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Marine Introduction Wire Rope Lubrication Salt Water Resistant Grease for mechanical components Open Gear Lubrication Bearing Lubrication Chain Lubrication Biodegradable Lubricants Introduction: In the Marine industry, machines and equipment are often exposed to extreme working conditions. Environmental conditions such as salt water, humidity, dust and high temperature variations, as well as high shock loads and vibrations have to be managed. Frequent component replacement, machine downtime and possible production or operational losses represent an enormous cost factor and since redundant systems are in general not available, the selected lubricant is of major importance. Therefore both the reduction of friction, wear and corrosion as well as long machine life and reliability is required. Based upon years of experience, RS Clare has developed a special range of high performance lubricants for use in these severe conditions. The range of lubricants includes: The use of CLARE high performance lubricants offers: • Proven product performance. • Full technical back up by qualified personnel. • Site survey of lubricant requirements. • Regular reports on product performance. • On site analysis of products. • Laboratory sampling of products during lubrication cycling. • Increased product reliability to assist in achieving maximum equipment utilisation. • Assistance to control lubricant expenditure by extending lubricant life. WIRE ROPE LUBRICATION Hoist rope, un-lubricated and exhibiting severe corrosion Wire ropes working in these industrial environments often operate in severe service conditions. Wire ropes are a fundamental part of many types of plant and equipment. Downtime due to frequent replacement is expensive and can restrict production rates. The use of high performance lubricants specifically designed for the application of wire ropes rope dressings is extremely important. A wire rope lubricant must be able to penetrate completely to the core of the rope and then remain within the rope during service without dripping off or flowing out of the rope. The lubricant must provide complete protection against corrosion and wear and thus help to achieve maximum service life of the wire rope. Un-lubricated wire ropes corrode very quickly when working in marine environments and the frictional conditions between dynamic ropes and the pulley sheaves are such that degradation of the rope due to wear also limits working life. Conventional lubricants, such as bitumen based lubricants that simply coat the surface of the wire rope without penetration to the core, offer only limited corrosion protection. These lubricants form a film on the rope surface that salt water vapour can penetrate and then become encapsulated within the rope. Temperature changes cause condensation and corrosion actually begins from within the wire rope. These conditions are extremely hazardous as a rope may exhibit no corrosion externally although the core may be severely corroded. ‘CLAREGUARD GRL’  HIGH PERFORMANCE WIRE ROPE LUBRICANT CLAREGUARD GRL applied to the trolley rope on a Quayside Container Handling Crane. CLAREGUARD GRL is a thixotropic grease, specially developed for use only on wire ropes. Thixotropic means that the grease consistency reduces (becomes softer) when the lubricant is worked or sheared. The unique formulation provides excellent penetration properties whilst ensuring minimum fling off after application, either by manual or automatic application methods. Pressure application systems, such as the Masto Lubricator, force the lubricant into the wire rope under positive pressure. This method provides a very effective means of application ensuring the lubricant reaches the core of the rope in a single application and can also increase the time period before relubrication is required. The following photo demonstrates the thixotropic characteristics of GRL. The lubricant must be sheared or stirred before application, this reduces the consistency of GRL to semi fluid, allowing ease of application and full penetration. After GRL has been applied, the consistency increases and ensures that GRL remains within the wire rope, minimising fling off. When CLAREGUARD GRL is applied using a pressure application system, such as the Masto Lubricator, the lubricant is sheared as it is driven through the air operated pump. ‘WATERGUARD’ SALT WATER RESISTANT GREASE FOR WIRE ROPES AND OTHER MECHANICAL COMPONENTS A wire rope sample before and after the application of Waterguard WATERGUARD is recommended for the lubrication of the following components subjected to salt water corrosion: • Anchor and Mooring winch equipment. • Open Gears – low to moderate load. • Roller fairlead bearings • Levers, spindles and turnbuckles • Plain and rolling element bearings operating under moderate to high load. • ‘Grease filled’ CPP variable pitch propeller hubs. The following photographs show severely corroded equipment. WATERGUARD is a salt water resistant grease suitable for the lubrication of wire ropes. It is used to provide maximum corrosion protection to ropes operating in constant or intermittent sub sea conditions, for example vessel tow ropes and mooring ropes. WATERGUARD is also suitable for other wire rope applications. It is not a thixotropic grease and in order to ensure complete penetration, it should always be applied to the wire rope using a pressure application system. WATERGUARD exceeds the requirements of NATO G460 and Def Standard 91/34 XG286. By combining dual metallic thickening soaps, Waterguard provides enhanced water resistance properties and an increased upper working temperature. The soap is supplemented by the latest ‘state of the art’ structure modifying additive. The new additive technology is a structure modifier that chemically reacts with the grease thickener and becomes an integral part of the grease soap. This provides superior wash off resistance in applications subjected to high levels of direct and indirect water spray or the washing effect of heavy seas. The product also contains special additives that provide excellent resistance to salt water corrosion. The grease can be pumped easily at lower temperatures, has