An automotive stamping plant operating large presses to produce body panels was experiencing high surface finish defect scrap. Lubricating oil contamination was causing surface imperfections that would be visible after painting.
The uncoiler / washer lube oil system was protected by an off-line filtration system fitted with stacked disc cellulose media filter inserts (elements). Oil analysis revealed an operating ISO code of 23/19/11. Patch analysis showed cellulose fibers were shedding into the oil from the filter inserts downstream of the filtration system.
Hy-Pro recommended a full system clean-out, lower operating ISO codes and eliminating cellulose fiber shedding ingression to eliminate defects. The lube oil was transferred to a clean storage tote using a Hy-Pro FCL10 off-line filter cart with 6M (β 7[c] > 1000) media element and recirculated to reach an ISO code of 17/13/11. The reservoir, existing off-line filter assembly and sieve were then cleaned revealing a high volume of sediment and cellulose fibers. The off-line filter systems cellulose stacked disc elements were upgraded to Hy-Pro HP2727L43-6MB pleated glass elements (β 7[c] > 1000). Finally, the fluid was returned to the system.
17 days later the operating ISO code had decreased further to 17/13/9 and NO DEFECTIVE PARTS had been produced. Eliminating the defects, longer filter element life and the extension of useful oil life saved the stamping plant hundreds of thousands of dollars per year.
To verify the results the stamping plant put another set of the cellulose stacked disc filter inserts back in the offline filter system and within 15 days the operating ISO code was 23/19/11 again.
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What HY-PRO provided:
Today's diesel engines require cleaner fuel with injector pressures approaching 30,000 PSI and the evolution of injectors into sophisticated expensive electronic components. Diesel engine manufacturers have learned that ultra fine particles that were of little consequence at 3,000 PSI are now causing premature failures at 30,000 PSI. Diesel fuel lubricity has also decreased with the move to ULSD (ultra low sulfur diesel) fuels. These changes and others have resulted in:
Hy-Pro solutions to these problems include:
What HY-PRO provided:
Subpar filtration on each of a tire plant’s 35 tire grinders (tire uniformity optimizers) was wreaking havoc on servo valves. In one year this plant repaired or replaced 198 valves at an average cost of $2,200 each. The system experiencing the most problems was chosen by the tire manufacturer to test Hy-Pro’s equipment and elements. Many servo valves require a maximum operating ISO fluid cleanliness code of 16/14/11 while the most sensitive valves require a 14/12/9. Analysis showed the current operating ISO code was 22/20/17.
Hy-Pro suggested implementing a total system cleanliness approach by adding a 1gpm FPL off-line filter panel fitted with a ß2.5[c] > 1000 filter element to the 25 gallon hydraulic reservoir to reduce contamination levels and extend valve life. A spin-on breather was also added to the reservoir to exclude solid particulate ingression from the atmosphere.
Hy-Pro designed, manufactured and shipped a custom FPL filter panel specific to the customer’s requirements in 1 week. Hy-Pro and the local distributor were on site to install and startup the system. Days after installing FPL and breather the operating ISO code had been reduced from 22/20/17 to 13/9/7 which represents a 99.9% reduction in particles 4m[c] and larger. Subsequently filter panels and breathers were added to each of the 34 other tire grinding systems.
In the first six months after installing the remaining units, the tire manufacturer only repaired or replaced 3 servo valves suggesting they’ll only service 6 throughout the entire year. 1 year after installation and clean-up of the first unit the original 13” 1 micron element is still collecting dirt.
In addition to the savings realized by reducing servo valve failures the manufacturer experienced a 2% increase in production rate due to the valves operating more efficiently.*
*Before adding offline filtration to the system the non-bypass filters in front of the valves were clogging and reducing flow to the valves causing them to operate at a reduced capacity.
Download the 2 page PDF below for a breakdown of the more than $4,000,000 the manufacturer will save in servo valve costs over 10 years!
What HY-PRO provided:
To obtain the 5 Star rating from CAT their dealer / service centers must meet new fluid cleanliness specifications for engine oil, hydraulic oil and transmission fluid.
The service center in this case study wanted to achieve X/16/13 ISO code from their dispensing nozzles in the service bays on all fluids which involves fluid pumped from bulk oil tanks through long pipe and hose runs.
To ensure that all fluids would be on target all the time Hy-Pro designed and delivered a solution to deliver fluid with an ISO code of X/14/11 for hydraulic & transmission fluids and X/15/12 for engine oil at the dispensing nozzle.
