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Bel-Ray Specialty Lubricants: Tech Notes, Vol 3, Issue 4

April, 2012

INDUSTRIAL DIVISION
New Food Industry Focused Partner for Bel-Ray in Romania

Bel-Ray Company is pleased to announce the addition of Techno G as a food industry focused distributor for Romania. Techno G is located in the center of Romania; an excellent location not only for logistic reasons, but also for the fact that Sibiu is one of the most beautiful cities in all of Romania!

Techno G’s main focus is the food industry, where their sales come from equipment and consumables. They have successfully been trading for 10 years, and offer a wide range of made-to-order offerings to their customer base such as installations, service, and maintenance support. Although they are small in workforce, with seven employees, they more than make up for this small staff with their superior knowledge of the food industry in the Romanian and wider Eastern European markets. Techno G’s Managing Director, Nelu Gavrila, leads his team from the frontline; a leadership trait he developed as a Major in the Army at a very young age. His first job in his second professional life was Sales Manager for Master Food Mars. Mars philosophy and training was a great experience for Nelu, and the right start in his professional business activity in the food industry. Following that he went on to manage a company producing and distributing food ingredients and raw materials for the food and beverage industry.

Techno G’s partners for equipment are all premium suppliers in their field: Spiromatic Belgium for silos, VMI France for kneaders and mixers, Kaak Netherlands Group for bake-ware, Benier Netherlands for dough make-up, Daub Germany for ovens, MCS Italy for proofers and ovens, Rondo Switzerland for sheeting and laminating equipment, Ibonhart UK for slicing and packaging equipment.

They also sell consumables like clip band, knives, blades and of course oil, which is where Bel-Ray comes in. The relationship with Bel-Ray is the result of searching for a premium, reliable partner for which Techno G can develop serious business in this field. It usually takes a little bit of time until everything is organized, but we are sure this will be a very successful partnership for expanding the Bel-Ray No-Tox Food Grade Lubricant sales in the Eastern European market, having the support from the Bel-Ray team, with the market opportunities and the right products and sales expertise.

Nelu commented that, “It’s interesting for us to sell consumables; it gives us a certain cash-flow and a good connection with our customers. It is a target for us to increase our business with the help of Bel-Ray’s premium brand of superior performing products.”

MINING DIVISION
How to Achieve Maximum Wire Rope & Sheave Life on Draglines

Goal – To maintain a thick lubricant film on the sheaves and to have that lubricant film almost dry to touch or tacky dry. The rope lubricant must be able to maintain a boundary layer or sacrificial lubricant film on both the sheaves and drag ropes. The action of the ropes running over the sheaves will wear away this sacrificial boundary layer. Therefore, the rope lubricant must be able to establish and maintain a high retention lubricant film for periods of 30 minutes or more without replenishment.

Thick lubricant film maintained on drag sheaves; film thickness will build
up as much as 10mm.

Over-Lubrication - If there is too much lubricant going onto the sheave, the lubricant film will be too wet, resulting in poor

Over-Lubrication will attract dirt and dust onto ropes. The lubricant will struggle to maintain a consistent lubricant film between ropes and sheaves.

retention on the sheave, which means too much lubricant will be transferred to the rope. This wet film will attract dirt and dust. Then as the rope runs over the sheave with the dirt and dust adhered to it, this will cause wear to both the rope and the sheave at the slide load contact points. Over-lubricating the sheave will result in a very thin boundary layer between the rope and sheave. This lubricant film will be thinner than the dust particles adhered to the rope, causing wear.

Under-Lubrication - Not enough lubricant going onto the sheave results in a dry rope and dry sheave, which means full metal-to-metal contact in the high load areas, causing plastic deformation and fatigue breaks.

Bel-Ray has been producing high performance mining products for years. We provide professional on site lubricant application advice as part of our ongoing customer service support. We know what is expected of our mining lubricants, and we know how they work and how to get the best possible performance from them.

Under-Lubrication will cause premature rope failure and fatigue breaks, which will normally happen on drag ropes 20 to 30 meters back from the bucket.

Through extensive research and development, Bel-Ray has produced a unique dragline rope lubricant called Drag Cable Lubricant Summer. Drag Cable Lubricant Summer has been formulated to achieve and maintain the correct sheave and rope coverage. Most dragline rope lubricants available today do not change in consistency when applied to the ropes and sheaves, resulting in poor lubricant retention properties, hard to maintain lubricant films on both sheaves and ropes, and high consumption rates. Rope lubes with poor retention properties, when used on draglines, will cause excessive lube fling-off inside the dragline house, resulting in increased house-keeping and operators turning the lube system off to decrease lubricant discharge from both the hoist and drag ropes. Does this sound familiar?

