INDUSTRIAL GEAR OILS

FUNCTION OF GEARS
ALMOST ALL MODERN MACHINERY MAKE
SOME USE OF GEARS AS A MEDIUM FOR

TRANSMITTING POWER WITH

CHANGE IN SPEED
CHANGE IN DIRECTION
CHANGE IN LOAD / TORQUE

PRIME MOVER

GEARS

OUTPUT

TYPES OF GEARS

SPUR GEARS
BEVEL GEARS
HELICAL AND HERRING BONE
WORM GEARS
HYPOID GEARS

REASONS FOR STRESS

ON GEAR LUBRICANTS
VELOCITY OF ROLLING / SLIDING GEARS
MESHING TOOTH EXPERIENCE SHOCK LOADS
STRESS ON THE FLANK
HIGH TOOTH FLANK TEMPERATURE

FUNCTIONS
INDUSTRIAL GEAR OILS PERFORM

LUBRICATION TO REDUCE WEAR FRICTION &

PREVENT DISTRESS
HEAT REMOVAL FROM THE HIGH FRICTION
POINTS TO THE SUMP
CUSHIONING AGAINST VIBRATION, SHOCK &
SONIC ENERGY LOSSES
PROTECTION FROM RUST AND OTHER
CORROSION OF THE EQUIPMENT
CLEANING CONTAMINANTS, DEBRIS OR SLUDGE
THE SYSTEM
SHOW INERTNESS TOWARDS ALL NONMETALLIC
PARTS OF THE SYSTEM

EVOLUTION OF INDUSTRIAL GEAR OILS

1930

Pb - naphthenate in naphthenic
base oils

1940

Doping of sulfurised oil in Pb-system for

improving antiscore performance

1950

Chlorinated hydrocarbon & sulfurised fat in

paraffinic base oils

1960

Advent of Sulfur-Phosphorus chemistry,

providing better load carrying ability and
thermal - oxidation stability

MOST ACCEPTED CHEMISTRY TODAY

PROPERTIES OF GEAR OILS

GEAR OILS SHOULD HAVE : SATISFACTORY ADHESION
COMPATIBILITY WITH METALLURGY & RUBBER
COMPONENTS
WATER AND AIR SEPERATION PROPERTY
OXIDATION STABILITY
SURFACES CLEANING PROPERTY
SATISFCATORY FILM STRENGTHS
SHEAR STABILITY
SATISFACTORY VISCOSITY - TEMPERATURE PROPERTY
REASONABLE COST
LONG DRAIN PERIODS

GEAR LUBRICANTS
(THE CRITICAL PROPERTIES)

PHYSICAL PROPERTIES
(i.e. Viscosity - kV )

CHEMICAL PROPERTIES
(i.e. Pour Point, Flash Point , Cu corrosion, S, P etc)

PERFORMANCE PROPERTIES
(i.e.AW / EP, AO, RI etc)

TYPES OF
INDUSTRIAL GEAR OILS
1) BASED ON S-P CHEMISTRY .
IOCL SERVO MESH SP Series ( 68 / 100 / 150 / 220 / 320 /
460 / 680)
2) ENERGY EFFICIENT GEAR OILS.
IOCL SERVO MESH EE Series ( 220 / 320 / 460 / 680 )
3) ANTI - MICRO PITTING GEAR OILS.
IOCL SERVO MESH PLUS Series ( 220 / 320 / 460 / 680 )
4) SYNTHETIC GEAR OILS.
IOCL SERVO SYNGEAR Series ( 68 / 100 / 150 / 220 / 320 /
460 / 680 )

SULPHUR PHOSPHOROUS
CHEMISTRY
INDUSTRIAL GEAR OILS

S - P CHEMISTRY BASED GEAR OILS

Most of todays industrial gear oils are based on S-P CHEMISTRY and meets USS 224
/ AGMA, IS / DAVID BROWN Gear Industries Ltd.. (UK) specs etc.
IOCL SERVO MESH SP Series ( ISO VG 68 / 100 / 150 / 220 / 320 / 460 / 680 etc.)
These are Extreme Pressure type industrial gear oils.
PERFORMANCE BENEFITS:
Have high load carrying ability
Low Foaming tendency
Protect gear tooth metals against Rust & Corrosion.
Ensures excellent wear protection
Ensure long service life - as they have good oxidation & thermal stability
Good Demulsivity
Minimize formation of sludge even at high bulk temperature
APPLICATION :
All Heavy Duty Enclosed Gear Drives with Circulation / Splash Lubrication system Operating under Heavy Load / Shock Load conditions , With Bulk Oil Temperature
of upto 100 deg C.
Can be applied in Gears involving Plain / Roller Bearings / Sliding Surfaces.

