Title of Invention	A MECHANICAL EXPANDER LUBRICANT FORMULATION/COMPOSITION AND A PROCESS FOR MANUFACTURING THE SAME
Abstract	The present invention relates to a mechanical expander lubricant formulation comprising Triglycerides in an amount of 1.0% to 10% preferably 3% to 8% and Polyol esters in an amount of 5 to 60% preferably 10% to 40% provided selectively to disperse completely in water phase with oil droplet size in the range of from 0.10 to 2μm at ambient temperature, and a process for manufacturing the same.

Full Text

FIELD OF THE INVENTION The present invention relates to a lubricant and, in particular, to a synthetic mechanical expander lubricant formulation which would be suitable for wide range of applications especially suitable for providing lubrication to mechanical expander machines. Importantly, the lubricant formulation and its method of preparation are especially suited for mechanical expander used for cold straightening and gauging of submerged arc welded (SAW) steel pipes /tubes. The lubricant of the invention would favour application as a water soluble mechanical expander lubricant and can be used either in neat or in emulsified form. Advantageously the lubricant formulation achieves favourable characteristics including good lubricity, load carrying ability under extreme pressure, good adhesive property and easy washability in cold water. BACKGROUND ART It is well known that expander tools provide for cold straightening and gauging of submerged arc welded steel tubes/pipes. Importantly, such mechanical expander equipments are used for cold deformed steel pipe / tube to make them circular within tolerance and also make them straight. Usually, the expander tool in collapsed condition is placed inside the welded pipe / tube and the tube diameter is increased by hydro mechanical pulling arrangement with large force. Such expansion of the pipe / tube is usually carried out in several stages. During expansion neat lubricant is fed to number of lubricating points (dual line dose system) at a high pressure around 250 bar. This lubricant lubricates the sliding surface of pull-rod housing and tool. Moreover, 5-10% concentration emulsion is used to reduce friction between expander tool and steel pipe / tube. While the availability of such mechanical expander lubricants and its use for such purposes have been known and made available to the art, in view of its desired wide scale application and use there has been a constant need to provide for mechanical expander lubricants which would have satisfactory lubricating properties and importantly excellent washability. Moreover, the presently available varieties of mechanical expander lubricants are usually found to involve constituents which are not freely available and accordingly manufacture and processing of such lubricants for mechanical expander machine is difficult. Also it has been difficult to provide for cost effective lubricant formulation, which would maintain its physical properties and chemical constituent over a long period of time ensuring uniform results. OBJECTS OF THE INVENTION It is thus the basic object of the present invention to provide a mechanical expander lubricant formulation which would be effective as a water dispersible type expander lubricant for use in mechanical expander machines for steel pipe and tube and which will have all the properties of a satisfactory lubricant with excellent washability. Another object of the present invention is directed to a synthetic mechanical expander lubricant, which would be simple and cost effective to manufacture and obtain by way of providing for a lubricant, which could be made available from components, which are freely available in abundance and throughout the year. Another object of the present invention is directed to a mechanical expander lubricant formulation which would have water dispersibility and excellent washability and which would maintain its desired specific properties and chemical constitution over a long period of time ensuring uniform results. Yet further object of the present invention is to provide for an effective formulation for mechanical expander which would be simple and cost effective to obtain to thereby favour large scale application and use as water soluble mechanical expander lubricant for wide range of application and, in particular, for providing lubrication to mechanical expander machine. Another object of the present invention is directed to a user friendly simple and cost effective process for straightening and gauging of steel pipe and tubes in presence of the selective expander lubricant which can be obtained simply and cost effectively from easily and abundantly available resources. SUMMARY OF THE INVENTION Thus according to the basic aspect of the present invention there is provided a mechanical expander lubricant formulation comprising: Triglycerides in an amount of 1.0% to 10% preferably 3% to 8% and