A technical guide to Shell tactic emv

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A technicAl guide

to Shell tActic eMV

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The information provided in this guide is of a general nature only. Potential users of Shell Tactic EMV Lubricators should seek advice tailored to their particular circumstances and, for this purpose, are welcome to contact Shell on the contact number provided. Shell is not liable for any costs, losses or damages, whether direct or indirect, arising from any reliance upon this document.

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Shell understands that successful

businesses use preventative

maintenance programs to help

reduce operational costs and

plant stoppages. Shell tactic eMV

automated lubrication system is

designed to extend the service life

of bearings and deliver superior

reliability results compared to

manual lubrication.

A reliable supply of clean lubricant is vital for

optimal bearing service. If bearings are not

sufficiently lubricated, the result can be premature

failure. The flow on being maintenance cost

increases and equipment downtime. In response

to this, Shell delivers Shell Tactic EMV lubrication

solutions to help maintain critical equipment.

As the demand for increased production output

grows, so too does the investment in preventative

maintenance strategies. As a result investment

in technically superior maintenance methods

such as the automated lubrication of fixed plant

equipment also increases.

However, automatic lubrication systems alone

do not provide complete lubrication solutions.

Systems such as the Shell Tactic EMV must be

combined with straightforward implementation

methods and realistic management plans in

order to help establish practical and sustainable

solutions.

This technical guide has been written to help

users of Shell Tactic EMV lubricators to develop

robust and practical lubrication programs.

Shell tActic eMV luBricAtorS

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Irregular greasing intervals Time Over-lubrication Adequate lubrication Under-lubrication

Manual greasing Manual greasing Manual greasing

Volume of grease

Very regular greasing intervals

Time Over-lubrication Adequate lubrication Under-lubrication Routine inspections Shell Tactic EMV greasing

Volume of grease

Advantages of automated lubrication

The risks associated with over-lubrication and lubricant starvation varies based on a range of factors such as bearing size, bearing type, speed, temperature, vibration and conditions associated with the operating environment. Automated delivery systems inject small amounts of grease at short time intervals which helps to ensure that sufficient fresh grease is consistently available for bearing re-lubrication and for the purging of seals. This method of grease delivery reduces the likelihood of lubricant starvation or over-lubrication from occurring while reducing the workload demand on maintenance personnel.

how the Shell tactic eMV lubricator works

The Shell Tactic EMV dispenses grease in small amounts at short time intervals. The time interval between each injection of grease varies depending on the time settings of each lubricator. The shortest time interval between injections is 1 hour and 30 minutes while the longest time interval is 18 hours and 12 minutes.

(Refer to page 11 for further information).

Lubricator time settings are selected based on factors such as bearing size, bearing type, speed, temperature, vibration and conditions associated with the operating environment. These factors, along with site specific requirements relating to equipment access opportunities and time based maintenance cycles are used to establish practical programs for the management of groups of individual lubricators.

The graphical representation is for illustration purposes only.

the optimal method of grease delivery to

rolling elements bearings is generally via

the addition of small amounts at short time

intervals. this optimal form of lubrication is

achieved using automated delivery systems

and cannot be practically achieved via

manual methods.

Bearings which operate in harsh environments demand the shortest re-lubrication intervals. Under such conditions manual lubrication becomes very labour intensive and often impractical.

When manual lubrication programs fail to regularly lubricate due to lack of available resources or lack of opportunities to safely access equipment, the absence of fresh grease can lead to lubrication starvation and contaminant entry. This will eventually result in premature bearing failure.

BeneFitS oF Short

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Shell tActic eMV luBricAtion ProgrAMS

contAMinAtion PreVention StrAtegieS

THE CONSISTENT AND REGULAR PURGE OF FRESH GREASE

THROUGH SEALS HELPS TO PREVENT THE ENTRY OF DAMAGING

CONTAMINANTS.

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Different bearing configurations and operating environments lead to different re-lubrication requirements and therefore different Shell Tactic EMV configurations. Listed below are three of the commonly accepted methods to help reduce contamination of rolling element bearings with taconite or labyrinth type seals.

1. Where the threat of contaminant entry is high and for larger bearings the use of individual, dedicated Shell Tactic EMV lubricators for the bearing re-lubrication point and the seal purge point(s) is most common – refer to the example image opposite.