ENERGY EFFICIENT
INDUSTRIAL GEAR OILS

BACKGROUND
STEEL INDUSTRY CONTRIBUTION
IN DEVELOPING GEAR OIL SPECIFICATIONS
EXTREME CONDITIONS OF
PRESSURES
OPERATIONS PREVAILING
LOADING
IN STEEL MILL
TEMPERATURE

TREMENDOUS

SEVERE SHOCK
#

HIGH SPEED &

#

CONTAMINATION WITH WATER,

DIRT,
ABRASIVES & MILL SCALE

NECESSITATED
STEEL INDUSTRIES TO DESIGN
# US STEEL
SPECIAL LUBRICANT SPECS .
# BRITISH STEEL Co.
OTHER THAN CONVENTIONAL
# HOESCH STEEL Co,
THUS STEEL INDUSTRY IS ALWAYS
A PIONEER FOR
GERMANY
INTRODUCING IMPROVED LUBRICANTS
TYPE
# NIPPON STEEL,

WHY STEEL INDUSTRY ?

ENERGY CONSUMPTION IN STEEL PRODUCTION
SPECIFIC ENERGY CONSUMPTION GigaCAL/TONNE
IN SIX ENERGY INTENSIVE INDIAN INDUSTRIES

22

ALUMINIUM

CEMENT

3.68CAUSTIC

PAPER

SODA
10.67

STEEL

0.916

FERTILIZER

SOURCE BICP ENERGY AUDIT, INDIA

8.5

13.1

SERVOMESH EE Series
ENERGY EFFICIENT GEAR OIL
Gears actuate machines which in turn exerts tremendous
pressures on the gear tooth
Gears operate under adverse conditions of shock loading, high
speed, high temp. & Contaminations like water, dust, metal scale
etc.
International specifications - USS 224 , AGMA, IPSS etc. Govern
the properties of these oils
There is no stipulation of energy saving potentials in specifications
But IOCL developed a unique grade SERVOMESH EE oil
meeting all above gear oil specs. with proven energy saving
potential - seeing the requirements of the Indian Industry.

SERVOMESH EE
ENERGY SAVER FOR
INDIAN INDUSTRIES

ENERGY SAVING
IN INDUSTRIAL GEAR SYSTEMS
APPROACHES

TO REDUCE THE
VISCOUS DRAG

REDUCING FRICTIONAL
LOSSES IN BOUNDARY
OR MIXED LUBRICATION
REGIMES

FRICTION REDUCERS
BY USING A
OPTIMUM
VISCOSITY OIL

SOLID

SOLUBLE

R1

R2

Boundary Lubrication
h=film thickness;
R=R1+R2(Combined surface roughness)

R1

R2

Mixed Film Lubrication

h=film thickness;
R=R1+R2(Combined surface roughness)

R1

R2

Fluid Film Lubrication

h=film thickness;
R=R1+R2(Combined surface roughness)

ENERGY EFFICIENT GEAR OIL

A new energy efficient formulation
By reducing friction
Meeting all national & international industrial gear oil
specifications with proven energy saving potential
Servomesh EE series (ISO VG 220 / 320 / 460 / 680)
The performance & energy saving potential of Servomesh
EE has been proven in different industry trials
# Steel
# Cement
# Power - NTPC Dadri

SERVOMESH EE Series
ENERGY EFFICIENT GEAR OIL
This is a significant advancement in gear lubrication technology.
It saves energy through reduction in frictional losses - reduces power consumption to the tune of 4% (approx..).
Has outstanding load carrying ability due to superior Extreme pressure property .
Provides smooth running through reduced vibration & noise.
It improves gear efficiency.
It has demonstrated improved thermal stability & oxidation resistance over
the conventional S-P gear oils.
It also extends oil & gear life and Prevents irregular wear - due to superior anti
wear property.
Possess better demulsibility , low foaming tendency & provides excellent rust &
corrosion protection to metal surfaces.
It has lower bulk oil temperature - to the tune of 3 deg C (approx...). - Lower
temperature rise signifying better energy efficiency.
Minimizes formation of sludge & deposits even at high temperatures.
These oils are RECOMMENDED for - all types of Enclosed gear drives , Heavily
loaded bearings - Industrial gears running at High speed / High pressures / Under
impact loads with Circulation / Splash lubrication systems.

ANTI MICROPITTING
INDUSTRIAL GEAR OILS

ANTI - MICROPITTING
GEAR OILS

SHIFT IS TOWARDS HIGHER UNIT LOAD IN THE

GEAR BOXES, WHICH TEND TO RAISE THE TEMPERTURE
#

OPPORTUNITIES
FOR NEW GEAR OIL TECHNOLOGY ALONG WITH :
- IMPROVED THERMAL / OXIDATION STABILITY
- IMPROVED AW / EP PERFORMANCE
- COMPATABILITY WITH GEAR METALLURGY

GEAR DAMAGE DUE TO NEW FORM OF TOOTH

SURFACE WEAR - MICROPITTING

PROBLEMS DUE TO MICROPITTING

MICROPITTING CAN RESULTS IN HIGHER NOISE /

VIBRATIONS IN THE GEARS --> Leading to:
#

LONGER DYNAMIC FORCES

SHORTEN GEAR LIFE

WHAT IS MICROPITTING
MICROPITTING IS :
TYPE

OF SURFACE DAMAGE THAT OCCURS

PREDOMINANTLY IN ROLLING - SLIDING CONTACTS

OF GEAR SURFACES.
CHARATERIZED BY THE PRESENCE OF FINE
SURFACE PITS , SHOWING FRACTURED LOWER
SURFACES
LEADS TO SURFACE WEAR AND SURFACE DAMAGE,
SUCH AS `SCUFFING AND ULTIMATELY TO GEAR
TOOTH FRACTURES

FACTORS - INFLUENING MICROPITTING

SURFACE ROUGHNESS

TANGENTIAL SPEED & LOADS etc.

