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Introducing the New Shell Omala Range of
Industrial Gear Oils
•
Choosing the right gear oil
•
Key benefits and value
delivery
•
Product performance
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Copyright of Shell International Petroleum Company 2010
June 2010
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Why are Gears Necessary?

Electric Motors (AC) run at specified speeds (3600, 2400, 1800 rpms)

Machines run at speeds normally MUCH less than the electric motors

Gears reduce the speed of the motor to match the machine

The resulting speed reduction increases ―torque‖ which is the Power to do the
work

The increase in torque has to be transmitted through the strength of the 1)
gear teeth, 2) coupling, 3) shafts and 4) bearings

All gears take the input rotational speed and change to ―usable‖ speed and
in the direction of the machine being driven

Sometimes gears are used to ―Increase‖ the speed for compressors or turbomachinery
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Gears – Parallel Shafts
Spur Gears
 Straight cut teeth
 Only a minimal amount of teeth in
contact at any given time
 Can be somewhat noisy
(chattering)
 Can only carry a low level of
loading
Copyright of Shell International Petroleum Company 2010
Planetary Gears
 Sometimes called epicyclic gears
 Involves multiple outer gears (planets)
revolving around a single gear (sun)
 The outer ring will assist in rpm
reduction or increase
 Exhibit higher power densities than
parallel axis gears
 Offered in many gearing combinations
 Downside: generally complex, may be
inaccessible and have high bearing
loads.
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Gears – Parallel Shafts
Helical Gears
 Teeth cut at an angle
 More than one tooth in contact at
any given time
 Thrust loading has to be considered
 Capable of carrying moderate to
high loads
 Not as noisy as spur gears
Copyright of Shell International Petroleum Company 2010
Double Helical Gears
(Herringbone)
 Teeth cut at an angle
 Number of teeth in contact has
increased even more
 Decreases thrust loading as seen
in Helical Gear sets
 Capable of carrying moderate to
high loads
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Gears – Angled Shafts (Change of direction)
Straight Bevel
Gear
 Right angle – Input to output shaft
 Straight cut teeth
 Can be noisy, just like spur gears
 Can only carry a low level of loading
Spiral Bevel Gear
 Right angle – Input to output shaft
 Teeth cut at an angle
 More teeth in contact
 Quieter than straight bevel gears
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Gears – Angled Shafts (Change of direction)
Hypoid Gear
 Right angle – Shaft centerlines off-set
 Teeth cut at an angle but also curved
somewhat
 High degree of sliding
 Can handle a high amount of
loading
 Found in rear axle differentials –
rear driven vehicles
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Worm Gear
 Usually a steel worm and bronze
wheel
 Used for high reductions
 Right angle – Maximum shaft off-set
 Tooth loadings relatively light
 Exclusive sliding action
 Worm can be below or above the
gear
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Gear Oil Functions

No. 1 - Provide Lubrication fluid
film to adequately
separate components (I.e. gear sets and bearings)






Controls friction
Controls wear
Minimize corrosion – Steel, yellow metals, seal materials
Act as cooling medium
Dampen shock loads
Handles contamination – water, dirt, entrained air
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Factors Influencing Lubricant Selection
 Gear type
 Open or closed
 Gear materials and
surface finish
 Worm (High Viscosity)
 Case Hardened or
Through Hardened
gearing
 Hypoid – Boundary
 Operating temperature
 Helical, spur, bevel
 Speed
 Load characteristics
Lubricant selection should always be
based on manufacturers’
recommendations if available
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June 2010
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Gear Oil Properties & Product Types
 Viscosity
 Foaming Tendency
 Oxidation Stability
 Demulsibility
 Adhesiveness
 EP Protection
 Multipurpose Use
 Misting Properties
 Rust / Corrosion Protection
 Compounded
 Low Temperature Flow
 Mineral Oil or Synthetic
 More…
OEMs generally know
what they want!
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June 2010
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Market Trends: Gear Box Design
Gear Box technology is
changing.
Lubricant technology is
changing.
Customer demands and
operational needs are
changing.
Maintenance and
operational techniques are
changing
Copyright of Shell International Petroleum Company 2010
Gear units above all have
the same output torque
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Market Trends: Gear Box Design
 Gear
boxes (and oils) are forced to withstand increasingly
tough operating conditions due to:
 Trend towards more compact units
 Severe operating conditions and temperatures
 Higher performance expectations (downtime unacceptable)
 Extended operating periods before scheduled maintenance
This leads to:
 Increased operating temperatures
 Increased loads and pressures
 Increased exposure to water and other contaminants
All this is in direct contradiction to what the customer
actually wants
Therefore, focus on gear
 Extended gear box life
 Extended oil life
oil is higher than ever!
 Greater gear box efficiency
Copyright of Shell International Petroleum Company 2010
June 2010
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June 2010
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PRESENTATION OVERVIEW
Highlights and features of the new portfolio
Navigating the Shell Omala portfolio of industrial gear oils
Identifying the new products