Synthetic Polyol esters in an amount of 5 to 60% preferably 10% to 40% provided selectively to disperse completely in water phase with oil droplet size in the range of from 0.10 to 2pm at ambient temperature. In the above disclosed mechanical expander lubricant composition there is provided selectively Triglycerides of Oleic / Palmitic acid enriched materials preferably rapeseed, karanja, palm , polyol esters comprising esters of C 8-i8: 0,1,2,3 monomeric, dimeric and trimeric carboxylic acids and bis, tri and tetra alcohol. The viscosity range of the polyol esters are maintained at 5-5000 est at 100°C. Importantly, the mechanical expander lubricant composition also comprises selectively dispersants, surfactants and co-solvents for dispersing the triglycerides/ polyol esters readily in water. Conventional ingredients preferably selected from dispersants, wetting agents, antioxidants, detergents, co-solvents, defoamers, biocides, EP/AW additives, rust preventives and multi metal passivators are included in the lubricant formulation for desired end characteristics depending upon the end use /application. In the formulation of the invention dispersants provided are selected from primary/secondary amines with C4 to C22 chain length, surfactants from ethylene oxide condensate of alcohols with chain length between C6 to C24 and co-solvents selected from alcohol with chain length from C4 to C18- Such dispersants are used at a weight concentration of 0.5 to 5 % and preferably 1 to 3 %, surfactants are used at a weight concentration of 1.0 to 40% and preferably 10 to 30% and co- solvents are used at a weight concentration of 1.0 to 20% and preferably 5 to 15%. The antioxidants are selected from sterically hindered alkylated para cresylic acid, secondary biphenyl amines and the weight concentration of anti oxidants is in the range of 0.1 to 5.0% and preferably 0.3 to 2.0%. EP/AW additives are selected from sulfur, nitrogen-phosphorus based compounds incorporated in amounts of 0.5 to 25% and preferably 5 to 15 %. Biocides comprise preferably biocides based on methylated, butylated isothiazolone derivatives and triazine in the range of weight concentration of 0.05 to 5% preferably from 0.1 to 1.0%. Rust inhibitors comprise rust inhibitors based on mono carboxylic acid with C3 to C12 chain length, sulfonates, half succinic acid esters, amine esters and basic metal salt incorporated in the range of 0.2 to 8 % and preferably 0.3 to 5 %. The multi-metal passivators comprise derivatives of heterocyclic compounds added in the range of 0.1 to 5% and preferably 0.3 to 3%. Also, in the mechanical expander lubricant composition oil-soluble, non-silicone type of defoamers is incorporated in the range of upto 2% preferably 0.1 to 0.5%. In accordance with another aspect of the present invention there is provided a method for the manufacture of the synthetic mechanical expander lubricant composition comprising: providing selectively the synthetic ester in amounts such as to provide for a lubricant which would disperse completely in water phase with oil droplets in the range of 0.10-2 µm at ambient temperature. In the above method the said ester and the other selective additives in said selective amounts and preferences as defined are provided to achieve desired dispersibility and water solubility. In accordance with another aspect of the present invention there is provided a method for straightening and gauging of steel pipes / tubes in the presence of an expander lubricant comprising selectively using the expander lubricant as defined hereinbefore. In such method during the step of expansion neat lubricant is fed to a number of lubricating points preferably following dual line dose system at a pressure of about 250 bar. The lubricant is used to lubricate the sliding surfaces of pull-rod and housing and tool that are subjected to high load in the range of about 1000 tons distributed over large area. Preferably, the method comprises using 5 to 10% concentration emulsion to reduce friction between expander tool and steel tube/pipe. It is thus possible by way of the above disclosed synthetic mechanical lubricant to provide for the first time the synthetic ester based expander lubricant for use in mechanical expander machine for steel pipes and tubes which will have all the properties of a satisfactory lubricant and also excellent washability. Importantly the lubricant formulation of the invention is adapted to provide optimum lubrication to sliding surfaces of the pull rod and housing of expander tool that are subjected to high load. It also disperses uniformly and forms stable emulsion in water at ambient temperature which can be spread onto the steel pipes/tubes to be expanded to reduce friction between expander tool and steel pipe / tubes. The synthetic mechanical expander lubricant composition of the invention advantageously includes hydro dynamic / boundary lubricants, dispersants, co- solvents, wetting