SPECIFIC FILM THICKNESS

CHEMICAL COMPOSITION OF
LUBRICANT ADDITIVES

COEFFICIENT OF FRICTION

OIL TEMPERATURE

SERVO MESH PLUS SERIES GEAR OILS

(ISO VG 100 / 150 / 220 / 320 / 460 / 680)
MICROPITTING IS ALSO A FUNCTION OF GEAR SURFACE ROUGHNESS
(LOWER BEING BETTER)
BUT TO MAKE LOWER SURFACE ROUGHNESS - GEAR
TOOTH PROFILES -- THE GEAR MAKING COST
GOES UP.
HENCE ROLE OF LUBRICANTS --- TO IMPROVE
MICROPITTING PERFORMANCE AS A MEANS OF
CONTROLLING COST

MICROPITTING RESISTANT TESTS

FZG INSTITUTE - GERMANY HAS DEVELOPED A
MICROPITTING RESISTANT RIG TEST
#

PROGRESSIVE LOADING STAGE

- GEARS ARE DISMOUNTED AFTER 16 hrs - RATED

ENDURANCE STAGE
-

AFTER 6 X 80 hrs - TOOTH FLANKS / DEVIATION i.e.

GEAR PROFILE & TOOTH GEOMATRY ARE OBSERVED

FLENDER AG - GERMANY HAVE ALSO

DEVELOPED THEIR OWN RIG TEST TO ASSESS
MICROPITTING RESISTANCE
#

MICROPITTING RESISTANT TEST - 100 hrs. - TOOTH PROFILE &

GEOMATRY.

SERVOMESH PLUS Series

ANTI MICROPITTING GEAR OIL
This is a significant advancement in gear lubrication technology.
It provides improved protection from Micropitting Failure - leading to extended
component life.
These are advanced Extreme pressure type industrial gear oil
Demonstrate improved thermal stability & improved oxidation resistance
over S-P technology gear oil.
Good demulsibility characteristics & low foaming tendency.
Provides rust & corrosion protection to metal surfaces - extended wear protection
also.
Excellent cleanliness by preventing sludge formation
These oils are recommended for -gear oils which are subject to micro-pitting heavily loaded industrial gear boxes subjected to heavy & shock loads.
Approved by M/s Flender India - Already in Use in ACC LTD.

SYNTHETIC
INDUSTRIAL GEAR OILS

SERVOSYNGEAR Series
SYNTHETIC GEAR OILS
This are industrial gear oils formulated from synthesized hydrocarbon based
fluids combined with suitable additive package.
They meet US Steel 224 specifications
Grades are available in ISO VG - 32 / 46 / 68 / 100 / 150 / 220 / 320 / 460 / 680
PERFORMANCE BENEFITS
Excellent resistance to oxidation & aging
Its use leads to extended component life.
Increased Oil Life
Reduced wear due to high load carrying capacity
Low Maintenance Cost
Excellent viscosity temperature behavior
Wide temperature applications

SERVOSYNGEAR Series
SYNTHETIC GEAR OILS
These oils are recommended for -lubrication of spur / helical / bevel / worm &
hypoid gears which are used in all manufacturing industries.
Successful Trial has been conducted at NTPC - Ramagundam over a period of
18 months in their Cooling Tower Gear Boxes in place of in use Servosystem 320 & Servomesh SP 320 - Huge savings were obtained in terms
of equipment availability / thermal capability & reduction in worm gear
failures.

LUBRICANT TRENDS
IN 21st CENTURY
THIS WILL BE GOVERNED BY FOLLOWING FACTORS:
INDUSTRY SPECIFICATIONS, LONGER DRAIN
INTERVALS
LOWER OIL CONSUMPTION/ FUEL ECONOMY
ENVIRONMENTAL ISSUES,EMISSIONS &LOWER BASE
OIL VOLATILITY
BIODEGRADABILITY, RECYCLABILITY
ENERGY EFFICIENCY

LATEST INDUSTRY TRENDS

(In Summary - For Gear Oils)
ANTI MICRO PITTING GEAR OILS - IOCL HAVE
DEVELOPED :- SERVO MESH PLUS Series
ENERGY EFFICIENCY CHARACTERISTICS
REALIZED THROUGH FRICTION REDUCERS SUCH
AS GRAPHITE, MoS2, SOLUBLE FRICTION
REDUCERS - IOCL HAVE DEVELOPED : - SERVO
MESH EE Series.
USE OF SYNTHETIC BASE MATERIALS FOR
OBTAINING HIGHER THERMAL STABILITY / VERY
LONG DRAIN PERIODS -- IOCL HAVE DEVELOPED
SYNTHETIC GEAR OILS :- SERVO SYNGEAR Series.

THANK YOU