12Nov

Mining Company Increases Productivity With Shell Gadus S3 V 460D

November 12, 2024 admin

Mining Company Increases Productivity With Shell Gadus S3 V 460D

COMPANY – Thriveni Earthmovers

LOCATION – India

APPLICATION – Hitachi EX670, EX870, EX110 & EX200 excavators

KEY EDGE – Shell Gadus S3 V 460D & Shell LubeExpert

IMPORTANT – 200% INCREASE IN RE-GREASING INTERVAL

SAVINGS – US $ 19,000 total reported annual customer saving.

CHALLENGE – Thriveni Earthmovers was performing manual re-greasing on its fleet of Hitachi excavators with a 12-hour interval. It wanted to extend product life to increase equipment availability and control maintenance costs.

SOLUTIONS – The Shell Lubricants team studied the application and operating conditions. A change to Shell Gadus S3 V 460D was recommended for its high base oil viscosity, lithium complex-based thickener technology and solid additives.

OUTCOME – TSwitching to the new product after a trial allowed the company to increase its re-greasing interval from 12 to 36 hours, leading to a reduction in downtime and labour costs.

The maintenance and productivity benefits associated with longer re-greasing intervals allowed the company to identify estimated annual savings of US $19,000..

02Jul

Grease compatibility with elastomers

July 2, 2024 admin

10Jun

How to control Industrial lubricants contamination?

June 10, 2023 admin

Industrial lubricants:

Contamination in Industrial lubricants will cause wear and tear in machines. Due to Particulate contamination & ingression of moisture it doesn’t take long for equipment to become gritty, dirty, and full of debris. It is hard to avoid in all equipment which use hydraulic or lube oil. Preventing the contamination is much easier and less expensive than clearing it from the contamination system.

What are the causes for the contamination in machine lubricants?

There are many reasons for solid particle contamination.

It can occur due to the addition of new oil.
Built in contamination
Along with the ambient air created by machine, machine borne particles will enter the lubrication system.
Water contamination can happen when oil stored outside will get exposed to the adverse weather.
Water spillage during the production process can also contribute to the water contamination.

What are steps we can follow to avoid this contamination?

General maintenance

Maintaining cleanliness is the key to avoid contamination. Dirt which gets inside the machine has to be in its surrounding area like exterior of the machine or the lubricant transfer equipment.

Prioritize the routine surface cleaning by establishing an equipment maintenance plan. Equipment and workspace should be regularly cleaned and detoxified using an enzymatic cleaner.

This should be done on the machinery, storage area of the lubricants and transfer equipment.

Train the Staff

Contamination can be a result of lack of knowledge of operating staff. It is important to train everyone who works with the system to understand the consequences of contamination. They will be well trained about the preventive steps to be followed

Proper Storage

Make sure your storage containers are not loose and generic. Store them in a clean designated place. Keep them color coded so that you can pick the right one when needed.

Oil change intervals

Changing oil and filter more often can keep the system contamination free but increases system’s vulnerability. Delaying the process will wear out the filtration system degrading the lubricants. It is necessary to perform regular condition checks for the better understanding of machine requirements.

Shell lube analyst is a must needed health check for your lubricants and equipment. Shell Lube Analyst helps your oil condition monitoring programmed. It improves equipment reliability and saves your maintenance money.

Need more information on machine and lubrication maintenance? Reach us Shell Lube Analyst.

10Jul

The Role of Shell Lubricants in Minimizing Friction, Wear, and Heat in Industrial Machines

July 10, 2022 admin

Introduction:

In the world of industrial machines, maximizing performance and longevity is essential for businesses to stay competitive. One crucial factor in achieving this is minimizing friction, wear, and heat within the machines.

This is where high-quality lubricants, such as those offered by Shell, play a pivotal role. In this blog, we will delve into the significance of Shell lubricants in minimizing friction, wear, and heat in industrial machines, and how they contribute to optimizing performance and extending the lifespan of these critical assets.

Understanding Friction and Wear: Friction and wear are inherent challenges in any mechanical system. When two surfaces come into contact and slide against each other, friction occurs, leading to energy loss, increased temperatures, and wear on the machine’s components.Shell lubricants are specifically formulated to reduce friction between moving parts, creating a thin protective layer that separates the surfaces and minimizes direct contact.
Lubrication as a Protective Barrier: Shell lubricants act as a protective barrier, preventing metal-to-metal contact and reducing the wear caused by friction. By providing a smooth and consistent lubricating film, these lubricants ensure that components glide smoothly against each other, reducing the potential for surface damage, abrasion, and erosion.This protective barrier extends the lifespan of machine parts, minimizing the need for repairs and replacements, and improving overall operational efficiency.
Heat Reduction and Thermal Stability: Friction generates heat, and excessive heat can lead to premature wear, thermal expansion, and potential system failures. Shell lubricants are designed with excellent thermal stability, meaning they can withstand high temperatures and maintain their lubricating properties even under extreme conditions.By efficiently dissipating heat, these lubricants help regulate the operating temperature of industrial machines, reducing the risk of overheating and maintaining optimal performance.
Load-Carrying Capacity and Extreme Pressure Protection: Industrial machines often operate under heavy loads and encounter extreme pressure conditions. Shell lubricants are engineered to withstand these demanding situations by providing exceptional load-carrying capacity and extreme pressure protection.They form a robust lubricating film that resists being squeezed out or ruptured, ensuring that critical machine components remain adequately protected and perform reliably under heavy-duty operations.
Contaminant Control and Cleanliness: Industrial environments are prone to contaminants such as dust, dirt, and metal particles, which can compromise the performance and longevity of machines.Shell lubricants are formulated with advanced additives that help control and suspend contaminants, preventing them from depositing on vital machine surfaces. This ensures that the lubricant remains clean and free from harmful particles, minimizing the risk of abrasive wear and maintaining optimal machine performance.
Specialized Formulations for Diverse Applications: Shell offers a wide range of specialized lubricants tailored to specific industrial applications. Whether it’s high-speed machinery, heavy equipment, or extreme temperature environments, Shell lubricants are formulated to meet the unique demands of each application.These tailored formulations ensure that machines receive the precise lubrication they need to operate at peak efficiency while minimizing friction, wear, and heat generation.