agents, anti oxidants, detergents, defoamers, rust preventive and muti-metal passivators, biocides, extreme pressure and anti-wear additives. The details of the invention, its object and advantages are explained hereunder in greater detail in relation to non-limiting exemplary illustration of the manner of preparation of the synthetic mechanical expander lubricant in accordance with the present invention as per the following example. EXAMPLE The preparation of the lubricant formulation in accordance with the present invention was carried out as hereunder: - Initially, polyol esters and triglycerides are taken in a mixing kettle through dosing pump and heated upto the temperature of 40 to 90°C. Thereafter, anti-oxidant was added and mixed thoroughly. The mixture thus obtained was maintained for about ½ to 1 hr. at 50-70°C. Next, extreme pressure and anti-wear additives were added through dosing pump and mixed for Vi - 1 hr. at 40-45° C. Thereafter, dispersants, detergents, co-solvents and defoamers were added and mixed for ½ - 1 hr. in the temperature range of 40-45°C. Next, rust preventives, multi-metal passivators were added and mixed together at the temperature range 40-45°C and then mixed thoroughly. Finally, biocides were added and mixed for ½ -1 hr. below 40°C to obtain the lubricant formulation in accordance with the present invention. The lubricant formulation of the invention thus obtained was next tested and applied for use as a lubricant for metal pipe expansion as discussed hereunder :- For the purpose the following stages were carried out: a) the oil tank was filled with expander lubricant of the invention upto a minimum half of its capacity; b) the lubricant was fed to expander tool during expansion through dual line dosing system. c) Excess lubricant was sent back to oil tank through return line. d) After pipe/ tube having been expanded, slag and ferrous scales on the expanded tool are washed with water at a pressure lower than 4 kg / cm2. e) Lubricant settling on the inner surface of the tube/pipe during expansion was washed with water at a pressure higher than 4 kg /cm2. f) After washing it was ensured that no lubricant film remained inside the pipe; g) The lubricant is properly dispersed in water forming emulsion and this emulsion was sent to the settling tank; h) Pipe/tube was washed with emulsion before it was subjected to expansion. This emulsion also provided lubrication between expander tools and steel pipe {cold die steel) The characteristic of the expander lubricant used as above in accordance with invention was tested and the results obtained are provided hereunder:- a) Specific gravity at 30°C : 0.959-0.995 b) Kinematic viscosity at 40°C, cst : 300-550 c) Kinematic viscosity at 100°C, cst: 40-60 d) Total acid number, mgKOH/g: 5-20 e) pH of 5% dispersion in DM water : 5.5-7.0 f) Weld load in 4-ball EP tester, kgs, ASTM D 2783: 250 - 450 g) Viscosity index : 120-200 h) Washability: Easily washable in cold / hot water. It would be clearly apparent that the lubricating formulation of the invention achieves desired water solubility and includes good lubricity, load carrying ability under extreme pressure and good adhesive property. It is possible to provide superior quality welded pipe (circular and straight) with improved lubricity using the lubricant of the invention. The expander lubricant importantly offers lower co- efficient of friction during straightening and gauging of pipes / tubes which lead to improved quality and less power consumption. The lubricating formulation of the invention would favour achieving eco-friendliness with improved house keeping and mill-cleanliness in its use and application as an expander lubricant. WE CLAIM: 1. A mechanical expander lubricant formulation comprising: Triglycerides in an amount of 1.0% to 10% preferably 3% to 8% and Polyol esters in an amount of 5 to 60% preferably 10% to 40% provided selectively to disperse completely in water phase with oil droplet size in the range of from 0.10 to 2µm at ambient temperature. 2. A mechanical expander lubricant composition as claimed in claim 1, comprising selectively Triglycerides of Oleic / Palmitic acid enriched materials preferably rapeseed , karanja, palm , polyol esters comprising esters of C8- 18: 0, 1, 2, 3 monomeric, dimeric and trimeric carboxylic acids and bis, tri and tetra alcohol. 3. A mechanical expander lubricant composition as claimed in any one of claims 1 or 2, wherein the viscosity range of the polyol esters are maintained at 5- 5000 cSt at 100°C. 4. A mechanical expander lubricant composition as claimed in any one of claims 1 to 3, comprising selectively dispersants, surfactants and co-solvents for dispersing the triglycerides/ polyol ester readily in water. 5. A mechanical expander lubricant composition as claimed in any one of claims 1 to 4, comprising conventional ingredients preferably selected from dispersants, wetting agents, antioxidants, detergents, co-solvents, defoamers, biocides, EP/AW additives, rust preventives and multi-metal passivators. 