High Surface Finish Defects at an Automotive Stamping Plant

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: ISO 4406, offline filtration, case study, fluid transfer, filters, DFE

An Aluminum Refinery Faces Premature Gearbox Oil Changes

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

The Application

An Australian aluminum refinery was consistently performing premature gearbox lube oil changes on seven 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 seven units.

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Topics: ISO 4406, case study, gearbox, aluminum refinery

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. Did it sink or swim? Find out below.

The Problem: Failed Hydraulics Seal and Lost Productivity

When a seal fails on a net hauler hydraulics system 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 seine through a seal leak, rendering the net hauler out of commission.

Faced with frequent fluid exchanges at a cost of $9,300 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, vacuum dehydrator, case study, VUD

Turbine Lube Oil Varnish and Removal Strategies: Part 4 of 4

Posted by Jim Harlan on Wed, Nov. 05, 2014

Combined Cycle Journal recently published an article on turbine lube oil varnish written by Peter Dufresne Jr. and his team at EPT. We’ve divided the article into four blogs to make it easier to digest -- click here to find parts onetwo and three


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Topics: case study, varnish, SVR, hydraulic oil, contaminination, lube oil, turbine oil

Diesel Fuel Filtration 101

Posted by Jim Harlan on Wed, Apr. 02, 2014

Diesel engines are widely used today. You can find them inside buses and tractor trailers traveling our roads, humming along in construction equipment and drill rigs, submerged in marine environments and helping save lives in hospital generators, amongst many other applications. Diesel engines are popular for good reason. Not only do they have cleaner exhaust emissions, they are also known for more reliable starts in extreme temperatures.

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Topics: water, Water Contamination, diesel, filtration, case study, contaminination

Equipment Failure at a Plastic Injection Molding Facility

Posted by Jim Harlan on Mon, Sep. 09, 2013

The Problem: Frequent Equipment Failure 

A plastic injection molding facility was experiencing frequent equipment failures due to hydraulic fluid contamination. The failures were affecting their budget with unexpected loss of productivity, increased maintenance hours and replacement parts.

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Topics: hydraulic fluid, contamination, plastic injection molding manufacturer, case study

Saw Mill Hydraulic and Lube Oil Contamination Control

Posted by Jim Harlan on Tue, Jun. 18, 2013

The Problem: Contaminated Fluid Means Downtime 

Sawmills operate using multiple pieces of large equipment and heavy machinery with hydraulic systems. Unfortunately, when this equipment becomes degraded with contaminated fluid, it means unplanned downtime for the sawmill and lost profits and decreased production levels. The financial burdens due to contaminated oil can feel enormous when the resulting costs are added up. 

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Topics: hydraulic fluid, contamination, saw mill, case study

Hydraulic Valve OEM System Upgrade Reduces Failures

Posted by Jim Harlan on Fri, May. 24, 2013

cranes and hydraulic valves

The Problem: Hydraulic Fluid Contamination 

A manufacturer of mobile, multi-function valves for heavy lifts and cranes was battling hydraulic fluid and contamination-related failures on four operating production lines.

After facing multiple challenges, including 25 hydraulic pump replacements in a single year due to wear and failure, a finished product consistently testing below quality specifications and fluid repeatedly measuring above suitable ISO code levels, the manufacturer needed a new solution. 

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Topics: hydraulic fluid, case study, hydraulic valve

Improving Diesel Engine Life

Posted by Jim Harlan on Thu, May. 09, 2013

The Problem: Premature Failure of Diesel Engines  

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.

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Topics: diesel, case study, COD, FSL, DFE

Keeping Clean in a Dirty Environment [Case Study]

Posted by Aaron Hoeg on Fri, Feb. 08, 2013

dirty mining excavator

Mining is a dirty business, as you can imagine, and equipment used to aid in mining efforts is not immune to the filth. Yet it is imperative to keep fluid clean. Not only will it save time and money, it lessens the amount of downtime for repairs, which is always a great goal.

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Topics: contamination, case study, hydraulic

  

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