excellent adhesion to metal surfaces and is mechanically stable. The incorporation of an extreme pressure additive gives a high Timken OK load. Example of application of WATERGUARD on turnbuckle threads: Thread of a turnbuckle, lubricated with Waterguard, after 6 weeks of service without relubrication. No corrosion visible and good metallic condition of the thread. The same turnbuckle thread after 16 weeks without relubrication, remaining in excellent condition. The photo above shows turnbuckle threads, lubricated with conventional grease, suffering from heavy corrosion. OPEN GEAR LUBRICATION The photographs show OPEN GEAR 2000 applied to open gears and a roller swing rack. The grease provides a high strength, adhesive lubricating film on the metal surfaces, thus protecting the tooth flanks and other components from excessive wear. The tooth flanks of open gears are exposed to wear under severe working and environmental conditions. Reliable wear protection with simultaneous low lubricant consumption can only be guaranteed by the use of lubricants with high performance extreme pressure / anti wear (EP / AW) additive systems. Dirt and dust must not readily adhere to the lubricant applied to the gears, whilst the lubricant must also resist water wash off. OPEN GEAR 2000 is based upon a high viscosity base fluid, a highly water resistant inorganic thickener and contains a combined extreme pressure and anti wear additive system. It is designed to achieve a semi dry lubricant film thus minimising contaminant attraction, even in the most arduous conditions. The photograph shows a slew ring, lubricated automatically with GA open gear grease, after 9000 hours operation. The visible tooth flanks are in excellent condition. The BERULIT GA 2500 open gear grease is based upon a high viscosity semi synthetic base fluid and a temperature and water resistant complex soap thickener. It contains specially selected additives and extra pure solid lubricant in a high concentration. GA 2500 is a semi fluid greases designed for manual application or through an automatic spray system. BEARING LUBRICATION Transmission shaft bearings lubricated with BRB LEM grease. High specific loads as well as severe operating conditions require specially developed lubricating greases for the lubrication of rolling element and plain bearings. Besides very good wear protection, these lubricants must also guarantee high worked or mechanical stability and corrosion protection. Such bearings often operate at slow speed and under high and shock loads. Such applications require a grease with a viscous base fluid and solid lubricants in order to avoid breakdown of the lubricating film between the rolling element and raceway. Bearings operating at higher rotational speeds and under low to moderate loads require a grease with a lower viscosity base oil and corresponding additives to ensure complete wear protection. CLARETECH bearing greases have been specially designed for a range of bearing applications: HIGH LOAD is a soap thickened grease containing extreme pressure additives and high load solids. It incorporates a blend of mineral and synthetic oils to enhance the operating temperature and thermal stability. The grease is inhibited against oxidation and corrosion. It has excellent mechanical stability enabling it to withstand breakdown in structure. The high viscosity base oil provides an integral lubricating film that resists breakdown under high loads, ensuring effective lubrication in all conditions. Suitable for low to moderate speed, plain and anti friction bearings. BRB LEM is a soap thickened grease with extreme pressure (EP) and anti wear additives. It is suitable for anti friction bearings operating at moderate to high speed. LC HT is a complex soap thickened grease with extreme pressure (EP) additives. This grease has an increased drop point providing effective lubrication at bearing operating temperatures up to 170°C. CHAIN LUBRICATION CLARETECH Chain Lubricants are designed to provide long service life, high load bearing capability, good adhesion properties and effective penetration into the pin and bush components. CLARETECH chain lubricants may be applied both manually or by means of a drip feeder or automatic spray system. MOLY OIL 30 is a specially formulated fluid based lubricant containing a solid lubricants for enhanced load bearing capability. It provides effective lubrication up to temperatures of 170°C with excellent adherence and minimum pick up of contaminants. P80 CL is a high viscosity fluid based chain lubricant containing a solvent carrier and solid lubricants. It provides maximum adherence and load protection in high speed / high load chain applications such as power transmissions at temperatures up to 180°C. BIODEGRADABLE LUBRICANTS The majority of lubricating oils and greases are based on refined mineral oils. Although crude oil is a naturally occurring substance, once removed from the earth and processed it exists in such a form that cannot be broken down by the environment. If mineral oil based products enter the environment, their inability to be broken down or absorbed by the environment means that they can be classed as a polluting substance. A full range of biodegradable lubricating oils and greases, based on synthetic and vegetable oils, are available. The product range includes wire rope lubricants, open gear greases, bearing greases, chain lubricants, enclosed gear oils, hydraulic fluids and compressor oils. LUBRICATING GREASE: SPECIFICATION AND APPLICATION GUIDE PRODUCT APPLICATION NLGI GRADE TEMPERATURE RANGE CLAREGUARD GRL Wire Ropes 1.5 -20°C to +80°C WATERGUARD  Wire Ropes / Bearings / Gears 2 -25°C to +120°C HIGH LOAD Bearings – high load / slow – medium speed 1 & 2 -15°C to +120°C BRB LEM Bearings – medium load / medium – high speed 2 -20°C to +120°C LC HT Bearings – high temp / medium to high speed 2 -20°C to +170°C OPEN GEAR 2000 Open Gears – dry lubrication film 2 -15°C to +170°C BERULIT GA2500 Open Gears – wet lubrication film 00 -10°C to +180°C LUBRICATING OIL: SPECIFICATION AND APPLICATION GUIDE PRODUCT APPLICATION ISO VISCOSITY TEMPERATURE RANGE MOLY OIL 30 Chains – standard use 30 -20°C to +170°C P80 CL Chains – high speed 220 -15°C to +180°C