A hydraulic shovel was experiencing contamination related hydraulic failures (swing motors, piston pumps, servos) impacting an entire surface mining unit including several haulers. The excavator had experienced premature component failure in the first 27 months including:
The oil was heavily contaminated yielding accelerated oxidation requiring oil replacement after 2,255 hours. In addition to excessive downtime the excavator was not operating reliably and was approaching the end of the warranty period.
The challenge was to reduce downtime associated with contamination related premature pump failures, minimize costly component repairs or replacements and extend the useful life of the oil.
ISO fluid cleanliness codes were consistently reading 22/20/17 which is not suitable for any precision hydraulic system. A target ISO code of 15/13/10 was established based on the criticality of the system which lead to improvements in maintenance practices, upgrading to synthetic oil and upgrading the original cellulose return-line element to Hy-Pro DFE Rated glass media. After the changes copper levels, indicative of pump shoe wear, dropped by 70%. Fluid service life was extended to 17,000 hours and fluid cleanliness of 15/12/9 was achieved. The anticipated future cost avoidance was $193,872.
What HY-PRO provided:
A manufacturer of mobile, multi-function valves for heavy lifts and cranes was battling hydraulic fluid contaminated related failures on four operating production lines. Learn more about the solution!
Several conditions had prompted the search for a solution including:
One of the four production lines was turned over to the Hy-Pro team (including Hy-Pro distributor M&R Hydraulics) for a solution. A four month trial on Hy-Pro DFE rated element upgrades and other improvements including repair to reservoir air leaks and breather upgrades was conducted in comparison with the current element supplier with at target ISO code of 17/15/13.
With the improvement and Hy-Pro elements on board ISO codes dropped from 22/21/19 to 12/11/17 which represented a 99.9% reduction in particles 4µ[c] and larger, a 99.9% reduction in particles 6µ[c] and larger and a 99.9% reduction in particles 14µ[c] and larger. The plants expectations were exceeded leading to great reductions in downtime, higher productivity, and a finished product that consistently achieve its quality standard.
This case also details how distributor value added services such as fluid analysis / trending/ reporting, maintaining element stock levels and becoming an integral part of the lube team.
What HY-PRO provided:
A coal fired power plant typically has several coal mills feeding fluidized coal dust to fire each turbine. The gearboxes these coal mills utilize can have high levels of particulate contamination as fine coal dust passes by shaft seals into the high viscosity gear lubricant.
The challenge was to extend gearbox life to avoid premature rebuilds which can cost over $600,000 not including down time. The plant also wanted to switch to a synthetic oil so eliminating the need for annual drain and refill intervals was crucial because the synthetic was triple the price of the original oil in service.
The plant had found that mobile filter carts would reduce the contamination level but after removing the cart the contamination quickly returned. So the dedicated FSL off-line system was installed on one unit and the ISO codes dropped from X/21/16 to X/15/11 over several days and after 60 days the ISO Code was stable at X/13/11. Thusly the plant decided to monitor the oil condition and only change if the additive package was depleted instead of annually. It was also determined that running on clean synthetic oil saved enough money (based on AMP draw reductions) to pay for the installation of the FSL unit and change to the synthetic oil.
What HY-PRO provided:
The stakes are high for peaking power plants; when called upon they have a limited number of hours to begin producing electricity for the grid. Unit trip or fail-to-start conditions result in contractual fines, necessitate purchasing power to fulfill obligations, forced & unscheduled outages and lost profit. A combined cycle peaking plant (2 GCT on 1 ST) experiencing multiple trips related to electrohydraulic control (EHC) servo valve failure turned to Hy-Pro for help.
A variety of contaminants including water, acid, particulate, gels and dissolved metals coupled with low resistivity were fouling the valves, causing expensive trips & fail to starts and encouraging the maintenance team to consider flushing the system, disposing of and replacing the expensive phosphate ester hydraulic fluid.
Hy-Pro suggested that a Total Systems Cleanliness approach be adopted in order to address each of the contaminants, stop the unit trips & fail to starts and prevent the impending premature fluid replacement. An FSAPE2 offline acid remediation and particulate filtration skid with a TMRN2 reservoir headspace dehydrator was installed on the reservoir. A dessicant breather was also added to the reservoir and the pump discharge filter element was upgraded to high efficiency microglass.
Within four months, contaminants and resistivity were brought within specifications eliminating the necessity for fluid replacement. Gels were removed from the system. Servo valve fouling was decreased to the point where the plant was no longer experiencing trips or fail to starts.
Download the PDF below to see $ savings!
The plant is in immediate contact with an oil supplier to purchase and expedite replacement fluid, but the supplier is unable to fulfil the request of 60,000 liters, worth $200,000, in the allotted amount of scheduled shutdown time. The plant worries that the inability to restart the system in the scheduled time will lead to unforseen downtime.
