A CASE STUDY-HIGHER FILTRATION CAPACITY OF DEDICATED Motorized OIL FILTRATION SYSTEM
REDUCED COST OF WATER-GLYCOL FILTER ELEMENT SPARES.
Saved weekly 18 hours of production breakdown.
Location north india –client a leading manufacturer of cars- solved tedious breakdown and saved production downtime 18 hours per week.
SYNOPSIS
The largest manufacturer of cars was struggling with water-glycol hydraulic oil contamination concerns in the casting division. Malfunctioning of valves and machine breakdown was making tasks cumbersome for the production and maintenance team.
PROBLEM
Failure of servo valves and unplanned shutdown were putting a lot of unwanted pressure on the production and maintenance teams of the casting division.
The Toshiba machines were having water-glycol power packs in the basement of the casting unit.
All power packs were having bypass filtration units of Japanese make, and media was being changed
at intervals of 3 months.
There were 28 power packs and the frequency of breakdown was leading to downtime of up to 18 hours.
Oil analysis reports were reflecting bad oil conditions.
SOLUTION
The flow rate of the bypass unit dedicated by OEM was @ 2 lpm for a powerpack capacity of 500 liters. Over time and due increase in the window period of changing interval of choked filters, there was an increase in contamination concentration of the machine driving fluid. Due sandblasting effect increase in contamination was leading to servo valves being prone to failure.
A dedicated motorized DESTINY MAKE -OIL CLEANING unit was installed with a flow rate of 5 lpm and thence oil analysis was carried out from an inhouse lab for before and after results.
The results indicated a reduction in contamination counts and over repeat analysis gradually oil cleanliness was brought to better than new condition.
With indigenous high quality and certified -Made in India-Water glycol filter elements, customer recovery was up to 30% reduction in spare cost and better results -negligible dependence on import, reduced delivery time, and promotion of local and national.
All 28 power packs were migrated to WATER GLYCOL HYDRAULIC OIL Dedicated filtration units.
The frequency of water-glycol filter element change is being maintained at 3 months with oil standards better than new clean oil.
| FLOW RATE | FREQUENCY OF FILTER CHANGE | FREQUECY OF BREAKDOWN/MONTH | COST OF SPARES | |
| BEFORE | @2LPM | QUATERLY | 18 HRS PER WEEK | IMPORTED-HIGH |
| AFTER | @10 LPM | QUATERLY | 2 HRS PER WEEK | LESS THAN HALF |
BENIFITS
THE COST SAVING is evident in form OF REDUCED MACHINE DOWNTIME and lesser purchase of new oil and NO UNPREDICTABLE BREAKDOWN for the maintenance and production team. Depending on expensive spares minimized.
COST SAVING-HIGH IMPORT
Since Water Glycol consists of mostly water, the lubrication properties are much different compared to oil-based fluids.
Oil based fluids relation between viscosity and temperature is based on viscosity index. Water Glycol has a much better viscosity temperature behavior than mineral oils.
Temperature must be monitored when using Water Glycols, temps exceeding 120F (50C) accelerates the aging process of the fluid. Too much water loss increases viscosity and reduces fire resistance. Water loss can also affect viscosity, pH, and lubrication quality.
All added water to the system must be distilled or deionized water. This is because the calcium and magnesium present will react with additives, causing them to precipitate out and effect fluid performance.
Contamination in Water Glycol
- Iron particles,
- Aluminum particles,
- Carbon particles,
- Dirt.
APPLICATION
- Die-casting Machines
- Coke Furnace Door Openers
- Ladle-tilting Mechanisms
- Furnace Chargers and, Dischargers,
- Basic Oxygen Furnace Hydraulics
- Fork Lifts
- Straddle Trucks
- Electric Welders,
- Rod, Tube and Strip Mills,
- Hot Metal Shears,
- Aircraft Carrier Catapults,
- Airport Air Bridges and
- Continuous Metal Casters.
Pros and Cons
Don’t change your oil, filter it!
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