Applications For Greases

OBEGI CHEMICALS EGYPT
APPLICATIONS FOR GREASES

SHELL GADUS
Eng. Ahmed Elsisy

Technical Support
1
WHAT ARE GREASES?
A solid or semi-fluid lubricant consisting of a thickening agent in a liquid lubricant
Greases are used as a lubricant which stays in position
They are used for the lubrication of a wide variety of equipment such as:
– Bearings
– Couplings
– Open gears
– Wire ropes / cables
2
WHEN ARE GREASES USED?
Oils are the lubricants of 1st choice, but greases are used when:
 The parts to be lubricated are difficult to reach or require
infrequent lubrication
 An effective seal against contaminant ingress is crucial
 The system is unable to retain oil
Most common applications are in bearings, gears and joints
3
OIL OR GREASE ?
Factors Grease Lubrication Oil Lubrication
Temperature Up to 120°C Up to 200°C
With special grease up to 220°C Up to high temps with special oils
Speed Factors Up to moderate speeds Up to high speeds
Load Up to high loads Up to high loads
Bearing Design Relatively simple May need to be more complex with

arrangements for oil feed
Stop-start operation Yes Risk of damage to bearing

surfaces
Runs for long periods Yes No
without attention
Central lubricant supply No Yes

for other machine
elements Grease cannot transfer heat
efficiently or operate hydraulic
systems
Dirty Conditions Yes Circulating system with oil filters
required 4
Good sealing properties prevent entry
WHAT IS THE GREASE FOR?
The primary function of grease is to lubricate equipment
A secondary function such as noise reduction may also be important
To protect the application the grease must:
 Function as a lubricant
 During shock loading (stop/start)
 In the presence of water and/or other contaminants
 During temperature variations
 Over time
 Stay in place
 Adhere to the surfaces
 Maintain its consistency or mechanical stability during changes to temperature and/or wear and vibration
 Resist the effect of water wash out
5
ADVANTAGES & DISADVANTAGES OF GREASES
Copyright of Shell Lubricants 6

SYMPTOMS OF PROBLEMATIC BEARINGS
 Hot Running
 Noisy Running
 Short Life – Frequent Replacement
 Excessive Vibration
 Difficult to Turn / Friction
Other than Improper design, causes are Lubrication,

Installation, Contamination, and or Improper uses
Likely that it is a combination

CAUSES OF BEARING FAILURES
Fatigue Failure – 34%

 End of bearing useful life due to fatigue failure
 Including improper selection / uses
 Overloading / Preloaded
Improper Handling & Installation – 16%
 Premature bearing damage
 Misalignment / Unbalancing
 Clearance
Contamination during operation – 14%
 Dust, water, steam, chemical, etc
 Improper seal & seal position
 Seal damage
Improper Lubrication – 36%
 Wrong Grease
 Under / Over Grease
 Compatibility
 Contaminated Grease

CAUSES OF BEARING FAILURES
IMPROPER LUBRICATION
 Wrong or low quality grease
 Under protection, wear / corrosion
 Leaking / Fling off
 Not suitable for specified service interval
 Dirty Grease
 Abrasive wear
 Under grease
 Could be too long service interval
 Over packed
 Too much feed / initial fill
 No drain, wrong seal
 Causes high internal friction and high temperatures

APPLICATION METHOD FOR GREASES
Manual Method
 Grease gun (risk of over greasing and/ or mixing the greases)
 Spatula (high risk of contamination)
 Brush (for open gears, high risk of contamination)
Automatic Method
Single point lubricator (Shell Tactic EM device that can be filled with required
grease)
Centralized lubricating systems
 Single line (single point injectors or progressive)
 Multiple lines with single point injectors
 Two line systems with progressive distributors

TECHNOLOGY OF GREASES
Greases consist of three important components:

 The lubricating fluid
 The additives
 The thickener (soap or non-soap)
The thickener is the critical component in ensuring that the grease stays in place and selection of
thickener depends on the specific operating requirements
 Operating temperature
 Shear stability
 Water resistance
 Pumpability
There are a variety of thickeners on the market

 Lithium
 Lithium complex
 Calcium
 Aluminium complex
 Calcium Sulphonate
 Polyurea
 Clay
 Others

COMPOSITION DIFFERENCE OF GREASES AND
OILS
Base oil (65 - 98%)

Grease
Base oil (85 - 95%)
Additives (0-15%)
Oil
Additives (5 - 15%)
Thickener (2-20%)
Grease Formulation Oil Formulation

COMPONENTS OF A GREASE
GREASE
BASE OIL ADDITIVES THICKENER
Antiwear / EP
Anticorrosion
MINERAL SYNTHETIC Antioxidant
Increasing adhesive ability
Metal deactivation
Soap Non soap
Non organic organic

simple mixed complex
Li Li/Ca Li
Ca Ca Clay Polyurea
Ba Al Silica Gel
Al Na
Na

FUNCTION OF A THICKENER
The thickener functions in a similar

manner to a washing sponge: under
light pressure on the sponge, only a … but under heavy pressure,
little water is forced out of it ... a lot of water is ejected.

