Sasan Power Maximises Boom Foot Pin Life With Shell Lubeexpert

COMPANY – Sasan Power Ltd

LOCATION – India

APPLICATION – CAT 7495 excavator shovels

KEY EDGE – Shell LubeExpert

IMPORTANT – Avoidance OF COSTLY REPAIRS

SAVINGS – US $92,000 total reported annual customer saving

CHALLENGE – This mining company was running a fleet of CAT 7495 excavators and wanted to monitor lubricant performance in order to maximise the life of its components, increasing equipment availability and productivity.

SOLUTIONS – Following a Shell LubeExpert test, the Shell Lubricants team made recommendations to replace a broken grease pipe line that was causing the boom foot pin to run dry.

OUTCOME – After acting on the advice to replace the pipline and fit a new grease nipple, the flow of grease to the pinions and gears was restored, protecting the components from wear.

The timely maintenance to the lubrication system helped to avoid costly repairs and the associated costs of downtime, with the company reporting estimated annual savings of US$92,000.

Company Optimises Lubrication With Shell Lubeexpert

COMPANY – GMMCO Ltd

LOCATION – India

APPLICATION – CAT 7493 HD haul trucks

KEY EDGE – Shell LubeExpert

IMPORTANT – Significant reduction IN LUBRICANT COSTS

SAVINGS – US $22,000 total reported annual customer saving

CHALLENGE – GMMCO was operating a fleet of CAT 7493 HD haul trucks in a high dust environment in ambient temperatures up to 45C. The company wanted to optimise the grease consumption in the trucks’ moving joints with a view to bringing down operating costs.

SOLUTIONS – The Shell Lubricants team used the Shell LubeExpert service to analyse the current lubrication set-up. This included a detailed report on the performance of the injectors which identified over-greasing in a number of units.

OUTCOME – After changing the injectors, the OEM-specified greasing levels were achieved, delivering optimum protection to the machinery. This resulted in a drop in grease consumption across the fleet of 32 vehicles.

Based on reduced consumables costs, the company has reported estimated annual savings of US$22,000.

Mining Company Improves Equipment Performance With Shell Lubeexpert

COMPANY – Sasan Power Ltd

LOCATION – Singrauli, India

APPLICATION – CAT 7495 shovels & excavators

KEY EDGE – Shell LubeExpert

IMPORTANT – Major reduction IN OPERATING COSTS

SAVINGS – US $41,000 total reported annual customer saving

CHALLENGE – This mining company was operating CAT 7495 shovels and excavators under heavy loads at its open cast mine. It wanted to ensure that its lubrication processes and high viscosity Shell Gadus S4 OGT were offering maximum protection.

SOLUTIONS – The Shell Lubricants team used the Shell LubeExpert service to carry out a systematic inspection of a shovel that was showing high grease consumption. The audit recommended maintenance work on two injectors that were by-passing.

OUTCOME – After new injectors were fitted and the system was tested, grease delivery was shown to be stabilised. This ensured optimum levels of lubrication and long-term protection.

The reduction in consumables costs saw the company reporting estimated annual savings of US $41,000.

Mining Company Reduces Operating Costs With Shell Lubeexpert

COMPANY – Sasan Power Ltd

LOCATION – India

APPLICATION – Cat 7495 shovels and extractors

KEY EDGE – Shell LubeExpert

IMPORTANT – 27% REDUCTION IN GREASE CONSUMPTION

SAVINGS – US $29,000 total reported annual customer saving

CHALLENGE – This mining company was operating a fleet of CAT 7495 shovels and excavators. It wanted to optimise grease consumption in order to get the best value out of its lubricants and control operating costs.

SOLUTIONS – The Shell Lubricants team carried out a detailed inspection of the equipment and, working with the Sasan engineers, identified the root cause of high grease consumption on one of the shovels.

OUTCOME – Maintenance work on the bypassing injectors that were over-delivering grease to the hoist system enabled the business to bring its annual grease consumption down from 11,800 to 8,640kg.

Based on reduced consumables costs, the company has reported estimated annual savings of US$29,000.

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

IMPORTANT – Significant – Maintenance Cost Reduction

SAVINGS – US $971,000 total reported annual customer saving

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 US$971,000 per vehicle.

The Use Of The Shell Lubeanalyst Oil And Equipment Condition Monitoring Service Helped An Integrated Steel Plant Save An Impressive Us$600,778 On Lost Production

LOCATION – India

APPLICATION – Hot rolling and finishing mill

KEY EDGE – Shell LubeAnalyst

SAVINGS – US $600,778 total reported annual customer saving

CHALLENGE – An Indian customer operates a large, efficient integrated steel plant specialising in hot rolling and finishing of flat strip. In the high-humidity, hot, dusty environment, the customer’s lubricant is subjected to the toughest operating conditions. The challenge was to maintain the plant’s reliability and high production levels.

SOLUTIONS – Understanding lubricant and equipment condition is vital in helping to maximise production output while preventing downtime caused by mechanical failures. Shell Lubricants recommended the Shell LubeAnalyst service for close monitoring of oil condition and performance.

OUTCOME – The Shell LubeAnalyst service means the engineers on-site receive rapid, highquality diagnostics reports via email or the Web, and can identify any abnormalities and rectify or prevent mechanical breakdowns at an early stage to avoid unplanned downtime and lost production.

The steel company can monitor equipment and lubricant condition accurately and schedule in oil changes and equipment maintenance. As a result, equipment maintenance, labour hours and downtime are lower, which has increased production. This exercise resulted in a reported total annual cost saving of US$600,778.

COMPANY – Thriveni Earthmovers

LOCATION – India

APPLICATION – Hitachi EX110 excavators

KEY EDGE – Shell LubeAnalyst

IMPORTANT – IMPROVED MAINTENANCE PLANNING

SAVINGS – US $16,000 total reported annual customer saving.

CHALLENGE – This mining company was operating Hitachi EX110 excavators at its underground iron ore mine in very hot, dusty conditions. It wanted to ensure that its lubricant was delivering maximum protection.

SOLUTIONS – The Shell Lubricants team used the Shell LubeAnalyst service 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.

The reduction in maintenance and unscheduled downtime saw the company reporting estimated annual savings of US$16,000.

Metals Company Reduces Operating Costs With Shell Lubeanalyst

LOCATION – Torangallu, India

APPLICATION – MHI mill gearboxes

KEY EDGE – Shell LubeExpert & Shell LubeAnalyst

IMPORTANT – Significant – OIL MAINTENANCE COST REDUCTION

SAVINGS – US $119,000 total reported annual customer saving.

CHALLENGE – This metals company was operating MHI mills 24/7 in high temperature, dusty enviroments 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.

SOLUTIONS – 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.

Preventative maintenance has helped to reduce unplanned downtime, leading the company to report estimated annual savings of $119,000.

Dhansar Engineering Optimises Production With Shell Gadus S3 V460D 2

COMPANY – Dhansar Engineering Company

LOCATION – India

APPLICATION – Komatsu & Volvo excavators

KEY EDGE – Shell Gadus S3 V460D 2

IMPORTANT – Upto 4x LONGER RE-GREASING INTERVAL

SAVINGS – US $63,000 total reported annual customer saving.

CHALLENGE – Dhansar Engineering wanted to optimise the re-greasing schedule and costs for its fleet of Volvo and Komatsu excavators. This was being done manually every 8 hours using its current product, so the company wanted to reduce the maintenance manpower required.

SOLUTIONS – Shell Lubricants recommended switching to Shell Gadus S3 V 460 D 2. With its high base oil viscosity with lithium complex-based thickener technology and solid additives, it was ideally suited to the company’s equipment and operating environment and would deliver a step-change in performance.

OUTCOME – Changing to the new product extended the re-greasing interval from 8 hours to 32 hours, with associated benefits including increased production levels and a reduction in downtime.

With fewer stoppages for re-greasing improving productivity and reducing operating costs, the company has reported estimated annual savings of US$63,000.

Dhansar Engineering Increases Haul Truck Uptime With Shell Gadus S3 V220C 2

COMPANY – Dhansar Engineering

LOCATION – Rajasthan, India

APPLICATION – Komatsu HD 785-100 T haul trucks

KEY EDGE – Shell Gadus S3 V220C 2

IMPORTANT – 75% Reduction in scheduled maintenance downtime

SAVINGS – US $120,000 total reported annual customer saving.

CHALLENGE – Dhansar Engineering was running a fleet of Komatsu HD 785-100 T haul trucks in ambient temperatures ranging from 0-50C. It wanted to extend its re-greasing interval to improve equipment availability.

SOLUTIONS – The Shell Lubricants team carried out trials that involved changing the setting on the lubrication system, including the injectors, to optimise the delivery of grease. The team also recommended a switch to Shell Gadus S3 V220C 2.

OUTCOME – The new re-greasing protocols and application of the new product reduced grease consumption from 10kg to 3kg per day and downtime also dropped – from 300 to 75 hours per year.

By extending its re-greasing intervals – leading to a reduction in costs for both manpower and consumables – the company has estimated annual savings of US$120,000.