greases for metallurgical industry - ЛУКОЙЛ · PDF fileGREASE CLASSIFICATION ACCORDING TO DIN 51 502 The lubricant is assigned a code, which reflects the composition, field of

GREASESFOR METALLURGICAL INDUSTRY

solutions verified by equipment

CONTENT

SINTERING PLANT 4

CONTINUOUS CASTING MACHINE 6

ROLLING PLANT 8

PIPES PRODUCTION 10

GREASES CLASSIFICATION ACCORDING TO DIN 51502 12

GREASES CLASSIFICATION ACCORDING TO NLGI 13

GREASES DESCRIPTIONS 14

GLOSSARY 15

SINTERING PLANT

At metallurgical plants the furnace charge is agglomerated in belt-type sinter machines, presented by a continuous chain of sintering trolleys with the bottom made of fire grates, further the sinter cake is supplied on the cooler band, then it is crushed in screens.

APPLICATION LUBRICATED UNITENVIRONMENTALTEMPERATURE, °Ñ

RECOMMENDED PRODUCT DIN 51 502 PACKAGING BASIC PROPERTIES

–30...+180 LUKOIL AQUAFLEX EP 1-420 KP1R-30Bucket 18 kgDrum 180 kg

• Trolley bearings

Sintering trolleys

Elements of cooler chain

Grate

Water-resistant high-temperature grease with high load carrying capacity

–20...+160 LUKOIL STEELFLEX 1-240 KP1P-20Bucket 18 kgDrum 180 kg

• Sealing (beam)High-temperature complex calcium grease, specially designed for centralized system

–30...+140 LUKOIL CARBOFLEX OG 0-680 HD OGF0N-30Bucket 18 kgDrum 180 kg• Driving gear clutch Extremely high protection at boundary friction

–30...+170 LUKOIL AQUAFLEX EP 1-180 KP1P-30Bucket 18 kgDrum 180 kg• Rolling bearings


–30...+160 LUKOIL THERMOFLEX EP 1-180 KP1P-30Bucket 18 kgDrum 180 kg• Rolling bearings

Universal high-temperature grease, resistant to water impact, has high adhesion

–20...+180 LUKOIL POLYFLEX PU 1-460 KP1R-20Bucket 18 kgDrum 180 kg• Plain bearings Low wear at high temperatures

–30...+160 LUKOIL THERMOFLEX EP 2-180 HD KPF2Ð-30Bucket 18 kgDrum 180 kg• Rolling bearings Special grease with protection against shock loads

–30...+160 LUKOIL THERMOFLEX EP 1-180 KP1P-30Bucket 18 kgDrum 180 kg• Rolling bearings

Special high-temperature grease, resistant to water impact, has high adhesion

OPERATING CONDITIONS

Abrasive dust in drivesand bearings of sintered trolleys

High operating temperatures 150–250 °C

Abrasive dust and highloads on the coolerchain links

PROBLEMS SOLVED AT OPERATION• Protection of friction couples zone from dust ingress• Stability of operation at high thermal loads

Continuous operation and complicated conditions of relubrication

Continuous casting is the moulding of metal into water-cooled mould, wherefrom partially hardened intermediate product is continuously rolled out. CCM – Continuous Casting Machin or SPP – Slab-Producing Plant. At present nearly 60% continuously casted intermediate products are moulded on slab CCM. Liquid steel is continuously moulded into water-cooled oscillating casting box, called mould. Downstream the mould a secondary cooling zone is situated. In this zone due to the forced surface cooling the intermediate product is hardened all over the cross section. Due to the continuity of the process a complete evenness of the melt all over its volume is achieved. Such process of metal casting is a way to receive melt of unlimited length.


