VUD Prevents Bearing Failure & Unplanned Outage

Posted by Jim Harlan on Tue, May. 16, 2017

Saves >$15,000,000 by removing water and particulate from common reservoir lube oil.

The Application

In boiler water feed pump applications, water often finds its way into the oil lubricating the pump’s bearings. This was the scenario at a paper manufacturing facility that turned to Hy-Pro for help.

The Problem

In this application, the boiler water feed pump bearing lube system was combined with the facility’s steam turbine lube oil system. The water, and the particulate contamination it was bringing with it, were decreasing the fluid’s ability to lubricate the bearings and causing premature wear on the bearings. The facility was attempting to remove free water with water absorbing filters (changed weekly) but the rate of ingression was too high for the filters to be as effective as needed. And since absorbents only remove free water, the filter elements were unable to address the dissolved and emulsified water present in the oil.If the situation were to continue much longer, a premature replacement of the steam turbine and boiler feed pump bearings would be necessary outside of the scheduled maintenance periods. While possible, this solution would cost millions of dollars without addressing the root of the problem. 

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Topics: water in oil, water, Water Contamination, iso cleanliness codes, ISO Fluid Cleanliness Codes, filtration

Varnish in AW Hydraulic Oil

Posted by Jim Harlan on Tue, May. 02, 2017

Saves >$200K/year by reducing downtime, defective units, idle labor and oil costs.

The Application

During the manufacturing process of refrigerators, isocyanate is hydraulically injected into the body of the appliance to improve insulation. After injection, the chemical transforms from liquid to foam.
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Topics: varnish in hydraulic oil, iso cleanliness codes, ISO Fluid Cleanliness Codes, filtration

Hydraulic Pump Reliability

Posted by Jim Harlan on Tue, Feb. 21, 2017

The Problem

Pumps are the heart of hydraulic systems. When the pump fails, the entire system is down until the pump is operational again. This poses a serious threat to any operation relying on hydraulic systems for productivity. 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.

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Topics: hydraulic fluid, contamination, fluid cleanliness, dirt, iso cleanliness codes, ISO 4406, filtration, Fluid Analysis

Cleanliness Requirements for Fluid Transfer

Posted by Jim Harlan on Tue, Feb. 07, 2017

The Problem

Today’s oil suppliers are often required to provide fluid at or below a specified ISO Cleanliness Code. One such supplier was experiencing short filter element life (15 days) on the system (7 element multi-round housing) used to achieve the required ISO Cleanliness Code of 18/16/13 in a single pass as 15W-40 oil is transferred from their bulk storage tanks to tanker trucks for delivery.

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Topics: hydraulic fluid, contamination, fluid cleanliness, dirt, iso cleanliness codes, ISO 4406, filtration, Fluid Analysis

Sheet Metal Stamping | Automotive Manufacturing

Posted by Jim Harlan on Tue, Jan. 03, 2017

The Application

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 Problem

The uncoiler / washer lube oil system was protected by an off-line filtration system fitted with CJC 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.

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Topics: contamination, fluid cleanliness, dirt, maintenance, ISO 4406, filtration

Gearbox Lube Oil - Aluminum Refinery

Posted by Jim Harlan on Wed, Dec. 14, 2016

The Application

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.

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Topics: hydraulic fluid, contamination, fluid cleanliness, dirt, hydraulic filters, iso cleanliness codes, ISO 4406, fluid samples, filtration, Fluid Analysis

Hydraulic Valve Performance Test Stands & Clean Oil

Posted by Jim Harlan on Tue, Nov. 29, 2016

The Application

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:

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Topics: hydraulic fluid, contamination, fluid cleanliness, dirt, hydraulic filters, iso cleanliness codes, ISO 4406, fluid samples, filtration, Fluid Analysis

Video: Your Lab Reports Are Probably Wrong - Here's How To Save Them

Posted by Scott Howard on Tue, Aug. 16, 2016
When looking at a lab report it is assumed the information on the report is accurate. A certified lab will not usually make an error in the report, but if so it is obvious and easily fixed. Ever hear the saying "By the time the lab gets the report the error has already been made?" For the most part this is true. Where people are led off course is believing the particle count on the lab report is the gospel. This is natural, but unfortunately not always the case with a bottle sample unless you already employ the techniques listed in the video below.
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Topics: hydraulic fluid, fluid cleanliness, dirt, hydraulic filters, ISO 16889, iso cleanliness codes, ISO Fluid Cleanliness Codes, diesel, ISO 4406, fluid samples, filtration

Fluid Analysis Reference Guide

Posted by Jim Harlan on Tue, May. 10, 2016

Do you have trouble translating your fluid analysis reports into useful information you can act upon? If you were to notice high levels of Ba on your report would you know what it is and where its likely coming from? If you could use a hand we’ve got the perfect tool in our new Fluid Analysis Reference Guide.

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Topics: Fluid Analysis

Vacuum Dehydrator Called On To Save Fishing Season

Posted by Jim Harlan on Fri, Apr. 15, 2016

One of our V1S vacuum dehydrators was recently put to the test in a marine application with hydraulic oil contaminated by more than 2500 ppm of water. Sink or swim? Find out below.

The Problem- When a seal fails on your net hauler hydraulics out at sea, the costs and lost profits stack up quickly. In this instance, 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.

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Topics: hydraulic fluid, contamination, water in oil, fluid cleanliness, water, dirt, Water Contamination, hydraulic filters, maintenance, fluid samples