bearing

But all bearings will
eventually fail
Spalled Area
Ball Path

Three Main Causes of Premature
Failures
 Mistakes in handling
 Mistakes in installation
 Mistakes in maintenance

Specific Catastrophic Failures
LUBRICATION
25%
EXCESSIVE
LOADS
16%
CONTAMINATI
ON
15%
MISALIGNMEN
T
15%
CORROSION
10%
OVERHEATING
6%
LOOSE/TIGHT
FIT
8%
REVERSE
LOAD
5%

Lubricant Failures
Lubricant failure will lead to excessive wear,
overheating and bearing failure.
Silver/gold
Blue/black raceways

Solutions
 Confirm operating parameters
– speed, load, temperature
 Do not use mixed lubricants
 Use proper Flushing Techniques and procedure
 Use the most suitable, cost effective lubricant
 Consult with lubricant supplier for benefits on longer
oil/grease drain cycles
 Review lubrication program and budgets

Corrosion
Corrosion results from the chemical attack on
the metal by hostile fluids or atmospheres.
Ball path
Ball Path
Red/brown
stains or
deposits on rings

Here, large surface corrosion damage is
clearly visible.

Solutions
 Diversion of corrosive fluids
 Integrally sealed bearings
 Stainless steel bearings
 Assembly plans helpful
 Selection of lubricants resistant to corrosive
environments

Excessive Loads
Severe spalling due to excessive load.
Spalled area
Ball path

Solutions
 Reduce load
 Re design using a bearing with higher load
carrying capacity
 Use High Performance Lubricants to increase
surface area
 Increase surface area with solids and extend
life

Contamination
Clean work areas, tools, fixtures and hands will
reduce bearing contamination failures.
Irregular dents or
material embedded in
raceways
Balls will be
similarly dented,
dull, or scratched

Solutions
• Clean work areas
• Keep grinding operations away from assembly
areas
• Keep bearings in original packing
• Keep seals in good shape
• Use of high performance lubricants will be
helpful

Portfolio of Steel Plant Lubricants
 Heavy duty greases (ISO Vg- 680-1000)
 Roll neck greases (ISO Vg- 320-460)
 High temperature greases (Drop point 260+)
 Gear oils synthetics (PG/PAO –680/460)
 High temperature chain oils
 Open gear lubricants- non drip type.
 Future trend
– Calcium complex greases as MPG for steel mills with or without SOLIDS

Bearing in Steel Plant environment
 Conditions
– High temperatures
– High pressure cooling water
– Mill scales
– Shock loads
– Emulsions
– Acid Fumes
 Application Areas
– Roll Neck Bearing
– Chock Liners
– Table Roll Bearings
– Blower Fans
– Motors
– Coilers and decoilers

Summary of Environment of Lubricants in
steel plant
Temperature Water/humidity Speed
Contamination Shocks Loads

Success Stories at
Visakhapatnam Steel Plant
India

Equipments Lubricated with Molykote
at Vizag Steel
 Hammer Crushers
 Blender Reclaimers
 ID/FD Fans
 Motors
 Pumps
 Vibratory Screens
 Chains
 Stelmore and Fan bearings in
New Wire Rod Mill
 Conveyor Bearings
 And, many many more
A Bird Eye View of Visakhapatnam Steel Plant
with the Thermal Power Plant in the Foreground

Why the customer chose to go for
Molykote Products
 Increasing demands on enhancing production without capacity expansion
 Downtime had to be avoided
 Unscheduled stoppages had to be avoided
 Reliability had to be increased. Chances for human errors to be minimized.
 Manpower costs as a %age of total lubrication costs had gone up due to
wage increases.
 Molykote products have a pedigree of proven performance and had shown
excellent results in wherever they were used. Hence, more products were
allowed in when new applications were found.

Hammer Crushers
 Conditions – Heavy Shock Loads, Dust,
Vibrations and high loads
 Concerns – Daily relubrication schedule
increases chances of human errors
 Desired – Weekly Lubrication Schedule.
 Product Recommended – Molykote Long-
term 2+.
 Results – Relubrication period extended
to weekly within 3 months of application.
 Volume – 4 x 180 kg drums/ year

Blender Reclaimer
 Spherical Roller Bearings
 Concern – Bearings go through a phase of
abrasive wear followed by failure.
 Relubrication Schedule – Daily
 Product Used- Conventional EP Grease
 Product Recommended – Molykote Longterm 2+
 Current Relubrication Schedule – Once in 5 days
without bearing failures. Extension to 7 days lead
to bearing failures. So now schedule in once in 5
days.
 Used since 2002. 2 x 180 kgs drums /year.

Vibratory Screens
 Conditions – Continuous operation, weekly
shutdowns, vibrations, shock loads.
 Concern – Failure can result in lot of downtime
in the entire plant process
 Desired – More reliable lubrication without
extending relubrication schedule
 Product Tried – Molykote Longterm 2+
 Result – Schedule can be extended to 12 days.
 Expected Volume - 720 kgs/year
Many screens have extended their
schedule from one week to 45 days.
This particular screen in the picture is
the most critical in the plant’s
Sintering Zone.