The distributor working with Hy-Pro representative came up with a plan of action on how to rectify the situation. The plan: to recondition the oil by installing and continuously running two Hy-Pro Soluble Varnish Removal (SVR) 1200 machines with ICB technology as well as an in-depth sampling and testing regimen. Included with the machines were two extra sets of ICB filters ready to swap out with used filters as needed ensuring that the plant would not have to wait on anything to continue day-to-day operations.
After installation and within the scheduled shutdown time, the Hy-Pro products brought MPC and ISO code values down to an acceptable level to resume operation, while continuing the reconditioning process for another five months. After six months of continuous filtration, the plant was able to recondition the previously unusable oil to a before-new cleanliness level; MPC values dropped from 250 to 6.54; ISO codes improved from 20/17/10 to 13/12/11 and the customer could not have been happier. Overall, the customer was prepared to spend $200,000 on new oil to fix their problem. With Hy-Pro products, the customer spent less than $40,000, saving over $!60,000 and producing ISO codes much lower than the new oil.
What HY-PRO provided:
50 plus wind turbines in a wind farm were out of warranty and the operator was looking for a North American filter element manufacturer that could improve cleanliness and supply all of the hydraulic, lube and breather elements required for complete wind turbine servicing.
Hy-Pro DFE rated elements were tested and approved as suitable upgrades to the OEM specified filters and all of the turbines in the wind farm are now running on Hy-Pro elements.
What HY-PRO provided:
An Australian aluminum refinery was consistently performing premature gearbox lube oil changes on 7 base drive units due to oil and particulate contamination. With an average operating ISO code of 20/18/16 and average water levels of 4742ppm, the 360 liters / 90 gallons of ISO VG320 gear oil was being changed far too often. Cost per gearbox oil change (excluding crane, lost production, labor) is $17,962.60 which adds up to $125,738.20 for all 7 units.
Conditioning gearbox lube oil is a huge opportunity for savings. By removing dirt and water the lube oil can be used until another characteristic of the oil fails (ie viscosity or additive) which can result in exponentially longer fluid life and prevent gearbox failure. To remove the particulate and water from the oil a Hy-Pro V5 vacuum dehydrator was selected to remove all phases of water (free, dissolved, emulsified) and remove particulate with an oversized 3M (β5[c] > 1000) filter element. The V5 was rotated between the 7 top drives on a 2-day service interval rapidly purifying the oil by turning the sump volume 75 times daily.
On each unit, water was rapidly reduced an average of 98% from 4742ppm to 96ppm. Particulate contamination size 4μ[c] and larger decreased by 95% as average ISO code decreased from 20/18/16 to 15/13/8. The refinery increased reliability and profitability while reducing the environmental impact of premature oil disposal. Oil life has been extended reducing the need for oil changes. Gearbox life should also triple under these conditions leading to even more substantial savings.
What HY-PRO provided:
Recently, a hydraulic valve manufacturer was losing 25 pumps a year on their centralized hydraulic system at a cost of $2,440 each. That’s only the pump cost, when you account for maintenance resources, lost oil and lost production each failure costs ~$25,320.
System analysis showed that fluid contamination was out of control with an ISO Fluid Cleanliness Code of 22/21/19. That translates to a minimum of;
20,000 particles per ml > 4µ[c]
10,000 particles per ml > 6µ[c]
2,500 particles per ml > 14µ[c]
The manufacturer set an ISO code limit of 17/15/13 and turned to Hy-Pro for help achieving their goal. While surveying their system, we noticed and addressed three factors contributing to their problems.
Fluid analysis samples were taken over the following 140 days to verify the condition of the fluid. The final sample returned an ISO Fluid Cleanliness Code of 12/11/7. That translates to a maximum of;
40 particles per ml > 4µ[c]
20 particles per ml > 6µ[c]
1 particle per ml > 14µ[c]
Pump failures related to fluid contamination (~$633,000 annually) were eliminated through the 99.8% reduction of particulate contamination within the fluid.
What HY-PRO provided:
A hydraulic valve manufacturer required pristine fluid (< 14/12/9) to test flow across an 80 micron orifice on their test stand. Gross amounts of contamination in the fluid would skew the test results, invalidating any data collected. The system held 100 l (26.4 gal) of ISO VG 32 fluid with a flow rate of 25 lpm (6.6 gpm).
Through observing the manufacturer’s sampling practices, discussing fluid handling best practices and interpreting their lab reports; 3 independent problems were identified:
1. Insufficient Filtration – The current 12μ filter had allowed the ISO code to elevate to 19/18/16 (4388 / 2413 / 610).
2. New Oil ≠ Clean Oil – New oil was believed to be clean oil and it was not being conditioned when added to their system. New oil is not clean oil, in our experience, it usually has an ISO code around 25/22/19 (304,800 / 381,000 / 4763).
