A technical guide

to Shell Tactic EMV

 TABLE OF CONTENTS
SECTION PAGES
Introduction 3

Benefits of Short Re-Lubrication Intervals 5

Contamination Prevention Strategies 6

Workplace Safety and Efficiency Gains 9

Shell Tactic EMV Product Overview 10

Remote Installation Guidelines 12

Shell Tactic EMV Remote Installation Kits 14

Electric Motor Lubrication Solutions 16

Slurry Pump Lubrication Solutions 17

Conveyor Pulley Lubrication Solutions 18

Fan Lubrication Solutions 19

Contact Shell 20

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.

2
Shell Tactic EMV Lubricators
AN Introduction to Shell Tactic EMV Lubrication Programs

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.

3
4
Benefits of Short
Re-Lubrication Intervals
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.

Manual greasing Advantages of automated lubrication

The risks associated with over-lubrication and lubricant starvation
Over-lubrication varies based on a range of factors such as bearing size, bearing
type, speed, temperature, vibration and conditions associated
Volume of grease

with the operating environment. Automated delivery systems

Adequate
inject small amounts of grease at short time intervals which helps
lubrication 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
Under-lubrication
or over-lubrication from occurring while reducing the workload
Manual greasing Manual greasing
demand on maintenance personnel.
Time

Irregular greasing intervals

Shell Tactic EMV greasing How the Shell Tactic EMV lubricator works
The Shell Tactic EMV dispenses grease in small amounts at short
Over-lubrication time intervals. The time interval between each injection of grease
varies depending on the time settings of each lubricator. The shortest
Volume of grease

time interval between injections is 1 hour and 30 minutes while the

longest time interval is 18 hours and 12 minutes.
Adequate
lubrication (Refer to page 11 for further information).

Under-lubrication Lubricator time settings are selected based on factors such as

Routine inspections bearing size, bearing type, speed, temperature, vibration and
conditions associated with the operating environment. These
Time
factors, along with site specific requirements relating to equipment
Very regular greasing intervals access opportunities and time based maintenance cycles are used
to establish practical programs for the management of groups of
The graphical representation is for illustration purposes only.
individual lubricators.

5
 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.

6
Contamination Prevention Strategies
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.
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.
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.
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.
7
8
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
Access to lubrication
points located behind
safety cages or guards
Access to lubrication
points located at heights
or in confined spaces
Minimisation of repetitive
manual tasks
Shell Tactic EMV Solution
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.
Shell Tactic EMV lubricators can be used to
lubricate points which would otherwise demand
more frequent working at heights and confined
space entry.  space permits and access.
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.
Assessment criteria for
improvements
Efficiency Gains:
■ 
Time is liberated from shutdowns by servicing
lubricators while equipment is operating.
■ T ime is saved by not having to complete
isolations to access lubricators.
■ T ime 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.
■  limination of the manual handling of cages
E
and guards.
Efficiency Gains:
■ Time is saved by reducing the frequency of
demand to gain working at heights or confined
■ R educed requirement for equipment such as
elevated work platforms.
■ R educed demand on personnel and equipment
associated with confined space entry.
Safety Improvements:
■ Reduced risks associated with working at
heights and confined space entry by reducing
the frequency of the activity.
Efficiency Gains:
■ Automated delivery of grease via a mechanised
system in place of manually applied strokes of a
grease gun.
Safety Improvements:
■Reduced manual work load and reduced
physical demand.

9
SHELL TACTIC EMV
PRODUCT OVERVIEW

General specification & grease types

Available products Shell Tactic EMV drive unit
Shell Tactic EMV Gadus S5 T100 2 110gm
Shell Tactic EMV Gadus S5 T100 2 225gm
Shell Tactic EMV Gadus S3 V460D 2 225gm
Shell Tactic EMV Gadus S3 T220 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

Accessories and thread type
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
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.

*Factors such as low ambient temperatures or difficult to pump grease types may restrict the maximum recommended grease line to less than 5 metres.

Components & construction

Reusable Parts
LCD-display
The Shell Tactic EMV drive system and
with push button Protection cap
push-on protection cap are reusable.
The system automatically performs a
Shell Tactic EMV self test when each new battery set
Gear motor
Shell Tactic EMV drive unit reusable
is inserted. The drive should also be
Battery pack
LCD-display with push button inspected for physical damage before
(Discharge period and function) each new grease canister is used.
Piston
Single Use Parts
Shell Tactic EMV
Battery pack Shell Tactic EMV grease canisters are
factory filled in a controlled environment
to help ensure against the inclusion
Shell Tactic EMV of contaminants. A new battery set is
lubricant canister
supplied with each grease canister and
should be exchanged when a fresh
grease canister is applied.