2. For smaller sized bearings running at relatively low speeds the application of a single lubricator to the bearing re-lubrication point only, set to dispense at an elevated rate, can provide sufficient fresh grease for bearing re-lubrication and seal purging.

3. As an alternative strategy manual and automated lubrication programs can be combined by utilising Shell Tactic EMV to help achieve a constant purge of fresh grease through seals while maintaining periodic manual lubrication for the bearing point re-lubrication.

Bearings operating in industries such

as minerals processing and mining

are inevitably subjected to sources of

contamination by solid particulates

and moisture. if these contaminants

are allowed to enter bearings via

poorly maintained seals or poor

lubricant handling practices they can

cause accelerated wear and the early

onset of fatigue.

For solid contaminants, the rate of wear increases as the size, concentration and hardness of the contaminants increases. Smaller particles lead to abrasive wear, while larger particles can cause indentations to bearing raceways which can then become initiation points for fatigue wear. Shell Tactic EMV lubrication programs use greasing practices to help prevent the introduction of contaminants. Consequently there can be a long term financial return because equipment experiences a longer bearing service life and reduced downtime.

contAMinAtion PreVention StrAtegieS

taconite seal purging example:

Automatic lubrication of taconite seals help to provide a constant protection against the ingress of contaminants. The image below demonstrates the grease entry point and seal

purge point for a typical taconite seal arrangement. Regular lubrication of this point creates a positive purge of grease which passes through the seal and exits the bearing housing, thereby preventing the entry of contaminants.

The photograph below shows the result of a successfully purged seal using Shell Tactic EMV. The ring of grease around the exit point of the taconite seal provides evidence that while the grease is exiting the bearing housing, ingress of contaminants is prevented.

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WorkPlAce SAFety And eFFiciency

gAinS uSing Shell tActic eMV

Shell tactic eMV automatic lubricators are maintenance

tools which can make a positive contribution to work

place safety and efficiency. in harsh climates this is

particularly important – especially for large sites where

the physical demands of performing regular manual

greasing in hot weather can increase the risk of heat

exhaustion to workers.

However, it is important to note that the implementation of automatic lubrication systems does not mean that the frequency of equipment inspections should be reduced. In fact, the proper use of automated systems can liberate time. This can then be invested into other preventative maintenance tasks such as routine equipment inspections, filter and breather maintenance and oil cleanliness management activities.

here are 3 ways to helP improve workplace safety and save time:

Maintenance

challenge

Shell tactic eMV Solution

Assessment criteria for

improvements

Access to lubrication points located behind safety cages or guards

Remote mounting of Shell Tactic EMV lubricators at safe to access locations makes inspection and servicing possible while equipment is operating.

This helps to remove reliance on valuable time during maintenance shuts which would otherwise be required to access such points.

efficiency gains:

■ Time is liberated from shutdowns by servicing

lubricators while equipment is operating.

■ Time is saved by not having to complete

isolations to access lubricators.

■ Time is saved by eliminating the need to remove

and re-instate cages and guards.

Safety improvements:

■ Elimination of tool work required to remove

guards and cages.

■ Elimination of the manual handling of cages

and guards. Access to lubrication

points located at heights or in confined spaces

Shell Tactic EMV lubricators can be used to lubricate points which would otherwise demand more frequent working at heights and confined space entry.

■ Time is saved by reducing the frequency of

demand to gain working at heights or confined space permits and access.

■ Reduced requirement for equipment such as

elevated work platforms.

■ Reduced demand on personnel and equipment

associated with confined space entry.

■ Reduced risks associated with working at

heights and confined space entry by reducing the frequency of the activity.

Minimisation of repetitive manual tasks

Converting manual greasing tasks to automated grease delivery using Shell Tactic EMV will help to minimise the highly repetitious use of manual grease guns. In addition it can save time by automating an otherwise laborious manual task.

■ Automated delivery of grease via a mechanised

system in place of manually applied strokes of a grease gun.

■ Reduced manual work load and reduced

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components & construction

reusable Parts

The Shell Tactic EMV drive system and push-on protection cap are reusable. The system automatically performs a self test when each new battery set is inserted. The drive should also be inspected for physical damage before each new grease canister is used.