3. Bottle Sampling Practices – Observing the manufacturer’s sample collection procedures (after the filtration upgrade) revealed that the samples were being contaminated through improper valve & bottle flushing due to poor sample collection practices.
Opportunities to improve fluid handling/sampling practices were identified and the onboard filtration was upgraded from a 12μ filter to a 1μ filter element (HP52NL10-1MB).
Online particle counts showed ISO codes had been reduced to 14/11/0 (127 / 16 / 0) which represented a 96.8% reduction in particles > 4μ in size and enabled the manufacturer to complete the testing of their new valve.
What HY-PRO provided:
A high-production copper mine relied on a lubrication system for their Nordberg® MP Series™ crusher*. This system used a duplex filter assembly with eight elements manufactured by a competitor.
Donaldson Hy-Pro, along with our distributor, proactively approached the mining company with an alternative filtration solution. In line with The Hy-Pro Way of doing business, we proposed a comprehensive solution that would address common issues with the current filter element.
The Donaldson Hy-Pro element uses key design upgrades, including a sealing mechanism to increase filter efficiency and a rigid outer support tube for better durability. These improvements offered significant costsaving benefits for the mining company.
The Donaldson Hy-Pro element delivered exceptional results for the copper mine:
The Donaldson Hy-Pro element surpassed the alternative in every respect. Our solution provided superior filtration performance, reduced operating costs, and extended the life of critical system components. This case study demonstrates the value of Donaldson Hy-Pro’s filtration solutions and our commitment to proactive customer service.
A small steam turbine lube reservoir formerly fitted with a gravity settling water removal arrangement was contaminated with water levels reaching 800 ppm. The plant had increased the reservoir temperature in an attempt to dissipate water which was resulting in higher than OEM recommended bearing temperatures.
Hy-Pro was asked to provide a solution to consistently maintain water levels < 150 ppm on the 500 gallon / 1875 liter lube reservoir and enable the plant to lower the reservoir temperature to reduce excessive bearing temperatures.
Hy-Pro COT10 was installed and baseline oil analysis showed that the oil visibly cloudy and 788 ppm at the inlet of the coalesce skid. Analysis of the oil sample on the COT10 outlet showed visibly clear oil and 80 ppm. Approximately 6 hours after starting the coalesce skid the oil analyzed on the inlet of the COT10 showed visibly clear oil and 78 ppm. After several months of operation the turbine was taken off line for maintenance and upon start up there was a high ingress of water around the shaft seals which resulted in several gallons of accumulated water discharged by the coalesce skid. Eventually the reservoir temp was lowered and the water levels remained under control below 150 ppm.
At this plant there was no auxiliary heat to keep the oil warm during downtime so the turbine was traditionally started with a slow rolling manual start. After installing the COT10 with on-board heaters the reservoir temp could be maintained keeping the oil warm, clean and dry to eliminate the need for the slow start-up procedure.
What HY-PRO provided:
RULER (Remaining Useful Life Evaluation Routine) is used to quantify and trend remaining levels of Phenol and Amine anti-oxidant (AO) levels which is one of the factors considered in determining useful oil life. Once phenol AO levels drop below 20% of new, the rate of sludge and deposit formation can potentially increase and the oil may be condemned.
Figure 1 shows AO level trending after the installation of SVR1200 on a combustion turbine lube reservoir after the oil was replaced. After a year in service with SVR on board there is very little change in AO levels. This same turbine was losing ~20% of the phenol AO package annually without SVR. In addition to controlling varnish the SVR also extends the useful life of the oil by protecting the AO additive package.
As long as the elements are maintained, this turbine lube oil system will not have problems with varnish deposit formation and this new group II fluid has the potential to greatly exceed useful life expectations with high anti-oxidant additive levels. In addition to reducing AO additive depletion the SVR enables oil below 20% remaining phenols to stay in service.
What HY-PRO provided:
A peaking power plant was concerned about unit trip or fail-to-start conditions as one of the GE 7FA turbines had critically high varnish potential QSA® 100 (MPC ΔE ~60). The phenol anti-oxidant additives were also at a critically low level of ~4% of new oil level. Maintenance had also noticed that the main lube, pump discharge and actuator filter elements were coated with varnish deposits when changed so they were being changed quarterly instead of annually. Servo valves were also being changed periodically because of varnish deposits to avoid a possible unit trip or fail-to-start.