10
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.

Setting,
1 2 3 4 5 6 7 8 9 10 11 12
months

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

cm3
Canister Size
per 4.0 2.0 1.3 1.0 0.80 0.67 0.57 0.50 0.44 0.40 0.36 0.33
120cm3 day
Hrs : Mins

10h : 36m

12h : 12m

13h : 42m

15h : 12m

16h : 42m

18h : 12m
Time
1h : 30m

3h : 00m

4h : 36m

6h : 06m

7h : 36m

9h : 06m

between
cycles 0.26cm3 0.53cm3
per per
cycle cycle

Status Screen Lights Action

Dwell Shows the TIME Single GREEN flash Inspect lubricator. Mark and date the position of the
Lubricator is between and VOLUME every 7 seconds piston to confirm inspection.
dispensing cycles settings

Run Single GREEN flash Inspect lubricator. Mark and date the position of the
Lubricator is dispensing every 1 second piston to confirm inspection.
grease

Single GREEN flash The purge feature has been activated by holding the SET
Purge every 1 second button for 10 seconds.
Grease is being dispensed

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

Overload Double RED flash Manually purge the point to clear blockage.
Excessive resistance to every 7 seconds Investigate possible causes and rectify.
grease flow

Low Battery Double RED flash Replace battery set.

Battery set is damaged every 7 seconds
or depleted

11
 SHELL TACTIC EMV
REMOTE MOUNTING SYSTEMS
SIMPLE TO INSTALL USING BASIC HAND TOOLS

A. Full length protection covers A D. Stainless steel bracket

Covers to help protect lubricators
There are two main categories
from solid and liquid contaminants.
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
D steel assembly screws.
E
B. Manual purge point

Used for convenient

additions of supplementary F. Support flanges
grease, line purging and grease F
blockage clearing. Provide support to lubricators
to help prevent damage from
impacts and vibration.

G. Heavy duty hose

B
Supplied with 3 8” internal
diameter and easy to use push-
lock type swivel hose ends.

C. Elbows
G
Elbow fittings are full bore with
¼” BSP threads.

12
Shell Tactic EMV Systems Remote Installation Guidelines
For maximum pressure to the lubrication point, direct mounting is Where remote installation of the Shell Tactic EMV is planned the
preferred. However, this will not be practical in all circumstances. In following guidelines are to be followed:
many cases remote mounting is required to help provide safe and
■ Identify a safe point of access to mount stainless steel bracket
convenient access or to prevent lubricator damage. Therefore, remote
installations are recommended under the following circumstances: ■ Use grease line with 3 8” internal diameter
■ Restrict grease line length to 5 metres*
1. W
 hen protective guards or safety cages have to be removed to
access the lubrication point. ■ Use only full bore hose ends and elbow fittings**
■ Route grease lines under or around cages, not through
2. W
 here it is difficult or unsafe to access the lubrication point while
equipment is running. ■ Prime grease lines and fittings with grease
■ Test the grease delivery path to ensure bearing and seal points
3. W
 hen the bearing is subject to high vibration or temperature can receive grease freely
which may damage the lubricator.
■ Protect lubricators with full length covers to suit operating
4. W
 hen the lubrication point is exposed to excessive amounts environment
of water or impact from solid material. ■ Include manual purge points
■ Protect grease lines from damage using spiral wrap

*Factors such as low ambient temperatures or difficult to pump grease types may restrict the maximum recommended grease line to less
than 5 metres. **Refer to images above.

13
 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.

Standard Duty Beam Clamp Mount Installation Kits

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.
Example Installation Kit Contents – SK230

1
3
2
10
9

SK130 (with 30mm beam clamps) SK230 (with 30mm beam clamps) 8

SK165 (with 65mm beam clamps) SK265 (with 65mm beam clamps) 11 6
7

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 1 8” BSP M

SK330 (with 30mm beam clamps) SK430 (with 30mm beam clamps) 5 2 x Manual purge kit 11 0.5m spiral wrap
SK365 (with 65mm beam clamps) SK465 (with 65mm beam clamps) 6 4m grease line 3 ” internal diameter
8

Heavy Duty Beam Clamp Mount Installation Kits

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.