Many rope lubricants manufactured today are oil- or greasebased, designed to penetrate into the rope core. This type of rope lubricant works well in many applications. However, when you are talking about lubricating dragline hoist and drag ropes, from Bel-Ray’s experience, this type of rope lube does not perform well.

Why?

The loads placed on both the hoist and drag ropes on draglines, especially large diameter rope, 85mm to 150mm, are

Rope lube is normally sprayed on to the drag sheaves, which then transfers onto the drag ropes

huge. Most, if not all, rope manufacturers pre-lube these ropes internally during the manufacturing process. When new drag or hoist ropes are installed on a dragline, a large amount of the pre-lube oil will be extruded from the internals of the rope because of the huge forces placed on the rope, causing it to stretch and twist as it runs over the sheaves. The re-lubrication of these ropes is normally by spray or dripper, with the lubricant being applied to the sheaves, or in some cases, drippers will apply the rope lube to the top of the drag ropes with the excess transferred to the sheaves

The hoist ropes will normally have drippers at the boom point sheaves directed onto the hoist ropes at 11 o’clock in front of the sheaves. This is where the rope will flatten slightly and open the outer strands to allow some penetration to the external strands. Some draglines such as Marions are fitted with sprays or drippers at the gantry sheaves, which are also lubricated using drippers or sprays. Normally, the boom point drippers will apply rope lube to the front two-thirds of the hoist ropes. If hoist gantry drippers are operating, they will re-lubricate the back third of the hoist ropes and the hoist drum.

Hoist boom point drippers are usually located at 11 o’clock in front of the boom point sheaves. Drag Cable Lubricant Summer will form a thick pliable layer on the externals of the hoist ropes, sealing the ropes and stopping moisture from entering the rope core, while reducing wear between the rope and sheave. In most cases Drag Cable Lubricant Summer will provide good lubricant protection to the hoist rope drum and the back third of the hoist ropes once the hoist ropes have been end-for-ended.

However, many draglines only lubricate the hoist ropes at the boom point. Based on inspections of both hoist and drag ropes which have been sectioned, there is no evidence that the lube being applied to the externals of the hoist and drag ropes penetrates any deeper than the outer strands. This is understandable when you consider the huge forces applied to the ropes, and is why using a penetrating type rope lube on dragline ropes is a waste of time.

The lubricant applied to the ropes during manufacture will give the best and only protection to the inner cores of the ropes. We need to protect the outer strands of the ropes, sheaves, and the rope drum.

Wet oil-type rope lubes, especially on drag ropes, will not form a tough lubricant film; they will attract dirt and dust and will flick off the ropes inside the house. Drag Cable Lubricant Summer, however, will form a tough lubricant layer on both the sheaves and the drag ropes, almost dry to the touch.

When using Drag Cable Lubricant Summer on hoist ropes, it is necessary to apply enough rope lube each time to build up a thick outer layer on the external rope strands. This layer will remain pliable, effectively sealing the rope and preventing moisture, etc. from penetrating the internal strands.

Once the hoist ropes are end-for-ended, this thick layer of Drag Cable Lubricant Summer which has built up on the front two-thirds of the hoist ropes will afford some protection to the hoist drum and the back third of the hoist ropes through to the end of the hoist rope life.

In most cases, once the hoist ropes have been end-for-ended, the pre-lube oils excreting from the internals of the rope have stopped coming to the surface of the outer strand. The back third of the hoist ropes and the hoist drum can dry out completely. This situation is most common on draglines which only have lubricant applied at the boom point. Wear, commonly called rifling, may start to appear on the hoist rope drum. This condition is called rifling because it looks like the rifling you can see when you look down the barrel of a rifle. You need to get some lube back onto the hoist drum and the back third of the hoist ropes; this can be applied manually with a bucket or spray canister. In some cases, a drop down spray bar has been installed at the back of the hoist rope drum connected to the main open gear lube line running to the hoist open gears. This system will fire when the open gear lube system operates and can be left in place until a sufficient lubricant coating is applied to the hoist ropes and hoist drum.



Hoist ropes and the hoist rope drum can dry out completely when the ropes are end-for-ended. In this photo you can see rifling starting to appear on the hoist rope drum. Sometimes a drop down spray bar is installed at the rear of the hoist rope drum. This can be lowered into place behind the hoist rope drum and runs off of the open gear lube system supplying lube to the hoist open gears.