The contamination challenge was to remove the varnish deposits suspected throughout the lube and hydraulic systems that were supplied with oil from a common reservoir for both systems (common GE 7FA design). With phenol anti-oxidant additive levels extremely low the propensity for deposits to form was very high.
The SVR was installed on the combination lube and hydraulic reservoir and reduced the varnish potential from MPC ΔE = 60 to MPC ΔE = 35 in 15 days and to condition normal within 45 days. After 60 days MPC ΔE stabilized at single digits. Maintenance personnel removed the filter elements after achieving condition normal and reported no varnish deposits. Inspection of servo valves also yielded no evidence of varnish deposits. Filter element changes have been extended to standard annual intervals.
What HY-PRO provided:
Colorimetric analysis per ASTM D02.C0.01 WK13070 is used to determine varnish potential. A petroleum ether mixture agglomerates soluble by-products rendering them insoluble and visible for patch analysis. The patch is analyzed with a spectrometer measuring DE reported as the MPC DE value.
Figure 1 depicts SVR1200 installed on 7FA gas turbine experiencing unit trips from sticking servos.The SVR1200 had an immediate impact on the 6000 gallon turbine lube reservoir running GST32 lube oil. Within 45 days the lube oil varnish potential had been reduced from critical to condition normal.
Starting phenol level was ~5 which means it only had 5% phenols relative to a new sample, well below the lower threshold to condemn the oil for low levels of anti-oxidant additive package. Even though phenols were depleted the SVR was able to restore and maintain condition normal.
Since installing the SVR1200 there have been no CT varnish related fail-to-start conditions or unit trips!
Before installing the SVR the filter elements and servo valves were accumulating varnish deposits. To prevent unit trips the plant was changing servos and elements monthly in hopes of avoiding unit trip. After the successful restoration of the fluid with the SVR1200 the filter change interval has been extended back to 12 months PM and there has been no evidence of varnish deposits on filter elements or servo valve components.
What HY-PRO provided:
Figure 1 depicts the restoration of a heavily varnished CT where the MPC varnish potential value dropped from ~63 to ~35 in 25 days and then remained at that level indicating the need to change the SVR filter elements. Once the elements were changed the MPC drop continued and single digit MPC values were achieved. Condition monitoring via MPC or QSA is the most reliable way to know the elements are spent. A heavily varnished system might require two sets of elements to reach “Normal” condition and get into maintenance mode.
What HY-PRO provided:
Salt water began entering the hydraulic fluid on a 245 ft (75 m) purse seiner through a seal leak, rendering the net hauler out of commission. Faced with frequent fluid exchanges at a cost of $9300 plus disposal, or worse, substantially larger lost profits from downtime for replacement of the seal, the vessel owner was in desperate need for a solution to allow him to continue operating without fear of malfunctioning equipment.
Through fluid analysis it was found that the 265 gal. (1000L) reservoir of ISO VGA 32 hydraulic fluid contained 28564 ppm of water. If the ppm could not be reduced below 200 ppm it would inevitably have to be replaced.
A goal of reducing the water content to < 150 ppm was set and a V1S portable vacuum dehydrator was installed on the reservoir. The V1S ran for 10 days with samples for analysis being drawn on days 1, 3, 8 and 10.
With the V1S in service the water content in the hydraulic reservoir was reduced to a level where the net hauler was functioning properly again even before reaching the 150ppm target. Breaking down the numbers, the V1S removed at least 7 gallons / 26.5 liters of water and even more depending on ingression. The fishing vessel was able to continue operations and avoid frequent expensive oil replacement by installing the V1S.
Download the case study handout below for more info!
What HY-PRO provided:
A large papermill was living with the extra expense of main-bearing lube filter elements that were reaching their terminal DP change limit on an average 3-week interval. This was disruptive and costing the company over $70,000 in additional filter expense. This mill never stops, running all day every day, so staying operational is a top priority. In addition to frequent filter changes, the mill was missing its 17/15/12 ISO fluid cleanliness code, the maximum limit for particles 4u and larger.
The actual average ISO fluid cleanliness code for the mill was 18/15/12, which is twice the particle limit allowed in the system. High ISO codes, coupled with frequent filter changes are not just expensive, but also leave the paper machine vulnerable to even more costly breakdowns and downtime.
The company upgraded to Hy-Pro's HP619L40-6EB filter elements with the goal of improving cleanliness to a 17/15/12 or better and extending element life. The change interval was extended to 4 weeks with ISO codes trending to 17/15/12. To fully support our customer, Hy-Pro experts followed up with consultation about change frequency and longer element life associated with achieving lower ISO codes.