Lubrication via centralizedsystem

CONTINUOUSCASTING MACHINE

High thermal loadon bearings

Shock loads

Lack of time and difficulty in maintenance

High humidityand water impact

PROBLEMS SOLVED AT OPERATION

• Protection of friction zone against water ingress • Long-life lubrication• Protection against damages caused by shock loads

• Easy pumping via long lubrication pipes

–20...+180 LUKOIL POLYFLEX PU 1-460 KP1R-20Bucket 18 kgDrum 180 kg

• Feeders, centralized lubrication system

CCM

Pivoting valve

Low wear at high temperatures



–20...+160 LUKOIL THERMOFLEX EP 1-460 KP1P-20Bucket 18 kgDrum 180 kg

High-temperature complex lithium grease with high load carrying capacity, for centralized systems


• Secondary cooling zone bearings

Special high-temperature grease, the best degreeof pumping, anti-seize protection





–20...+160 LUKOIL THERMOFLEX EP 1-460 KP1P-20Bucket 18 kgDrum 180 kg

• Withdrawal and straightening unitsHigh-temperature complex lithium grease with high load carrying capacity, for centralized systems

–45...+120 LUKOIL PIPEFLEX 141C Bucket 30 kg• Sliding surfaces and threading, for easy assembling Special pipe seal grease, lead-free formula



Flat steel is one of the most cost-effective types of metal products. It is very convenient for producing of different pressed workpieces and light and strong constructions. Sheets of different types are widely used in transport machine building, in particular, in automobile industry, shipbuilding, production of agricultural machines, electrical industry and other branches of economy.

Cooling wateringress intothe mill roll

High thermal loadon bearings

Shock loads

ROLLING PLANT

–10...+180 LUKOIL THERMOFLEX EP 1-1500 HD KPF1N-10Bucket 18 kgDrum 180 kg• Cardan joint

• Gears

• Roller conveyor bearings

• Cardan joint

• Gears

Hot rolling mil

Cold rolling mill

Galvanizing

Special grease for slow-speed units, subjectedto shock loads

–30...+120 LUKOIL POLYFLEX EP 00-160 KP00K-30Bucket 18 kgDrum 180 kg

Universal gear grease with protectionfrom shock loads

–20...+160 LUKOIL STEELFLEX 1-240 K1P-20Bucket 18 kgDrum 180 kg


–10...+180 LUKOIL THERMOFLEX EP 1-1500 HD KPF1N-10Bucket 18 kgDrum 180 kg

• Milling roller

Special grease for slow-speed units, subjectedto shock loads

–30...+120 LUKOIL POLYFLEX EP 00-160 KP00K-30Bucket 18 kgDrum 180 kg

Semi-liquid gear grease on lithium basewith EP additives

–25...+120 LUKOIL POLYFLEX EP 2-220 LC KP2Ê-20Bucket 18 kgDrum 180 kg

Water resistant grease with EP additivesand protection against wear and shock loads

–30...+180 LUKOIL AQUAFLEX EP 2-420 KP2P-30Bucket 18 kgDrum 180 kg

• Roller bearings in hot zoneWater-resistant high-temperature greasewith high load carrying capacity


PROBLEMS SOLVED AT OPERATION• Protection of friction zone against water and steam ingress

• Stability of operation at high thermal loads• Protection against damages caused by shock loads



For protection and preservation of threads of pump and compressor pipes and casing pipes and for sealing of thread joints and lock joints of pipelines the thread sealing lubricants are used.

LUKOIL PIPEFLEX greases protect the metal from corrosion at operation in hydrogen sulphide and carbon dioxide media at oil, gas, gas condensate and highly flooded fields, secure protective properties during pipes storage and transportation even by sea transport.

Specially designed composition secures excellent sealing of joints and thread protection against wear and corrosion, that allows to prevent most of short-circuitings and gas shows and to secure ecological compatibility and continuity of drilling.