Single use Parts

Shell Tactic EMV grease canisters are factory filled in a controlled environment to help ensure against the inclusion of contaminants. A new battery set is supplied with each grease canister and should be exchanged when a fresh grease canister is applied.

general specification & grease types

Available products Shell Tactic EMV drive unit

Shell Tactic EMV Gadus S5 T100 2 110gm

Shell Tactic EMV Gadus S3 V460D 2 225gm

Shell Tactic EMV Gadus S3 V220C 2 225gm

Packaging Products come in boxes of 10 units.

Time settings 1, 2, 3, ... through to 12 months in monthly increments

Dispensing rates From 0.3 to 8.2cm³ per day, depending on the time settings and the canister size.

Pressure output 6 bar rising to 8 bar if required

Operating temperature –10 to 60°C average ambient temperature for the unit drive. Remote mounting from application can be used

to reduce ambient temperature. The dispensing rate is not affected by temperature.

Remote installation Up to 5 metres* of grease line with 10mm internal diameter

Product dimensions Individual items

Drive unit: diameter (including cover) 75mm; length 102mm

120cm3_{canister: diameter 66mm; length 106.8mm}

250cm3_{canister: diameter 66mm; length 156.8mm}

Mounted units

Drive unit + 120cm3_{canister: diameter 75mm; length 178mm}

Drive unit + 250cm3_{canister: diameter 75mm; length 228mm}

Accessories and thread type All canisters have a ¼ inch BSP male thread.

All Shell Tactic EMV drive units come with a support flange and wet cap as standard. All canisters include a new set of batteries as standard.

Shell tActic eMV

PRODUCT OVERVIEW

Shell tactic eMV drive unit reusable

Shell tactic eMV lubricant canister Protection cap

Shell tactic eMV Battery pack

LCD-display with push button

Piston

Shell Tactic EMV Battery pack Gear motor

LCD-display with push button (Discharge period and function)

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Shell tActic eMV diSPenSing rAteS And inSPection ProtocolS

The availability of lubricator time settings in monthly increments means that the Shell Tactic EMV can be adapted to the service scheduling requirements of most operations without the need to compromise on lubricant dispensing rates.

The Shell Tactic EMV drive system combines an LCD screen and a set of four light windows to communicate its operational status to maintenance personnel. The table below provides a quick reference to the screen and light combinations. In simplest terms, a flashing red light means that a lubricator requires attention.

canister Size

250cm3 cm3 per day 8.3 4.2 2.8 2.1 1.7 1.4 1.2 1.0 0.93 0.83 0.76 0.69

canister Size

120cm3 cm3 per day 4.0 2.0 1.3 1.0 0.80 0.67 0.57 0.50 0.44 0.40 0.36 0.33

time

between

cycles

h rs : Mins 1h : 30m 3h : 00m 4h : 36m 6h : 06m 7h : 36m 9h : 06m _{10h : 36m} _{12h : 12m} _{13h : 42m} _{15h : 12m} _{16h : 42m} _{18h : 12m}

Setting,

months

1

2

3

4

5

6

7

8

9 10 11 12

0.26cm3 per cycle 0.53cm3 per cycle

Status

Screen

lights

Action

dwell

Lubricator is between dispensing cycles

Shows the TIME and VOLUME settings

Single green flash every 7 seconds

Inspect lubricator. Mark and date the position of the piston to confirm inspection.

run

Lubricator is dispensing grease

Single green flash

every 1 second Inspect lubricator. Mark and date the position of the piston to confirm inspection.

Purge

Grease is being dispensed

Single green flash

every 1 second The purge feature has been activated by holding the SET button for 10 seconds.

canister empty

Canister expected to be empty Double every 2 secondsred flash Service the lubricator using a new canister and battery set.

overload

Excessive resistance to grease flow

Double red flash

every 7 seconds Manually purge the point to clear blockage. Investigate possible causes and rectify.

low Battery

Battery set is damaged or depleted

Double red flash

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Shell tActic eMV

reMote Mounting SySteMS

SIMPLE TO INSTALL USING BASIC HAND TOOLS

B. Manual purge point

Used for convenient additions of supplementary grease, line purging and grease blockage clearing.

d. Stainless steel bracket

There are two main categories of brackets – Standard Duty and Heavy Duty. The example shown here is the Heavy Duty C-section design which provides extra protection to lubricators.

e. Stainless steel beam clamps

Simple to use beam clamps supplied with case hardened cup head set screws and stainless steel assembly screws. Covers to help protect lubricators

from solid and liquid contaminants.