As a result, the papermill achieved a filter lifespan of 11 weeks after validating that the Hy-Pro upgrades maintained a 16/14/12 ISO code as differential pressure increased up to terminal DP, with a whopping 75% reduction of dirt in this critical paper machine main lube system.
What HY-PRO provided:
Maintenance professionals explained that though the ISO codes had not exceeded the "high limit" parameters set by the oil manufacturer, they were, however, hovering closer and closer to it, causing the use and purchasing of more filters. Continued research provided maintenance professionals with the information needed to conclude that if the current oil analysis trend was to continue that there could be unexpected downtime in the near future. Because of these three contributing factors, Hy-Pro was contacted and given an opportunity to assess the situation and offer reliable solutions if able.
When Hy-Pro's representatives arrived, they initiated their investigation by identifying the lube oil filters they would need to start a system test, ensuring there were proper sample ports for oil testing.
Using particle counting technology, it was found that the paper products manufacturer was achieving ISO codes of 17/14/10. Furthering the exploration, Hy-Pro representatives spoke with on-site maintenance professionals to find ut normal DP ratings, indicated for change, as well as the average element life, which was only 60 days for current filters. After collecting all the evidence, a plan of action was created taking into account goals set by the client. These goals included: reducing the number of filters being purchased each year, lowering labor costs, maintaining or improving current ISO code levels and saving money overall.
The plan of action would include documenting current ISO codes, replacing all current filters in the lube system with Hy-Pro filters, setting a time period of one week to come back and resample the oil, and finally providing replacement elements for when terminal DP was reached and elements needed to be changed. Additionally, they would need to document the length of the Hy-Pro element life and any further changes to the ISO codes.
After one week's time, Hy-Pros representatives returned to resample the oil. No issues had been reported and as far as the client was concerned, business was as usual. Results from the resampling concluded that, in seven days' time, ISO codes had dropped from 17/14/10 down to 15/13/9. These numbers hadn't been seen in quite some time.
Instructions were left for the client to notify Hy-Pro when they had reached terminal DP for the filter and had to change it out; spare Hy-Pro elements had been left for when this event would occur. Over the next fewmonths Hy-Pro heard nothing from the client. Hy-Pro checked in with them at month one and they nothing to report. After month two they still had nothing to report. Finally, after three months there was still nothing to report, so Hy-Pro set an appointment to come back to the facility on the fourth month to ensure all was right.
However, before arriving, the phone call finally came. At the 120-day mark, terminal DP was reached and the Hy-Pro filters were replaced. Hy-Pro tested the system again, ending with the same ISO code results, 15/13/9, and the client couldn’t have been happier.
What HY-PRO provided:
The lube system supplying cooled and filtered lube oil to the roller bearings on the paper machine dry end was consuming a substantial amount of filter elements. This large paper producer was searching for a solution to reduce bottom line profitability by reducing element consumption and ISO fluid cleanliness codes.
Hy-Pro was challenged to improve average element life of ~41 days and ISO code 20/15/9.
Hy-Pro lube specific element design HP8314L39-6LB was applied yielding a drop in ISO code from 20/15/9 to 19/11/6 which represents a 93.7% drop in particles 6u[c] and larger. Since the upgrade average element life has been extended from ~41 days to ~61 days.
What HY-PRO provided:
This paper mill was seeking improvements in ISO fluid cleanliness codes and average element life.
The challenge was to drop from ISO code 20/17/16 and extend element life beyond an element life average of ~30 days with the current filter elements utilized.
On-line particle counting was used to quantify fluid cleanliness before and after the upgrade to Hy-Pro DFE rated elements. The result was at least a 4 digit ISO code drop on each channel from 20/17/16 to 16/12/9. This translates into a 90.8% reduction in particles 4µ[c] and larger, a 98% reduction in particles 6µ[c] and larger and a 99.5% reduction in particles 14µ[c] and larger.
Element change intervals were documented yielding an 81% improvement in life after the upgrade from 29.5 days to 53.6 days. This can partially be attributed to the improvement in ISO codes for once the system is cleaner there are fewer internally generated particles to be removed. With fewer particles in the oil the rate of additive depletion can also be expected to decrease resulting in extension of useful oil life making this upgrade a substantial money saver.
What HY-PRO provided:
Saw mills operate multiple pieces of large equipment with hydraulic systems. When this equipment faces unplanned downtime due to important components becoming fouled from contaminated fluid profits decrease while production costs increase. This causes a huge financial burden that can feel exponential as components must be repaired or replaced. Implementing Hy-Pro's Total Systems Cleanliness Approach will reduce downtime and expenses while increasing efficiency and productivity.