PIPES PRODUCTION

INTESMO LLC has designed a range of products,meeting the requirements of ISO 13678 (API-5A3)

APPLICATIONLUBRICATED

UNIT

ENVIRON-MENTAL TEMPERA-

TURE, °ÑPACKAGING

BASICPROPERTIES

–50...+200 LUKOIL PIPEFLEX 111LT Bucket 30kg

Drill pipes, casing pipes, pump and compressor pipes

Standard compositionof grease

–45...+150 LUKOIL PIPEFLEX 112C Bucket 30kg Lighter composition of grease

–60...+300 LUKOIL PIPEFLEX 122S Bucket 30kg Copper-aluminium complex

–45...+120 LUKOIL PIPEFLEX 141C Bucket 30kg

• Lock jointsof drill pipes

Lead-free grease

–40...+120 LUKOIL PIPEFLEX 141EG Bucket 30kg Lead-free grease

–50...+200 LUKOIL PIPEFLEX 131HT Bucket 30kg Ecologically safe grease

–30...+120 LUKOIL PIPEFLEX 223TF Bucket 30kg Lighter composition of grease

RECOMMENDEDPRODUCT

Protection against direct contact of metal threadjoints and against tear at strong contact stresses and slidingof these surfaces over each other

Sealing of probable leakageoutlines at highinternal pressure

Inhibitingpropertiesof lubricants


PROBLEMS SOLVED AT OPERATION• Protection of pipes against corrosion during operation, storage and transportation

• Operation in Extreme North conditions• Sealing of thread joints

• Thread jointsof casing pipes and pump and compressor pipes

G R E A S E C L A S S I F I C AT I O NACCORD ING TO D IN 51 502The lubricant is assigned a code, which reflects the composition, field of application and some properties.

KPF2K–30

1. Designationof the lubricant

2. Base oils, additives and filters

3. Consistency(NLGI class)

4. Upper temperaturelimit, resistance to water

washout

5. Minimum operating

temperature, °Ñ

Code 1. DesignationK For roller bearings, plain bearings and sliding facesG For gearsOG For open gearsM For plain bearings and seals

Code 2. Synthetic base oilE Polyether base oilFK Fluorhydrocarbon base oilHC Synthetic hydrocarbon base oilPH Phosphate ester based oil PG Polyglycol base oilSI Silicone base oilX Other types of base oils

Code 3. Addition agentsP Extreme pressure additivesF Solid lubricants (graphite, MoS2, PTFE, etc.)

CodeUpper temperature

limit, °ÑResistance to water washout at

temperature (°Ñ) according to DIN 51 807

C 60 0 or 1 at 40 °ÑD 60 2 or 3 at 40 °ÑE 80 0 or 1 at 40 °ÑF 80 2 or 3 at 40 °ÑG 100 0 or 1 at 90 °ÑH 100 2 or 3 at 90 °ÑK 120 0 or 1 at 90 °ÑM 120 2 or 3 at 90 °ÑN 140 –P 160 –R 180 –S 200 –T 220 –U > 220 –

4. Upper operating temperature limitand resistance to water washout

G R E A S E C L A S S I F I C AT I O N TO NLGIThe classification is based the worked penetration of the grease, expressed in 0.1 mm.The worked penetration is the depth of the standard cone penetration into the grease layerwithin 5 seconds at the temperature 25 °Ñ after 60 double strokes.

NLGI Class Workedpenetration, 0,1 mm

Body Application

000 445–47500 400–4300 355–3851 310–3402 265–2953 220–2504 175–2055 130–1606 85–115

Liquid

Soft

Solid

Centralizedlubricating system,gear lubrication

Plain bearings,roller bearings, pumps

Sealing lubricants,locking lubricants

PRODUCT NAME COMPOSITION APPLICATION

AQUAFLEX EP 1-180Mineral oil / calcium sulfonate soap

Waterproof high-temperature grease with high load carryingcapacity for centralized lubrication systems.







PIPEFLEX 111 LTMineral oil / lithium soap /Pb / Zn / Cu / graphite

Waterproof low-temperature grease with high anticorrosionproperties, resistant to H2S and CO2.

PIPEFLEX 112 CMineral oil / lithium soap /Pb / Zn / Cu / graphite

Waterproof low-temperature grease with high anticorrosionand sealing properties.

PIPEFLEX 122 SMineral oil / lithium andaluminium soap / Cu / PTFE

Waterproof low-temperature grease with high anticorrosion,sealing and anti-oxidant properties suitable for highpressure operations.

