Shell Tactic Emv Tchnical Guide
Shell Tactic Emv Tchnical Guide
Shell Tactic Emv Tchnical Guide
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.
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Shell Tactic EMV Lubricators
AN Introduction to Shell Tactic EMV Lubrication Programs
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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.
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
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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.
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Contamination Prevention Strategies
Bearings operating in industries such Different bearing configurations and operating environments
lead to different re-lubrication requirements and therefore
as minerals processing and mining
different Shell Tactic EMV configurations. Listed below are
are inevitably subjected to sources of three of the commonly accepted methods to help reduce
contamination by solid particulates contamination of rolling element bearings with taconite or
and moisture. If these contaminants labyrinth type seals.
are allowed to enter bearings via
1. Where the threat of contaminant entry is high and for
poorly maintained seals or poor
larger bearings the use of individual, dedicated Shell Tactic
lubricant handling practices they can EMV lubricators for the bearing re-lubrication point and the
cause accelerated wear and the early seal purge point(s) is most common – refer to the example
onset of fatigue. image opposite.
For solid contaminants, the rate of wear increases as 2. For smaller sized bearings running at relatively low
the size, concentration and hardness of the contaminants speeds the application of a single lubricator to the bearing
increases. Smaller particles lead to abrasive wear, while re-lubrication point only, set to dispense at an elevated
larger particles can cause indentations to bearing raceways rate, can provide sufficient fresh grease for bearing re-
which can then become initiation points for fatigue wear. lubrication and seal purging.
Shell Tactic EMV lubrication programs use greasing 3. As an alternative strategy manual and automated
practices to help prevent the introduction of contaminants. lubrication programs can be combined by utilising Shell
Consequently there can be a long term financial return Tactic EMV to help achieve a constant purge of fresh
because equipment experiences a longer bearing service grease through seals while maintaining periodic manual
life and reduced downtime. lubrication for the bearing point re-lubrication.
The image below demonstrates the grease entry point and seal The photograph below shows the result of a successfully
purge point for a typical taconite seal arrangement. Regular purged seal using Shell Tactic EMV. The ring of grease
lubrication of this point creates a positive purge of grease which around the exit point of the taconite seal provides evidence
passes through the seal and exits the bearing housing, thereby that while the grease is exiting the bearing housing,
preventing the entry of contaminants. ingress of contaminants is prevented.
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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.
Here are 3 ways to HELP improve workplace safety and save time:
Maintenance Shell Tactic EMV Solution Assessment criteria for
Challenge improvements
Access to lubrication Remote mounting of Shell Tactic EMV lubricators Efficiency Gains:
points located behind at safe to access locations makes inspection and ■
Time is liberated from shutdowns by servicing
safety cages or guards servicing possible while equipment is operating. lubricators while equipment is operating.
■ T ime is saved by not having to complete
isolations to access lubricators.
This helps to remove reliance on valuable time
during maintenance shuts which would otherwise ■ T ime is saved by eliminating the need to remove
be required to access such points. 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
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and guards.
Access to lubrication Shell Tactic EMV lubricators can be used to Efficiency Gains:
points located at heights lubricate points which would otherwise demand ■ Time is saved by reducing the frequency of
or in confined spaces more frequent working at heights and confined demand to gain working at heights or confined
space entry. space permits and access.
■ 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.
Minimisation of repetitive Converting manual greasing tasks to automated Efficiency Gains:
manual tasks grease delivery using Shell Tactic EMV will help ■ Automated delivery of grease via a mechanised
to minimise the highly repetitious use of manual system in place of manually applied strokes of a
grease guns. In addition it can save time by grease gun.
automating an otherwise laborious manual task.
Safety Improvements:
■Reduced manual work load and reduced
physical demand.
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SHELL TACTIC EMV
PRODUCT OVERVIEW
Dispensing rates From 0.3 to 8.2cm³ per day, depending on the time settings and the canister size.
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.
*Factors such as low ambient temperatures or difficult to pump grease types may restrict the maximum recommended grease line to less than 5 metres.
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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
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
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SHELL TACTIC EMV
REMOTE MOUNTING SYSTEMS
SIMPLE TO INSTALL USING BASIC HAND TOOLS
C. Elbows
G
Elbow fittings are full bore with
¼” BSP threads.
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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.
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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.
1
3
2
10
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SK130 (with 30mm beam clamps) SK230 (with 30mm beam clamps) 8
SK165 (with 65mm beam clamps) SK265 (with 65mm beam clamps) 11 6
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Bill of Materials
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
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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
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Bill of Materials
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.
1
2
8
9
SK1CH SK2CH
4
6
10 5
7
Bill of Materials
4
3
2
1
9
10
5 8
SK1CHC SK2CHC
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6
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Bill of Materials
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:
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
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Pump lubrication solutions
For pump lubrication the following factors are generally relevant to the development of
the lubrication solution:
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 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
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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:
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
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Fan lubrication solutions
For fan bearing lubrication the following factors are generally relevant to the
development of the lubrication solution:
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
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