When all factors such as maintenance personnel hours, replacement parts, fluid consumed and the decrease in profitability are considered it is easy to understand the substantial cost impact that occurs due to fluid that is poorly cared for. Identifying your fluid contamination issues provides an excellent opportunity to lower operating costs and increase efficiency.
Applying the Total Systems Cleanliness Approach is necessary to maximize uptime, extend component life, extend fluid life, reduce maintenance resource demands and reduce fluid disposal costs. Upgrading to DFE rated G8 Dualglass filter elements with absolute efficiency, installing Hy-Dry Desiccant Breathers and installing additional off-line filtration where necessary can be very effective.
What HY-PRO provided:
Paper mills are commonly plagued with water contamination in hydraulic and lube oil. This particular mill used the V1 mini vacuum dehydrator to condition several small reservoirs with great success.
Application #1 was a super calendar CC 200 gallon / 757 liter lube reservoir running PM220 with a reservoir temperature of 110F / 43C and water contamination at 1400 ppm. After 48 hours of unattended operation the water level was reduced to < 100 ppm.
Application #2 was a wet end vacuum pump 300 gallon / 1,125 liter lube reservoir with a temperature of 125F / 51C. At the time of installation the fluid contained 20,000 ppm of water and after 72 hours of operation the water level was reduced to 60 ppm.
Application #3 was a 200 gallon / 757 liter tote of reclaimed AW46 hydraulic oil at ambient temperature of approximately 80F / 26C. The oil was contaminated with 10,000 ppm of water and after 24 hours the water level was reduced to < 100 ppm.
What HY-PRO provided:
A company shredding discarded grocery bags and other plastic films to produce recycled products was experiencing frequent hydraulic motor and charge pump failures on a closed loop hydraulic system driving a bag shredder. Microscopic slivers of the plastic generated by the process would find their way into the fluid and cause the pump or motor to fail. These failures created a large cloud of debris particles in the hydraulic fluid which would travel to the next component and further repeat this sequence of failure and increased fluid contamination until the failure is catastrophic throughout the system.
Generally occurring twice a year, these instances would cost the company approximately $110k in repairs, not taking into account the added cost for the downtime and maintenance hours. The frequency of these catastrophic failures needed to be reduced to increase profitability and plant efficiency.
When asked to survey the system, Hy-Pro noted a lack of filtration between the pump & motors and inefficient filter elements being implemented in existing housings. To make matters worse, because of the need to reverse the flow direction within the system, standard unidirectional filtration would not be sufficient to protect components from the ingested plastic.
All elements were upgraded to Hy-Pro DFE Rated G8 Dualglass filter elements. PFHB bi-directional flow filter housings were also installed on each hydraulic line leading to & from the pump to isolate each component in case of a failure. With bi-directional filtration on both sides of the motors, all contamination traveling to and from the motor would be captured by a filter and the failures they were experiencing would be prevented.
Failure rates have been reduced by more than half since upgrading to Hy-Pro elements and installing additional filtration. The debris cloud dumped into the hydraulic fluid during a recent pump failure was isolated by the filter elements inside the new PFHB filter assemblies. This saved the company over $60k compared to previous incidents where the motors would have been destroyed as well.
The DFE rated filter elements and PFHB Bi-Directional Filter Housing used in this application are ideal in various other applications including Steel Mills, Board Plants, Scrap Yards, Concrete Mixers, and other Hydrostatic Loop Circuit applications in which flow can reverse direction.
What HY-PRO provided:
Problematic ISO codes, premature fluid replacement and varnish buildup.
The Problem
At a ceramic molding facility, dirt and varnish accumulation inside the process vacuum pumps caused unexpected downtime and higher than normal oil replacement rates. High rates of particulate and moisture ingression are expected within this industry, and for too long, have maintenance professionals been left without practical and effective solutions.
The Solution
After consultation with Hy-Pro, the best solution was Hy-Pro’s COF. The installation was a dedicated unit with Hy-Pro’s VTM media to control three phases of oil contamination; dirt, water and varnish.
The Results
The result was outstanding, one month after installation, the COF combined with supporting VTM filter technology, ISO codes plummeted achieving world class fluid cleanliness of 13/11/7. It gets better.
Download the case study to see the full results and cost savings!
Lube oil systems in steel mills and paper mills are commonly plagued with water contamination which compromises the lubricating properties of the oil and reduces useful fluid life. Band-aid maintenance practices such as decanting free water from the bottom of lube reservoirs and the application of antiquated centrifuge equipment are common strategies used to combat water in lube oil. The typical result is shorter bearing life caused by poor lubrication, extra maintenance hours, higher than necessary oil consumption, down time and environmental impact from the decanting and oil recovery process.