PIPEFLEX 131 HTMineral oil / lithium soap/graphite/ PTFE

Environmentally friendly / waterproof low-temperature greasewith high anticorrosion and sealing properties.

PIPEFLEX 141 EGMineral oil / lithium soap /Zn / Cu / graphite

Waterproof low-temperature grease with high anticorrosion,sealing and antioxidant properties.

PIPEFLEX 141 CMineral oil / lithium andaluminium soap / Zn / Cu /graphite

Waterproof low-temperature grease with high anticorrosion,sealing and anti-oxidant properties.

PIPEFLEX 223 TFMineral oil / calcium soap /fluoroplastic

Waterproof grease with high anticorrosion properties.

POLYFLEX PU 1-460 Mineral oil / polyureaSpecial high-temperature grease based on polyureafor ultrahigh protection.

POLYFLEX EP 00-160 Mineral oil / lithium soap General purpose gearbox grease with protection from shock loads.

POLYFLEX EP 2-220 LCMineral oil / lithiumand calcium soap

General purpose grease with EP additives, used in highhumidity conditions.

STEELFLEX 1-240 Mineral oil / polyurea Special high-temperature grease for centralizedlubrication systems.

THERMOFLEX EP 1-1500 HDMineral oil / lithium complexsoap / MoS2

Grease for slow-speed heavy loaded bearings.

THERMOFLEX EP 1-180Mineral oil / lithiumcomplex soap

General-purpose high-temperature water-resistant greasewith high adhesion properties.

THERMOFLEX EP 1-460Mineral oil / lithiumcomplex soap

High-temperature complex lithium grease for centralized systemswith high load carrying capacity.

THERMOFLEX EP 2-180 HDMineral oil / lithium complexsoap / MoS2

High-temperature grease for work at boundary friction.

CARBOFLEX OG 0-680 HDMineral oil / aluminumcomplex soap / graphite

Special semiliquid lubricant for open gears, applied by spraying.High adhesion and water-resistance.

GLOSSARYAdhesion — bonding of the surfaces of dissimilar materials, stickness.

Boundary friction — a mode arising in case when friction surfaces are separated by a thin layer of lubricant (less than 0.1 µm), not exceeding the height of the surface microroughness (unevenness). Causes to high wear.

Operating temperature range — the range of temperatures in which the grease meets technical requirements and an interval is maintained between the lubricant batches supply.

Tribology — a branch of physics dealing with research and description of the contact interaction of solid deformable bodies at their relative displacement. The subject matter of tribological researches is the processes of friction, wear and lubrication. The main tribological factors for lubricating greases are welding load, scar diameter and wear index. The tests are carried according to GOST 9490-75, DIN 51350/4, ASTM D 2266, ASTM D 2596, ISO 20623.

Welding load — the minimum load at which the welding or conventional welding of the surfaces takes place (the torque on spindle exceeds the setting in GOST 9490-75). It characterizes the limit efficiency of the grease.

Wear index — dimensionless quantity which shows the ability of the lubricant to prevent the load wear (heavy wear caused by microwelding of the surfaces).

Scar diameter — the diameter of the wear scar after testing, measured in millimeters.

Solid fillers — solid materials which have the low friction coefficient. They are added into grease to reduce friction and wear, to prevent load wear, cold welding and fretting corrosion.

Base oil — dispersion media of different viscosities for manufacturing of greases

NLGI — National Lubricating Grease Institute; American National Institute of Greases.

DIN — Deutches Institut fur Norming e.V.; German Standards Institute.

ASTM – American Society for Testing and Materials.

INTESMO LLC Innovative Greases Technologies

Tel/fax: +7 (8442) 55-60-90 / 96-35-01e-mail: [email protected]

www.lukoil-masla.ru

Documents

greases for metallurgical industry - ЛУКОЙЛ · PDF fileGREASE CLASSIFICATION ACCORDING TO DIN 51 502 The lubricant is assigned a code, which reflects the composition, field of