F. Support flanges

Provide support to lubricators to help prevent damage from impacts and vibration.

c. elbows

Elbow fittings are full bore with ¼” BSP threads. A B c d e F g

g. heavy duty hose

Supplied with ” internal diameter and easy to use push-lock type swivel hose ends.

A. Full length protection covers

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Where remote installation of the Shell Tactic EMV is planned the following guidelines are to be followed:

■ Identify a safe point of access to mount stainless steel bracket ■ Use grease line with ” internal diameter

■ Restrict grease line length to 5 metres*

■ Use only full bore hose ends and elbow fittings** ■ Route grease lines under or around cages, not through ■ Prime grease lines and fittings with grease

■ Test the grease delivery path to ensure bearing and seal points

can receive grease freely

■ Protect lubricators with full length covers to suit operating

environment

■ Include manual purge points

■ Protect grease lines from damage using spiral wrap

Shell tActic eMV SySteMS reMote inStAllAtion guidelineS

For maximum pressure to the lubrication point, direct mounting is preferred. However, this will not be practical in all circumstances. In many cases remote mounting is required to help provide safe and convenient access or to prevent lubricator damage. Therefore, remote installations are recommended under the following circumstances:

1. When protective guards or safety cages have to be removed to access the lubrication point.

2. Where it is difficult or unsafe to access the lubrication point while equipment is running.

3. When the bearing is subject to high vibration or temperature which may damage the lubricator.

4. When the lubrication point is exposed to excessive amounts of water or impact from solid material.

* Factors such as low ambient temperatures or difficult to pump grease types may restrict the maximum recommended grease line to less

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1 4 3 5 8 11 7 2 6 9 10

Shell tActic eMV reMote inStAllAtion kitS

A range of installation kits are available which facilitate quality remote installation of Shell

Tactic EMV lubricators. The most common installation kits utilise stainless steel beam clamps

and cage hangers to attach to beam sections and square mesh safety cage.

Other, less common configurations are available upon request.

Available in 1, 2, 3 or 4-point configurations which are used where lubricators are to be mounted to beam sections.

The 2-point version shown below demonstrates the typical bill of materials.

Available in 1, 2, 3 or 4-point configurations which are used where heavy duty protection systems are to be mounted

to beam sections. The 2-point version shown below demonstrates the typical bill of materials.

Standard duty Beam clamp Mount installation kits

heavy duty Beam clamp Mount installation kits

SK130 (with 30mm beam clamps)

SK130C (with 30mm beam clamps)

example installation kit contents – Sk230

example installation kit contents – Sk230c

1 4 3 5 11 8 6 7 2 10 9 Bill of Materials

1 1 x 2-point C-section SS bracket 7 4m grease line ” internal diameter

2 2 x 30mm SS beam clamp 8 2 x 90 degree brass elbows ¼” BSP

3 2 x support flange ¼” BSP 9 2 x reducer ¼” BSP F to ” BSP M

4 2 x PVC covers 250mm long 10 2 x adaptor ¼” BSP F to ¼” BSP M

8 3

8 1

Bill of Materials

1 1 x 2-point stainless steel bracket 7 4 x Push lock hose tails ¼” BSP M

2 2 x 30mm SS beam clamp 8 2 x 90 degree brass elbows ¼” BSP

3 2 x support flange ¼” BSP 9 2 x adaptor ¼” BSP F to ¼” BSP M

4 2 x PVC covers 250mm long 10 2 x reducer ¼” BSP F to ” BSP M

5 2 x Manual purge kit 11 0.5m spiral wrap

6 4m grease line 38” internal diameter

8 1

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Available in 1, 2, 3 or 4-point configurations which are used where lubricators are to be hung on safety cages with square

cage mesh down to 25mm x 25mm. The 2-point version shown below demonstrates the typical bill of materials.