Understanding the performance hierarchy

Old  New Product Conversion
Products in Detail

Shell Omala S4 GX – Advanced Synthetic Industrial Gear Oil

Shell Omala S4 WE – Advanced Synthetic Gear Oil for Worm Gears

Shell Omala S2 G – Our Leading Industrial Gear Oil
Additional Information and Resources
Copyright of Shell International Petroleum Company 2010
INTRODUCING THE NEW PORTFOLIO - HIGHLIGHTS
Shell Omala: Helping you choose the right oil for your equipment
and business. The new portfolio features:
 Simple
 Easier
 Clear
to understand naming and range structures
to choose
benefits and tiering
 Improved
performance
 Extensive
equipment maker approvals
Building on the legacy of one of the world’s leading brands of industrial
gear oils.
Copyright of Shell International Petroleum Company 2010
June 2010
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1.0
Navigating the Shell Omala Portfolio of Industrial
Gear Oils
Identifying the new products
Understanding the performance hierarchy
Old  New portfolio conversion
Copyright of Shell International Petroleum Company 2010
IDENTIFYING THE NEW PRODUCTS
Developed with our customers in mind: New naming and associated
information designed to help confident product choice
 Tested
with customers
 Unique
suffixes, descriptors and icons to communicate applications
and benefits
 For
example:
Application or
Benefit and application
descriptors
benefit
indicator
Performance level
(tier) indicator,
higher is better
Application icons
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June 2010
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UNDERSTANDING THE SUFFICES AND ICONS
The following suffixes and icons are used in conjunction with the
Shell Omala range of industrial gear oils.
 These
feature on product labels, brochures and other
communications materials
PRODUCT SUFFIX & APPLICATION ICON KEY
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THREE DIMENSIONS OF PERFORMANCE: DEFINING THE
PRODUCT RANGE HIERARCHY
Customers recognise that industrial lubricants such as gear oils can
deliver value to their operations in three ways:
1.
Protection
• Asset life/return on
capital
• Fewer breakdowns
2.
Oil Life
• Less maintenance
• Increased productivity
3.
System
Efficiency
• Maintain performance
• Energy efficiency*
Our new portfolio is designed to let you choose the right level of
protection, oil life and system efficiency to meet your needs
* Certain products only
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June 2010
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EASY TO UNDERSTAND: RELATIVE PERFORMANCE
A simple ―check chart‖ helps identify the performance benefits of one
product versus another
 All
performance differences are supported by technical data
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June 2010
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SHELL OMALA: EASY TO CHOOSE, EASY TO UNDERSTAND
KEY FEATURES
Shell Omala ―G‖ Range

Extreme-pressure formulations for spur and
bevel enclosed industrial gears
Copyright of Shell International Petroleum Company 2010
Shell Omala “W” Range