Proven Results

To show the performance benefit using Drag Cable Lubricant Summer on your dragline ropes, we have BCM (Bench Cubic Meters) results from three of the P&H 9020 draglines operating in Australia. This data is based on the average BCMs achieved from the last 5 sets of hoist and drag ropes for each 9020 dragline.

Two of the P&H 9020 draglines are running 114mm ropes on both hoist and drag. One of the two, Ensham Coal Mine, has been using Drag Cable Lubricant Summer for the past 3 ½ years. The third P&H 9020 is running 102mm ropes. The best performing P&H 9020 on BCMs achieved for both hoist and drag is Ensham Coal Mine’s P&H 9020 running on Bel-Ray’s Drag Cable Lubricant Summer.

Bulga Coal Mine Ensham Coal Mine Walkworth Coal Mine

Rope Lube: Molybond
Hoist Rope Size: 114mm
Average BCM 4,900,000
Drag Rope Size: 114mm
Average BCM 2,200,000

Robe Lube: Bel-Ray
Hoist Rope Size: 114mm
Average BCM 6,000,000
Drag Rope Size: 114mm
Average BCM 2,450,000

Rope Lube: Tribol
Hoist Rope Size: 102mm
Average BCM 5,000,000
Drag Rope Size: 102mm
Average BCM 1,400,000

POWERSPORTS DIVISION
Bel-Ray Provides Today’s Engines with Proven Performance & Protection

Have you ever thought of the advancement of engine parts over the last fifty years? Of course you have, but consider this, back then engines were big, heavy machines that could withstand punishment and neglect and remain operational through harsh conditions. Over the years, parts became smaller, lighter and much more precise. This evolution of parts transferred directly to engine design, and allowed engine tolerances to tighten significantly in order to provide a much more streamlined and efficient machine. Because of these tight tolerances, particle contamination from air intakes can become an engine killer in modern machines, causing premature wear and catastrophic failure.

In the days of old, filters soaked with high weight engine oils were enough to filter the incoming air to stop large dirt and other large airborne particles from entering the engine. Newer machines, however, require a much more specialized product to filter out the fine dust and micro contaminants from the air intake. Filter oils evolved into the super tacky low air restriction formulas we see today. To maximize performance of air filter oil, there needs to be a balance between dirt extraction and air flow through the filter. Too tacky, and the oil will plug easily and starve the engine of oxygen. Too much air flow and large amounts of dirt will enter the engine.

To test the ability of air filter oils, the Bel-Ray laboratory constructed a test apparatus based on the ISO 5011/SAE J726 Standard for Performance Testing of Inlet Air Cleaning Devices. The apparatus was designed to mimic a 450cc motorcycle’s air box at full throttle in a highly dusty environment. The test method included feeding the system with a constant air flow with a steady rate of dust introduction into the air line. As time progresses, the filters become more loaded with dust and restrict the air flow until a set point of air restriction is reached. Relevant measurements are taken at specific points in order to evaluate the results. Bel-Ray Foam Filter Oil was put through this test along with sixteen competitor products in order to gauge performance. An entire report of this experiment and all of the results can be found on the

Bel-Ray website in the technical powersports section: www.belray.com/technical/powersports.

In this test, three correlations were made with the collected data. First, filter efficiency found by measuring the percentage of dust captured by the filter. The second correlation was the capacity of the filter oil. This was recorded as the time exposed to the dusty environment before the termination point. The third and final correlation taken from the data was the loading curve for each of the oils. The loading curve shows the performance during the entire duration of the test. For example, if a filter was plugged quickly, the curve will be short and steep. If the filter lasted a long time before plugging, the curve will be long and gradual. Most oils cause the filter to plug gradually in the beginning, but since plugging, once begun, causes more extensive blockages, the slopes quickly become very steep.

To summarize the results of the report mentioned above, the Bel-Ray Foam Filter Oil is in the upper echelon in dust removal with a dust extraction of more than 99.5%. Of the eight products that maintain an extraction rate of more than 99%, Bel-Ray Foam Filter Oil maintained acceptable air flow performance for more than a 40% longer time than the leading competitor.

This result shows that Bel-Ray Foam Filter Oil has an extremely effective balance of dust extraction capabilities and the air flow necessary for an effective air filter oil. Again, for a more in depth look into this test and the corresponding results, please visit the Bel-Ray website at www.belray.com/technical/powersports.