Available in 1, 2, 3 or 4-point configurations which are used where a heavy duty protection system is required to be hung on safety

cages with square cage mesh down to 25mm x 25mm. The 2-point version shown below demonstrates the typical bill of materials.

Standard duty cage Mount installation kits

heavy duty cage Mount installation kits

SK1CH SK1CHC SK3CH SK2CH SK2CHC SK4CH

example installation kit contents – Sk2ch

example installation kit contents – Sk2chc

1 3 2 4 7 10 6 5 8 9 1 3 4 8 6 7 2 9 10 5 11 Bill of Materials

1 1 x 2-point stainless steel bracket 6 4m grease line ” internal diameter

2 2 x support flange ¼” BSP 7 2 x 90 degree brass elbows ¼” BSP

3 2 x PVC covers 250mm long 8 2 x adaptor ¼” BSP F to ¼” BSP M

4 2 x Manual purge kit 9 2 x reducer ¼” BSP F to ” BSP M

5 4 x Push lock hose tails ¼” BSP M 10 0.5m spiral wrap

8 3

8 1

Bill of Materials

1 1 x 2-point C-section SS bracket 7 4 x Push lock hose tails ¼” BSP M

2 2 x cage hanger arms 8 2 x 90 degree brass elbows ¼” BSP

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Application Electric Motor

Lubricator Shell Tactic EMV 110 gram Installation Kit Direct

Lubricator Shell Tactic EMV 110 gram Installation Kit SK230

electric motor lubrication solutions

For electric motor lubrication the following factors are generally relevant to the

development of the lubrication solution:

n Motor manufacturer’s recommendations n Motor speed

n Grease trap / escape port design, access and condition n Operating conditions

n Characteristics of lubricant

n Bearing types

n Safe access requirements

n Desired service schedule (of lubricators) n Duty cycle

n Motor orientation (vertical or horizontal)

lubrication Assessment criteria

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Application Pump bearings

Application Slurry pump labyrinth seals Lubricator Shell Tactic EMV 225 gram Installation Kit SK265C

Application Slurry pump bearings & labyrinth seals Lubricator Shell Tactic EMV 225 gram

Installation Kit 2 x SK265C

Application Slurry pump labyrinth seals Lubricator Shell Tactic EMV 225 gram Installation Kit SK265C

Pump lubrication solutions

For pump lubrication the following factors are generally relevant to the development of

the lubrication solution:

n Pump manufacturer’s recommendations n Seal types

n Wash down procedures n Operating conditions n Characteristics of lubricant

n Bearing types and grease entry points n Safe access requirements

n Desired service schedule (of lubricators) n Duty cycle

n Typical bearing operating temperatures

lubrication Assessment criteria

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Application Conveyor pulley tail bearings Lubricator Shell Tactic EMV 225 gram Installation Kit SK1CH

Application Drive pulley bearing and seals Lubricator Shell Tactic EMV 225 gram Installation Kit SK3CH

Application Bend pulley bearing and seal Lubricator Shell Tactic EMV 225 gram Installation Kit SK2CH

conveyor pulley lubrication solutions

For conveyor pulley bearing lubrication the following factors are generally relevant

to the development of the Shell Tactic EMV lubrication solution:

n Bearing types and speeds n Operating conditions n Safe access requirements

n Grease performance characteristics

n Location of grease entry points on bearing housings n Seal types

n Desired service schedule (of lubricators)

lubrication Assessment criteria

installation examples

Application Head pulley bearing and seal Lubricator Shell Tactic EMV 225 gram Installation Kit SK230

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Application Fan jack shaft bearings Lubricator Shell Tactic EMV 110 gram Installation Kit Direct

Application Fan jack shaft bearings Lubricator Shell Tactic EMV 110 gram Installation Kit SK230C

Fan lubrication solutions

For fan bearing lubrication the following factors are generally relevant to the

development of the lubrication solution:

n Bearing types and speeds n Operating conditions n Safe access requirements

n Grease performance characteristics n Grease base oil viscosity

n Location of grease entry points on bearing housings n Seal types

n Desired service schedule (of lubricators) n Bearing temperatures

lubrication Assessment criteria

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For more information, please contact:

The Shell Company of Australia Limited

(ABN 46 004 610 459)

A technical guide to Shell tactic emv