6. A mechanical expander lubricant composition as claimed in any one of claims 1 to 4, wherein dispersants provided are selected from primary/secondary amines with C4 to C22 chain length, surfactants from ethylene oxide condensate of alcohols and phenols with chain length between C6 to C24 and co-solvents selected from alcohol with chain length from C4 to C18. 7. A mechanical expander lubricant composition as claimed in any one of claims 1 to 6, wherein dispersants are used at a weight concentration of 0.5 to 5% and preferably 1 to 3%, surfactants are used at a weight concentration of 1.0 to 40% and preferably 10 to 30% and co-solvents are used at a weight concentration of 1.0 to 20% and preferably 5 to 15%. 8. A mechanical expander lubricant composition as claimed in any one of claims 1 to 7, wherein antioxidants are selected from sterically hindered alkylated para cresylic acid, secondary biphenyl amines and the weight concentration of anti oxidants is in the range of 0.1 to 5.0% and preferably 0.3 to 2.0%. 9. A mechanical expander lubricant composition as claimed in anyone of claims 1 to 8, wherein said EP/AW additives are selected from sulfur, nitrogen- phosphorus based compounds incorporated in amounts of 0.5 to 25% and preferably 5 to 15%. 10. A mechanical expander lubricant composition as claimed in any one of claims 1 to 9, wherein selected biocides comprise biocides based on methylated, butylated isothiazolone derivatives and triazine in the range of weight concentration of 0.05 to 5% preferably from 0.1 to 1.0%. 11. A mechanical expander lubricant composition as claimed in any one of claims 1 to 10, wherein rust inhibitors comprise rust inhibitors based on mono carboxylic acid with C3 to C12 chain length, sulfonates, half succinic acid esters, amine esters and basic metal salt incorporated in the range of 0.2 to 8% and preferably 0.3 to 5%. 12. A mechanical expander lubricant composition as claimed in anyone of claims 1 to 11, wherein multi-metal passivators comprise multi-metal passivators based on derivatives of heterocyclic compounds added in the range of 0.1 to 5% and preferably 0.3 to 3%. 13. A mechanical expander lubricant composition as claimed in anyone of claims 1 to 12, wherein oil-soluble, non-silicone type of defoamers are incorporated in the range of upto 2% preferably 0.1 to 0.5%. 14. A method for the manufacture of the synthetic mechanical expander lubricant composition as claimed in anyone of claims 1 to 13, comprising: providing selectively the synthetic ester in amounts such as to provide for a lubricant which would disperse completely in water phase with oil droplets in the range of 0.10-2 µm at ambient temperature. 15. A method as claimed in claim 14, comprising providing said ester and the other selective additives in said selective amounts and preferences as defined to achieve desired dispersibility and water solubility. 16. A method for straightening and gauging of steel pipes / tubes in the presence of an expander lubricant comprising selectively using the expander lubricant as claimed in any one of claims 1 to 13. 17.A method as claimed in claim 16, wherein during the step of expansion neat lubricant is fed to a number of lubricating points preferably following dual line dose system at a pressure of about 250 bar. 18.A method as claimed in any one of claims 16 or 17, wherein the lubricant is used to lubricate the sliding surfaces of pull-rod and housing and tool that are subjected to high load in the range of about 1000 tons distributed over large area. 19. A method as claimed in any one of claims 16 to 18, comprising using 5 to 10 % concentration emulsion to reduce friction between expander tool and steel tube/pipe. 20. A synthetic mechanical expander lubricant, its method of manufacture and its use in method of straightening and gauging of steel pipes/tubes substantially as herein described and illustrated with reference to the accompanying examples. The present invention relates to a mechanical expander lubricant formulation comprising Triglycerides in an amount of 1.0% to 10% preferably 3% to 8% and Polyol esters in an amount of 5 to 60% preferably 10% to 40% provided selectively to disperse completely in water phase with oil droplet size in the range of from 0.10 to 2μm at ambient temperature, and a process for manufacturing the same.

Documents:

92-kol-2006-granted-abstract.pdf

92-kol-2006-granted-claims.pdf

92-kol-2006-granted-correspondence.pdf

92-kol-2006-granted-description (complete).pdf

92-kol-2006-granted-examination report.pdf

92-kol-2006-granted-form 1.pdf

92-kol-2006-granted-form 18.pdf

92-kol-2006-granted-form 2.pdf

92-kol-2006-granted-form 26.pdf

92-kol-2006-granted-form 3.pdf

92-kol-2006-granted-reply to examination report.pdf

92-kol-2006-granted-specification.pdf