To learn more check out this article on how vacuum dehydration can control and maintain water levels below saturation, extend bearing and fluid life, and eliminate the decanting routine.
What HY-PRO provided:
The high pressure plate mill hydraulic system has several filter locations including bulk tank recirculation, pump discharge, servo pilot, return and recirculation. Baseline ISO fluid cleanliness codes were 17/15/12.
The mill wanted the oil cleaner and Hy-Pro accepted the challenge to improve the system cleanliness.
After establishing the 17/15/12 baseline several filter element and breather upgrades were recommended. Once the upgrade to all Hy-Pro DFE rated elements was complete on-line particle counting confirmed an ISO code drop from 17/15/12 to 12/8/<1. Post upgrade there was a 97.2% reduction in particles 4µ[c] and larger, a 99.5% reduction in particles 6µ[c] and larger and a 99.9% reduction in particles 14µ[c] and larger.
What HY-PRO provided:
Steel mill rolling mill lube oil has long been accepted as oil that is commonly dirty and not much is done to remedy that. One steel mill partnered with Hy-Pro to come up with a solution achieve & maintain a suitable level of fluid cleanliness for their rolling mill lube oil.
Regular tests of heavy-duty gear oil were consistently at unacceptable ISO cleanliness ratings. Filter and oil replacements were becoming a frequent and costly occurrence. The challenge was to upgrade the current system equipped with only 74 micron wire strainers and improve from a 21/21/15 ISO code on their 6,000 gallon / 22,500 liter lube reservoir.
Dedicated FSL3 off-line high viscosity system (22 gpm, 82.5 lpm) was installed on the 6,000 gallon / 22,500 liter reservoir containing Mobil 634 gear lube. HP107L36-3MB 3 micron absolute rated Hy-Pro element was used in the FSL and with in three days of starting the trial the ISO code had dropped from 21/21/15 to 18/16/12. This yields an 87.5% reduction in particles 4µ[c] and larger, a 94.3% reduction in particles 6µ[c] and larger and a 90.1% reduction in particles 14µ[c] and larger.
What HY-PRO provided:
The hydraulic oscillator delivering molten steel for casting molds was operated by 250cc pumps driving a large servo valve. Frequent hydraulic fouling and relatively unreliable operation lead to the assumption that improving fluid cleanliness would improve reliability and productivity.
The system was originally fitted with 3 micron glass media elements on pump discharge, servo pilot and return filters plus there was a 1 micron element installed in the off-line filter skid yielding 15/13/8 ISO fluid cleanliness codes.
The pump discharge, servo pilot and return elements were upgraded to DFE rated Hy-Pro 3M media B5[c] > 1000 and the off-line skid element was upgraded to Hy-Pro 1M media B2.5[c] > 1000. On-line particle counting was used to verify the before and after ISO codes which dropped with the Hy-Pro upgrades from 15/13/8 to 13/11/6 resulting in a 75% reduction in particles 4m[c] and larger, a 75% reduction in particles 6m[c] and larger and a 74.7% reduction in particles 14m[c] and larger.
What HY-PRO provided:
A steel mill was experiencing rolling mill bearing reliability issues and high oil consumption as a result of daily decanting accumulated water from the bottom of the reservoir. The oil was very cloudy and losing its demulsibility (ability to shed water)
The contamination challenge was to reduce and maintain the water level from 29,000 ppm (2.9%) water in the oil to a suitable level that would eliminate the need to decant accumulated water. The mill also wanted to drastically reduce rolling mill oil consumption which was ~72,000 gallons / 270,000 liters per year at $8 a price of per gallon. The mill was also losing roller bearings with high frequency at a cost of $30,000 per bearing. In addition to the oil consumption, downtime and bearing replacement costs the decanted water and oil mixture was drained into a sealed retention pond from which the oil had to be periodically removed.
The VUD was installed and within one shift the water level dropped from 29,000 ppm to 17,735 ppm and after two weeks the water level was holding steady and measured at 383 ppm. The oil no longer had the cloudy appearance of chocolate milk or mud and the mill had stopped the daily routine of decanting accumulated free water and oil mixture from the bottom of the reservoir and into the pond. The operators also noticed that the oil had stopped leaking around roll stand gearbox labyrinth seals.
With the elimination of roll stand leaks, topping off to compensate for leaks and decanting initial estimates showed a 25,000 gallon / 93,750 liter (35%) reduction in annual oil consumption with a cost savings of ~$201,600. Major oil consumption has now been narrowed to oil lost in roll stand changes. Retention pond oil recovery efforts have also been greatly reduced.
What HY-PRO provided:
