Mining Company Increases Uptime With Shell Lubeexpert

COMPANY – Sasan Power Limited

LOCATION – Singrauli, India

APPLICATION – Caterpillar – CAT 495

KEY EDGE – Shell LubeExpert and Shell Gadus S3V 460D 2

SIGNIFICANT – Maintenance Cost Reduction

CHALLENGE – This open cast mining company wanted to optimise the performance and reliability of its CAT 495 shovels and was working with Shell India to monitor its equipment using Shell products backed by Shell LubeAnalyst, Shell LubeCoach and Shell LubeExpert.

SOLUTIONS – During a routine inspection, Shell’s engineer identified a pumping issue on the load and carry rollers. An investigation discovered a damaged return line was the cause and the engineer reported the need for a change of part.

OUTCOME – By carrying out regular inspections and troubleshooting activity through Shell LubeExpert, the company is able to avoid component failure that could lead to significant downtime, keeping machinery running and productivity high.

With its timely maintenance reducing the cost of replacement parts and the costs associated with downtime, the company has estimated savings of ₹ 7,21,18,597 per vehicle .

Indian Haulage Company Doubles Its Oil-Drain Interval By Using Shell Rimula R4

COMPANY – Haulage Company

LOCATION – India

APPLICATION – Heavy-duty diesel engines

KEY EDGE – Shell Rimula R4 l5W-40, Shell LubeAdvisar, Shell LubeVideaCheck

Savings – ₹ 1,80,109 total reported annual customer saving.

An Indian haulage company has a fleet of about 120 trucks, most of them made by Tata Motors. The company was using an API CF-4 lubricant that gave an oil-drain interval of 18,000 km but was looking for improvement.

Shell explained the benefits of using Shell Rimula R4 l5W-40 and suggested that the company should trial the lubricant. Shell also offered the Shell LubeAnalyst oil condition monitoring service and Shell Lube Video Check, a fibre­-optic tool that enables operators to inspect key internal engine components.

As a result of using Shell Rimula R4 l5W-40, the trucks’ oil-drain interval increased from 1 8,000 to 36,000 km, which gave the company a total reported annual saving ₹ 1,80,109 for 18 vehicles.

Construction Company Doubles Oil Life With Shell Tellus S3 M 46

COMPANY – Powermech Project Limited

LOCATION – Hyderabad, India

APPLICATION – Sany, IHI and Fuwa crawler cranes

KEY EDGE – Shell Tellus S3 M 46

Significant – 100% Increase in Oil Life

TOTAL ESTIMATED ANNUAL CUSTOMER SAVING ₹ 33,89,970.

CHALLENGE – Powermech was using a fleet of crawler cranes featuring Cummins QSB engines and Rexroth hydraulic pumps. With the cranes operating under high loads and in a hot and dusty environment, the company wanted to improve equipment reliability and extend oil life in order to boost productivity.

Solution – The Shell Lubricants team recommended a switch to Shell Tellus 53 M 46 for its superior anti-wear properties and filterability. The product’s results in a similar application and environment were used to demonstrate its ability to reduce the risk of contamination.

Outcome – In the 12 months after the switch, there were no equipment failures with the oil drain extending from 2,000 to 4,000 hours. This resulted in longer component life and helped the company reduce its oil inventory.

Value – Based on reduced maintenance time and oil consumption across its fleet of 70 cranes, the company has reported annual savings of ₹ 33,89,970.

Metals Company Reduces Operating Costs with Shell Lubeanalyst

LOCATION – Torangallu, India

APPLICATION – MHI mill gearboxes

KEY EDGE – Shell LubeExpert & Shell LubeAnalyst

Significant – OIL MAINTENANCE COST REDUCTION

TOTAL ESTIMATED ANNUAL CUSTOMER SAVING ₹ 86,85,911.

CHALLENGE – This metals company was operating MHI mills 24/7 in high temperature, dusty environments with a high level of water contamination risk. It wanted to ensure it was running the ideal lubricant set-up for reliability and cost-efficiency.

Solution – The Shell Lubricants team carried out monitoring with the Shell LubeAnalyst service. Recommendations included adjusting the heater settings, cleaning the tank manually and replacement or partial replacement of sumps to increase viscosity levels.

Outcome – With heating issues addressed, the oil viscosity is being maintained at an optimum level. This has improved gear reliability and reduced the incidence of unplanned shutdowns and loss of production. Ongoing monitoring through Shell LubeAnalyst and Shell LubeExpert delivers added peace of mind.

Value – Preventative maintenance has helped to reduce unplanned downtime, leading the company to report estimated annual savings of ₹ 86,85,911.

Dhansar Engineering Brings Down Total Cost Of Ownership With Shell Gadus S3 T220 2

COMPANY – Dhansar Engineering

LOCATION – Agucha, India APPLICATION: Komatsu HD 785 haul trucks

KEY EDGE – Shell Gadus S3 T 220 2

150% INCREASE IN COMPONENT LIFE

TOTAL ESTIMATED ANNUAL CUSTOMER SAVING ₹1,29,11,417

.

CHALLENGE – Dhansar Engineering wanted to improve the reliability of the bearings in its Komatsu HD 785 haul trucks, with component life currently standing at around 800hours.

Solution – Based on the high operating temperatures at the site, the Shell Lubricants team recommended switching to Shell Gadus 53 T 220 2 in order to extend the life of the damper bearings.

Outcome – Changing to the new product has transformed reliability, with bearing life increasing to 2,000hours.

Value – Increased uptime and productivity combined with savings on maintenance and replacement parts have seen the company reporting savings per vehicle estimated at ₹1,29,11,417.

VRL Logistics Transforms Oil Life with Shell Spirax S6 Axme

CHALLENGE – To extend the life of the oil in its rear axles to increase vehicle availability and reduce maintenance costs.

Solution – Carried out a field trial of Shell Spirax S6 AXME that demonstrated its durability.

Outcome – Extended its oil drain interval from 1,50,000 to 10,00,000 km leading to a significant reduction in planned downtime.

Factory Extends Equipment Life with Shell Omala S4 WE320

CHALLENGE – To access its lubrication set-up to improve reliability and streamline maintenance.

Solution – Shell Lubricants team recommended Shell Omala S4 WE 320, as its compatibility with the soft metal of the worm gears would reduce wear.

Outcome – Unplanned downtime has also been eliminated, extending the life of the gearboxes by five times.

Mining Company Extends Component Life with Shell LubeAnalyst

CHALLENGE – To ensure that its lubricant was delivering maximum protection.

Solution – Shell Lubricants team used the Shell LubeAnalyst to identify low viscosity levels. After further investigation and sample testing, a fuel pump issue was identified, allowing the company to carry out an immediate service and avoid a complete engine rebuild.

Outcome – Carrying out proactive maintenance ensured the life of the engine was extended and maintenance time and costs were reduced. This has also boosted site productivity.

Use of the shell lubeanalyst oil and equipment condition monitoring service helped an integrated steel plant save an impressive on lost production.
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