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Oil Sands mining presents unique challenges when it comes to lubrication. With intense working conditions, severe temperatures, unpredictable weather and unfavourable terrain, there is a constant need for the industry to go beyond today’s standards to protect the equipment that keeps operations alive. One company leading the charge in evolving protection is Petro-Canada Lubricants.
Facing expensive equipment wear
In early 2010, Petro-Canada Lubricants, a division of Suncor Energy was made aware of a mechanical issue with the hoist gear and pinions on electric-powered mining shovels operating in Western Canada. The gearing on these shovels was wearing out prematurely, requiring the early replacement of the hoist bull gears. This resulted in expensive replacement part costs and downtime for the shovel operator. After several visits to mining customers by Petro-Canada Lubricants Technical Services and R&D personnel, as well as consultation with an independent gear expert, it was decided that a new high viscosity/high performance lubricant for this application could address this issue.
Mining new solutions
The grease development team at the Petro-Canada Lubricants Research and Development facility in Mississauga, Ontario was assigned to develop this new product. Work first concentrated on developing a new, partially synthetic high viscosity base fluid to meet the requirements of AGMA 9005-E02, calling for a minimum viscosity of 6120 centistokes at 40 °C and 219 centistokes at 100 °C. This base fluid was combined with a suitable grease thickener, and fortified with a unique combination of specialized additives to achieve the desired level of performance. In light of the issues realized in the field, special emphasis was placed on improving extreme pressure and anti-wear properties. Various formulations were produced and tested in the laboratory to confirm that the necessary level of performance was attained.
After development was complete and the new product had been manufactured for the first time, the Petro-Canada Lubricants Research and Development group worked together with Technical Services and Sales representatives in the field to oversee the initial trial of the new product (Petro-Canada VULTREX™ OGL Heavy 6200) at a mining customer. Modifications were made to the shovel’s grease delivery system as directed by Petro-Canada’s shovel technical expert, and then the new product was applied for the first time.
Advanced performance results
The results of the initial trial were excellent, with the new product demonstrating the necessary performance on the hoist gear and pinions over the long term. Compared to the previous product that was used in this application, Petro-Canada VULTREX OGL Heavy 6200 showed improved adhesion to the gear face, resulting in less lubricant fling off from the gear and pinions. This resulted in a thicker, tenacious, plated lubricant film across the entire loaded side of the hoist gear. Another benefit of the conversion was reduced lubricant consumption, and less lubricant buildup under the hoist gear cavity. Based on the performance at the initial trial site, Petro-Canada VULTREX OGL Heavy 6200 was rolled out to similar equipment at many mine sites in Canada, where it has worked effectively under a wide range of operating conditions.
As a result of this co-operative development effort between Petro-Canada Lubricants and a mine in Western Canada, Petro-Canada Lubricants now has a superior open gear lubricant for the hoist gear and pinions on electric mining shovels. It is also suitable for use as an open gear lubricant for all requirements on mining shovels in warmer climates.