Low-EP grades suitable for use with yellow
metal components
Synthetic technology in Tier 4
Wide range of OEM approvals
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HOW DOES THE NEW PORTFOLIO RELATE TO THE OLD?
The table below summarises the conversion from the old product
name to the new product names
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June 2010
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2.0
Products In Detail
Shell Omala S4 GX
Shell Omala S4 WE
Shell Omala S2 G
June 2010
Copyright of Shell International Petroleum Company 2010
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INTRODUCING SHELL OMALA S2 G
KEY FEATURES & BENEFITS
Formulated to provide extra protection and
performance for industrial gears
Designed to provide long life and keep gears
working efficiently
Excellent water and corrosion protection
Widely recognised and approved by leading
equipment manufacturers
Copyright of Shell International Petroleum Company 2010
June 2010
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SHELL OMALA S2 G:
SHELL’S LEADING INDUSTRIAL GEAR OIL
Shell Omala S2 G are high quality, extreme-pressure oils you which can help
provide trouble-free performance in most enclosed industrial gear boxes
using steel spur and helical gears.
They are recommended for:
Enclosed industrial spur and bevel gearboxes – for excellent
protection and performance in extreme-pressure and highly
loaded gear systems.
Bearings and other components – for circulating and splashlubricated systems.
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June 2010
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DESIGNED TO PROTECT: HELPS INCREASE SERVICE LIFE
AND MAXIMISE YOUR RETURN ON INVESTMENT
Shell’s leading industrial gear oil:
— Every part of your machine or process has been meticulously engineered.
— You want a lubricant that has been designed to ensure your equipment is well protected and runs efficiently.
Shell Omala S2 G can help achieve this by providing excellent wear
protection.
— Demonstrated performance in the four main wear tests:
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DESIGNED FOR LONG OIL LIFE: TO HELP REDUCE
MAINTENANCE TIME AND INCREASE AVAILABILITY
Limiting fluid degradation can help to prolong oil life.
Shell Omala S2 G is designed to help you operate your equipment for longer
without interruption – for reduced maintenance requirements and enhanced
productivity.
In the industry-standard oil life test, Shell Omala S2 G achieved
up to 27% less thickening than the maximum allowed.
— After 312 hours at 121ºC (ASTM D2893)
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DESIGNED FOR HIGH EFFICIENCY: HELPING INDUSTRIAL
GEARS PERFORM AS THEY WERE DESIGNED.
Shell Omala S2 G is designed to increase productivity by helping equipment to
meet or exceed its design capabilities under challenging conditions.
Compared with the industry minimum requirements, it offers:
— up to 67% faster water separation to help ensure efficient and constant lubrication.
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DESIGNED FOR HIGH EFFICIENCY: HELPING INDUSTRIAL
GEARS PERFORM AS THEY WERE DESIGNED.
Today’s gearboxes are working harder than ever in hostile
and dirty environments
Shell Omala S2 G is specially formulated to guard against
foam problems that may lead to gear box wear, oxidation,
loss of lubricant and loss of viscosity.
Shell Omala S2 G significantly
exceeds industry requirements for
foaming resistance to protect your
equipment

...even when contaminated with cement dust
(1% cement, in ASTM D892 Seq II testing).
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SHELL OMALA S2 G PROVIDES RELIABLE, COST EFFECTIVE
PERFORMANCE TO HELP BENEFIT YOUR BUSINESS
Excellent all round protection for gears and bearings
Excellent oil life exceeding the industry standard requirements
Extremely wide range of OEM approvals and listings
For the most demanding applications consider synthetic Shell Omala S4 GX
Copyright of Shell International Petroleum Company 2010
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REAL WORLD VALUE DELIVERY: LONG MAINTENANCE
INTERVALS AND REDUCED OVERHAUL COSTS
Case Study 1: Dongying Artificial Board China
— Used LubeAnalyst to switch from a competitor product o Shell
Omala S2 G the customer was able to extend ODI from 1 year to
1.5 years
— Value delivered reported as: $8,000 per year approx
Case Study 2: Cement Mill - Asia
— Gearbox over-temperature was shutting down the plant in times of
high demand.
— Switching to Omala S2 G 680 resulted in 10C lower temperature
— Value delivered reported as: $16,000 approx
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2.0
Products In Detail
Shell Omala S4 GX
Shell Omala S4 WE
Shell Omala S2 G
Copyright of Shell International Petroleum Company 2010
INTRODUCING SHELL OMALA S4 GX
KEY FEATURES & BENEFITS
Synthetic oil designed to provide extra long life
and excellent protection under high loads
Resists breakdown by over long periods and high
temperature operations
Designed for severe or remote operations such as
wind-turbine use
Recognised and approved by leading OEMs
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SHELL OMALA S4 GX: A VERSATILE, ADVANCED,
SYNTHETIC INDUSTRIAL GEAR OIL
Shell Omala S4 GX is Shell’s fastest growing industrial gear oil to provide
your gear service with extra long life and excellent protection under high
loads.
It is recommended for:
A wide range of enclosed industrial gearboxes, particularly those under
high load where enhanced micro-pitting protection is required.
Systems requiring high levels of reliability – particularly recommended
for remote installations such as wind turbines, where maintenance is
infrequent and access can be difficult.
Extended life operations – for long-life applications, particularly where
extreme temperatures or pressures may be encountered
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DESIGNED TO PROTECT: HELPS INCREASE SERVICE LIFE
AND MAXIMISE YOUR RETURN ON INVESTMENT
Proven to have excellent load carrying capacity and exceptional
micropitting performance to help:
— Provide longer gear and bearing life than mineral oil-based products.
Shell Omala S4 GX can help achieve this by:

providing up to 90% less bearing
wear than standard FAG test limits

significantly exceeding the minimum gear protection
requirements, even during double speed testing.
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DESIGNED FOR LONG OIL LIFE: HELP YOU OPERATE
LONGER TO REDUCE MAINTENANCE TIME
Limiting fluid degradation can help to prolong oil life.
Designed to help equipment operate for longer without interruption – for
reduced maintenance requirements and enhanced productivity.
Proof: of Performance: In an industry-standard oil life test, Shell Omala S4
GX achieved up to 47% less thickening
— than the maximum allowed after 312 hours at 121ºC
— note that the lubricant is still within the industry standard limit after 34 days
Copyright of Shell International Petroleum Company 2010
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DESIGNED FOR HIGH EFFICIENCY: HELPING INDUSTRIAL
GEARS PERFORM AS THEY WERE DESIGNED
A gear oil needs to protect and lubricate efficiently.
Shell Omala S4 GX is designed to increase productivity by helping equipment
to meet or exceed its design capabilities under challenging conditions.
Shell Omala S4 GX:

provides up to 78% faster water
separation to help provide efficient
and consistent lubrication

has a 35% lower friction
coefficient than Shell Omala S2 G
to help reduce energy losses
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SEE HOW TRADING UP TO SHELL OMALA S4 GX CAN
BENEFIT YOUR BUSINESS
Exceptional micro-pitting performance for enhance protection
Recommended for protection with oil drain intervals of up to 4 years*
Longer Oil Life to help Reduce Maintenance Costs
27% less oil thickening than Omala S2 G in standard tests**.
High Efficiency Lubrication
Excellent air release and water separation to help provide strong consistent oil films and
low-friction to help reduce frictional energy losses.
* Based on Flender approval
** ASTM D2893 test method.
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June 2010
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REAL WORLD VALUE DELIVERY: LONG MAINTENANCE
INTERVALS AND REDUCED OVERHAUL COSTS
Case Study 1: Gold East (Jiangsu) - China
—Used LubeAnalyst to switch from a competitor to Omala S4 GX in
severe paper machine applications
—500% increase in oil drain intervals and lower oil volume usage
—Value delivered reported as: $6,000 per year approx per year
Case Study 2: Norilsk Nickel - Australia
—Upgraded to Shell Omala S4 GX to help cure over-heating mill drives,
lengthen oil life and improve efficiency.
—Potential to double oil life and a 2.1% energy efficiency measures
—Value delivered reported as: $74,000 approx per year
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2.0
Products In Detail
Shell Omala S4 GX
Shell Omala S4 WE
Shell Omala S2 G
Copyright of Shell International Petroleum Company 2010
INTRODUCING SHELL OMALA S4 WE
KEY FEATURES & BENEFITS
Designed to help maximise worm-gear life and
energy efficiency
Formulated with polyalkylene glycol base oils
Offers excellent service life and wear protection for
worm and spur gears
Is widely recognised and approved by leading
equipment manufacturers
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June 2010
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SHELL OMALA S4 WE: SHELL’S ADVANCED SYNTHETIC
HEAVY DUTY INDUSTRIAL WORM DRIVE GEAR OIL
Featuring a polyalkylene glycol base oil, which is designed to help maximise
worm-gear life and efficiency
Shell Omala S4 WE designed to help you increase productivity and cut
maintenance costs
Applications include:
Industrial worm-drive reduction systems – for use in severe operating conditions
such as high load under extreme temperature conditions.
Extended life operations – for long-life applications, particularly where
exceptional protection is required for inaccessible locations, for example wind
turbine yaw bearings or where high temperature or pressures may be
encountered
Suitable for bearings and other components in splash-lubricated systems.
Contains polyalkylene glycols and is not compatible with mineral oils or many
synthetic oils. Contact your Shell representative for changeover procedures.
Copyright of Shell International Petroleum Company 2010
June 2010
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DESIGNED TO PROTECT: HELPS INCREASE SERVICE LIFE
AND MAXIMISE YOUR RETURN ON INVESTMENT
Excellent load carrying capacity to help providing long component life
even under shock loading conditions.
Exceptional micro-pitting resistance
Performance demonstrated by:

up to 70% less worm-gear wear
than Shell Omala S1 W

up to 45% less spur-gear wear than
Shell Omala S1 W
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June 2010
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DESIGNED FOR LONG OIL LIFE: TO HELP REDUCE
MAINTENANCE TIME AND INCREASE AVAILABILITY
Limiting fluid degradation can help to prolong oil life.
Designed to help you operate your equipment for longer without interruption
– for reduced maintenance requirements and enhanced productivity.
In an industry-standard oil life test, Shell Omala S4 WE has over twice the oil
life.
— Compared with conventional oils such as Shell Omala S1 W
Copyright of Shell International Petroleum Company 2010
June 2010
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DESIGNED FOR HIGH EFFICIENCY: HELPING INDUSTRIAL
GEARS PERFORM AS THEY WERE DESIGNED.
A gear oil needs to protect and lubricate efficiently.
Shell Omala S4 WE is designed to increase productivity by helping equipment
to meet or exceed its design capabilities under challenging conditions.
Performance demonstrated by:

over 10 % greater worm-gear
efficiency than a standard mineral oil

a 75% lower friction coefficient
than conventional oils such as Shell
Omala S1 W
Copyright of Shell International Petroleum Company 2010
June 2010
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SEE HOW TRADING UP TO SHELL OMALA S4 WE CAN
BENEFIT YOUR BUSINESS
Lower wear and longer oil life compared to conventional oils
— Fewer unplanned shutdowns and longer equipment life
High efficiency lubrication
low-friction and demonstrated energy efficiency benefits
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June 2010
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REAL WORLD VALUE DELIVERY: LONG MAINTENANCE
INTERVALS AND REDUCED OVERHAUL COSTS
Case Study 1: Costa & Costa Lda – Portugal
— Large gearboxes used in macadam washing equipment:
Customer needed to maximise availability and reduce energy cost
— Shell Omala S4 WE replaced conventional products to give
longer oil life, lower wear and energy savings
— Value delivered reported as: $ 289,000 pa
Case Study 2: Tyre Manufacturer – Asia
— Productivity impacted by 3 monthly worm gear oil changes.
— Changed from local mineral product to Shell Omala S4 WE and
increase oil life to 3 years+
— Value delivered reported as: $18,000 approx
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June 2010
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SUMMARY & FURTHER INFORMATION
Shell Omala S4 WE offers real-world value delivery.
Shell has developed and marketed value-adding oils for year.
Customers around the world are benefiting from switching to Shell Omala S4
WE. For instance:
—one tyre manufacturer extended its oil-drain intervals from three months to three years in curing
press gearboxes to increase productivity
—customers operating worm gears, in particular bronze / steel gear sets, have increased gear life by
using Shell Omala S4 WE dedicated worm-gear oil
—crane and winch operators have benefited from the superior protection of Shell Omala S4 WE and
increased the life of their systems.
Many customers across a wide range of industries have benefited from the
proven, robust and reliable lubrication of Shell Omala S4 WE.
Further information available includes:
—Product brochures; Technical Data Sheet & Case Studies
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