Torpedo Ladle (SMS - Demag)
 Torpedo Ladle Spherical Sheet (Ladle
carries the hot metal from the BF to the
Converter for Lancing)
 Various products tried by customer with
poor results
 Product Suggested – Molykote Cu 7439
Paste
 Results – Good. In use for last 5 years.
 Volume: 20 kgs/year
Spherical sheets subjected
to oscillation and high temperatures
lubricated now with Molykote Cu 7439
for last 5 years, once during overhaul.

Largest 1st Fill order from Steel Customer 2010

Other Molykote Products Supplied
 Molykote D Paste
 Roll Shop Roll Assembly
– WRM Compactor Rails
– Water Management for Valve
Assembly
 Molykote GN + Paste
– Various assembly applications
at Area Repair Shops
 Molykote Z Powder
– Various dry lubrication
applications in utility plants,
converters and coke ovens.
 Molykote M 30 Chain Oil
– Furnace Area Chains
– Rolling Mill Conveyor Bed
Chains
 Molykote 1000 Paste
– Anti-seize applications
 Molykote 111 Compound
– O ring assembly
 DC 4 Compound
– Electrical Repair Shop

Continuous Casters
 Conditions
– High Temperatures
– Cooling Water
– Steam
 Application Areas
– Caster Bed Bearings
– Slide Gate Mechanism
– Mould Roller Axle Bearings
– Cooling Bed Roller Bearings
– Cassettes and strands
©2005Dow Corning, All rights reserved
Arupanjan Mukherji, Dow Corning India Pvt.Limited
Applications for the Steel Industry

Caster Types and OEMs
 Caster Types
– Slab caster
– Bloom caster
– Billet caster
– Round caster
– Thin strip caster
 OEMs
– SMS Demag
– Danielli
– VAI
– Concast India

Molykote Products in caster
bearing Lubrication
 Molykote G0102
 Molykote G6000
 Molykote P40
 Performance Parameters
– Resistance to steam and
water wash outs
– shear Stable
– Good corrosion protection
– Good load carrying capability
– Aging resistant in presence
of water and steam

Approvals and referrals
 Approvals
 SMS Demag
– G0102
– P40
– HP 870
 Danielli
– G 6000
 User Referrals
 P40
– Durgapur Steel Plant
 G0102
– Hadeed Steel – Saudi
Arabia , Places in India
 Molykote 41 Grease
– Emirates Steel – Abudhabi
– Vizag Steel Plant India

Fettarten nach der Spezifikation nach DIN 51502
K2N-30
DOW CORNING
www.dowcorning.com
High Performance
Grease
Molykote G-0102
High Load Bearing Grease
MOLYKOTE HP-870
Grease
Juni 2007
Betriebsmittel
Schmierstoff: Fett
Auswahl
SN 180
Teil 1Betriebsmittel
Schmierstoff: Fett
Auswahl

Approvals and Referrals
 From: ccmmechanical [mailto:ccm.mechanical@siscol.com]
Sent: Thursday, October 04, 2007 4:50 PM
To: Premier Bearings
Subject: Offer -Reg
Importance: High
 SISCOL/CCM/SM/171
 04/10/2007

 Dear Sir,
 With refence to your mail Dt:04/09/07 regarding synthetic greases requirement for our Bloom caster
project, Further we have forwarded your technical data sheet to our Principles M/s. Danieli Centromet Italy
for their approval, and we have received the approval for Molykote G-6000 grease for our centralized
lubrication system as well as manual lub systems.
 Kindly give your best offer for one unit based on that we will place order for our required qty.

 With Regards,
 M.RAVI,
 SR.MANAGER/MECH.
 Mob:+919994895131
 SISCOL.
Juni 2007
Betriebsmittel Schmierstoff:
Fett Auswahl
SN 180 Teil 1

Customer Referral continued

Continuous Caster
 Area – Secondary Cassette Cooling
Zone
 Component – Bush Rollers
 Concerns – High temperature with
cooling water washed out grease and
bush sticking with corrosion
 Molykote Product Recommended – P 40
Paste
 Results – After 220 heats and six
months of trials, product’s performance
good. Formal orders awaited.
Bush Bearings were lubricated
with Molykote P40. With steel mill
environment of high temperatures and
cooling water, P 40 Paste is an ideal
product for many applications.

Success in Durgapur Steel Plant, SAIL
Billet Caster from Concast –
P40 in Cooling Bed Bearing lasted for 2 months without Re-
lubrication
to lubricate from Ladle Turret to on line Pendulum shear with 17
heats average per day
by HAND packing.

Application in enclosed gears M Gear Guard and
Open gears for more than 3 months – P74

Application of Metal Protectors to prevent corrosion in Port crane
applications- Turkey

Wire Rope application P40 Paste - Port cranes in Turkey

Arcelor Meditéranée, France
•Ladle Trunion Bushes of Tilting
Mechanism is Lubricated by
Molykote P-40 to prevent
seizure

FAMAK S.A., Poland
 Continuous steel molding line for a
plate rolling mill
 G-0102 used for
– very high load
– slow movements
– high temperatures –continuos over 130°C;up to
+200°C in short periods
– humidity (housings of bearings additionaly water -
cooling)

Haynes Steel, USA
Single stand reversing sheet rolling.
Roll neck bearings 71 inch diameter
 Molykote G-0102
Used grease tested from mill shows little change in
properties
Bearing Life is increased.

Lubrication Basics

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