Example Installation Kit Contents – SK230C

1 3
2
9
10

5
SK130C (with 30mm beam clamps) SK230C (with 30mm beam clamps)
SK165C (with 65mm beam clamps) SK265C (with 65mm beam clamps) 11 7
6
8

Bill of Materials

1 1 x 2-point C-section SS bracket 7 4m grease line 3 ” internal diameter

8

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 1 8” BSP M

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

SK330C (with 30mm beam clamps) SK430C (with 30mm beam clamps) 5 2 x Manual purge kit 11 0.5m spiral wrap
SK365C (with 65mm beam clamps) SK465C (with 65mm beam clamps) 6 4 x Push lock hose tails ¼” BSP M
Standard Duty Cage Mount Installation Kits
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.

Example Installation Kit Contents – SK2CH

1
2

8
9

SK1CH SK2CH
4

6
10 5
7

Bill of Materials

1 1 x 2-point stainless steel bracket 6 4m grease line 3

” internal diameter
8

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

SK3CH SK4CH 4 2 x Manual purge kit 9 2 x reducer ¼” BSP F to 1 8” BSP M

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

Heavy Duty Cage Mount Installation Kits

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.

Example Installation Kit Contents – SK2CHC

4
3

2
1

9
10

5 8
SK1CHC SK2CHC
7
6

11

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

3 2 x support flange ¼” BSP 9 2 x reducer ¼” BSP F to 1 8” BSP M

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

SK3CHC SK4CHC 5 2 x Manual purge kit 11 0.5m spiral wrap

6 4m grease line 3
8 ” internal diameter
 Electric motor lubrication solutions
For electric motor lubrication the following factors are generally relevant to the
development of the lubrication solution:

Lubrication Assessment Criteria

n M
 otor manufacturer’s recommendations n Bearing types

n M
 otor speed n Safe access requirements

n G
 rease trap / escape port design, access and condition n Desired service schedule (of lubricators)

n O
 perating conditions n Duty cycle

n C
 haracteristics of lubricant n Motor orientation (vertical or horizontal)

Installation examples

Application Electric Motor

Lubricator Shell Tactic EMV 110 gram
Installation Kit Direct

Application Electric Motor Application Electric Motor

Lubricator Shell Tactic EMV 225 gram Lubricator Shell Tactic EMV 110 gram
Installation Kit Direct Installation Kit SK230

16
Pump lubrication solutions
For pump lubrication the following factors are generally relevant to the development of
the lubrication solution:

Lubrication Assessment Criteria

n P
 ump manufacturer’s recommendations n Bearing types and grease entry points

n S
 eal types n Safe access requirements

n W
 ash down procedures n Desired service schedule (of lubricators)

n O
 perating conditions n Duty cycle

n C
 haracteristics of lubricant n Typical bearing operating temperatures

Installation examples

Application Pump bearings Application Slurry pump labyrinth seals

Lubricator Shell Tactic EMV 225 gram Lubricator Shell Tactic EMV 225 gram
Installation Kit Direct Installation Kit SK265C

Application Slurry pump bearings & labyrinth seals Application Slurry pump labyrinth seals
Lubricator Shell Tactic EMV 225 gram Lubricator Shell Tactic EMV 225 gram
Installation Kit 2 x SK265C Installation Kit SK265C

17
 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:

Lubrication Assessment Criteria

n B
 earing types and speeds n Location of grease entry points on bearing housings

n O
 perating conditions n Seal types

n S
 afe access requirements n Desired service schedule (of lubricators)

n G
 rease performance characteristics

Installation examples

Application Conveyor pulley tail bearings Application Head pulley bearing and seal
Lubricator Shell Tactic EMV 225 gram Lubricator Shell Tactic EMV 225 gram
Installation Kit SK1CH Installation Kit SK230

Application Drive pulley bearing and seals Application Bend pulley bearing and seal
Lubricator Shell Tactic EMV 225 gram Lubricator Shell Tactic EMV 225 gram
Installation Kit SK3CH Installation Kit SK2CH

18
Fan lubrication solutions
For fan bearing lubrication the following factors are generally relevant to the
development of the lubrication solution:

Lubrication Assessment Criteria

n B
 earing types and speeds n Location of grease entry points on bearing housings

n O
 perating conditions n Seal types

n S
 afe access requirements n Desired service schedule (of lubricators)

n G
 rease performance characteristics n Bearing temperatures

n G
 rease base oil viscosity

Installation examples

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

19
For more information, please contact:

The Shell Company of Australia Limited

(ABN 46 004 610 459)
8 Redfern Rd, Hawthorn East, Victoria 3123
Emergency phone number (24 hours) 1800 651 818
Shell Technical Helpdesk 1300 134 205
Shell Customer Service 13 16 18
www.shell.com.au