OPERATION TEMPERATURES
Extended Range
Normal Range Depending on Base Fluid and Additives

KEY GREASE PROPERTIES
 Dropping Point
 High Temperature Capability
 Consistency
 Flow properties
 Varies with temperature
 Depends on the amount and type of thickener used

DROPPING POINT
Temperature where grease is fluid and drops from test orifice
Like a Melting Point - - A temperature range
Usable Temperature is less than the

Dropping Point

DROPPING POINT RANGE FOR GREASES
°F °C
Calcium 265-285 129-140
Lithium 380-400 193-204
Li Complex
Other Complexes 450+ 232+
Polyurea
Microgel® (clay) >500 >260

NLGI CONSISTENCY GRADES
NLGI Grade Worked Penetration

Description
0.1 mm, 25°C
000 445 - 475 Fluid

00 400 - 430 Semi-fluid
0 355 - 385 Very soft
1 310 - 340 Soft
2 265 - 295 Med soft
3 220 - 250 Medium
4 175 - 205 Stiff
5 130 - 160 Very stiff
6 85 - 115 Block

QUICK SUMMARY
Lubrication performance
(Oil) Operating Temperature
(Thickener Type and Oil Type)
Bearing Speed (rpm)

(Thickener and Oil)
Consistency
(Thickener Content)
Corrosion Protection
(Additives and Oil)
Bearing Load
(Additive and Oil)
Operating Parameters
Vibrations, Dirt, Dust, Humidity etc.
(Thickener Type)

SHELL GREASE FAMILY
Key
Shell Gadus S2 V 220 AD 2
KEY LETTERS USED
A = Wet (aqueous) conditions

C = Coloured grease
P = Extreme pressue
D = Contains solids (MoS2, graphite, etc.)
OG = Open gear
T = Extreme temperature applications (polyurea)
V = Versatile (lithium, lithium-calcium or lithium
complex)
U = Non-melting (microgel / clay)
Q = Noice-dampening (quiet)

SHELL GREASE FAMILY
22
Questions ?
Thank You
23

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OBEGI CHEMICALS EGYPT

APPLICATIONS FOR GREASES

Eng. Ahmed Elsisy

A solid or semi-fluid lubricant consisting of a thickening agent in a liquid lubricant

Greases are used as a lubricant which stays in position

 The system is unable to retain oil

Most common applications are in bearings, gears and joints

Speed Factors Up to moderate speeds Up to high speeds

Load Up to high loads Up to high loads

Bearing Design Relatively simple May need to be more complex with

Stop-start operation Yes Risk of damage to bearing

Central lubricant supply No Yes

Copyright of Shell Lubricants 6

 Short Life – Frequent Replacement

 Difficult to Turn / Friction

Other than Improper design, causes are Lubrication,

Likely that it is a combination

Copyright of Shell Lubricants 7

Fatigue Failure – 34%

Copyright of Shell Lubricants 8

Copyright of Shell Lubricants 9

 Grease gun (risk of over greasing and/ or mixing the greases)

 Spatula (high risk of contamination)

 Brush (for open gears, high risk of contamination)

Copyright of Shell Lubricants 10

Greases consist of three important components:

There are a variety of thickeners on the market

Copyright of Shell Lubricants 11

Base oil (65 - 98%)

Grease Formulation Oil Formulation

Copyright of Shell Lubricants 12

Soap Non soap

Non organic organic

Copyright of Shell Lubricants 13

The thickener functions in a similar

Copyright of Shell Lubricants 14

Copyright of Shell Lubricants 15

 High Temperature Capability

Copyright of Shell Lubricants 16

Temperature where grease is fluid and drops from test orifice

Like a Melting Point - - A temperature range

Usable Temperature is less than the

Copyright of Shell Lubricants 17

Calcium 265-285 129-140

Lithium 380-400 193-204

Other Complexes 450+ 232+

Microgel® (clay) >500 >260

Copyright of Shell Lubricants 18

NLGI Grade Worked Penetration

000 445 - 475 Fluid

Copyright of Shell Lubricants 19

Bearing Speed (rpm)

Copyright of Shell Lubricants 20

KEY LETTERS USED

A = Wet (aqueous) conditions

Copyright of Shell Lubricants 21

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