Conclusion:

In the realm of industrial machines, minimizing friction, wear, and heat is crucial for optimizing performance, increasing efficiency, and extending the lifespan of critical assets.

Shell lubricants play a vital role in achieving these goals by providing a protective barrier, reducing friction, dissipating heat, and ensuring the smooth operation of machines.

With their advanced formulations, load-carrying capacity, and contaminant control, Shell lubricants offer a reliable solution for businesses looking to maximize the performance and durability of their industrial machines.

By choosing Shell lubricants, companies can minimize downtime, reduce maintenance costs, and achieve sustainable success in their operations. Contact us to know more.

21Jan

Sasan Power Maximises Boom Foot Pin life with Shell Lube Expert

January 21, 2022 admin

Sasan Power Maximises Boom Foot Pin life with Shell Lube Expert

COMPANY: Sasan Power Ltd
LOCATION: India
APPLICATION: CAT 7495 excavator shovels
KEY EDGE: Shell Lube Expert

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

SOLUTION- Following a Shell Lube Expert 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 pipeline and fit a new grease nipple, the flow of grease to the pinions and gears was restored, protecting the components from wear.

VALUE- 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.

06Dec

Factory Extends Oil Life With Shell Tellus 2HF 68 SS

December 6, 2021 admin

Factory Extends Oil Life With Shell Tellus 2HF 68 SS

COMPANY – M/s Akshaya Associates

LOCATION – Chennai, India

APPLICATION – Schwing Stetter SP 1400 pumps

KEY EDGE – Shell Tellus 2HF 68 SS & Shell LubeAnalyst

SAVINGS – ₹ 10,55,572 total reported annual customer saving

SIGNIFICANT – 100% Increase In Oil Drain Interval

CHALLENGE – The factory was running a series of Schwing Stetter SP 1400 pumps in an environment with high levels of dust, concrete slurry and water contamination. The company wanted to identify a lubricant that would deliver an extended drain interval without affecting the performance of the pump.

SOLUTION – The Shell Lubricants team ran a field trial using Shell Tellus 2HF 68 SS, providing the Shell LubeAnalyst service (in tandem with OEM inspections) to demonstrate the outstanding longevity of the oil even under the factory’s extreme operating conditions.

OUTCOME – The product switch and close monitoring allowed the factory to confidently extend its oil drain internal from 2,000 to 4,000 hours and double the life of its filters. Following training the company was also able to improve maintenance practices and lubrication storage and handling.

VALUE – The combination of reduced maintenance and consumables costs saw the company report estimated annual savings of ₹ 10,55,572.

02Dec

Indian Logistics Company Extends Oil-Drain Intervals With Shell Rimula & Shell Spirax

December 2, 2021 admin

Indian Logistics Company Extends Oil-Drain Intervals With Shell Rimula R6 Lme And Shell Spirax S6 Axme

COMPANY – Logistics Company

LOCATION – India

APPLICATION -Engines and axles

KEY EDGE – Shell Rimula R6 Lme And Shell Spirax S6 Axme

SAVINGS – ₹ 2,22,38,531 total reported annual customer saving

A large logistics company in India operates a fleet of haulage and passenger transport vehicles. It has nearly 4,000 trucks manufactured by Ashok Leyland and over 5OO Volvo coaches. The company wanted to increase its vehicles’ oil-drain intervals beyond 108,000 km for engine oil and 150,000 km for axle oil, so asked Shell for advice.
The Shell technical team recommended that the company should trial Shell Rimula R6 IME 5W-30 heavy-duty engine oil to increase the engine oil-drain interval and to help improve fuel economy. Shell also recommended Shell Spirax S6 AXME 75W-90 axle oil. A trial was conducted on two Volvo buses to assess the oils’ performance in durability and fuel economy.

24Nov

Mining Company-Shell Rimula

November 24, 2021 admin

Indian Mining Company extends oil drain intervals with Shell Rimula R4

COMPANY – Mining Company

LOCATION – India

APPLICATION -Heavy-duty diesel engines

KEY EDGE – Shell Rimula R4; Shell LubeAnalyst

SAVINGS – ₹3,18,33,768

SIGNIFICANT – Reduction in maintenance cost

A leading Indian mining company operates a range of heavy-duty equipment, including items from Hyundai, Ashok Leyland, Volvo, and Schwing Stetter, in challenging working conditions. The company was using an engine lubricant that gave a maximum oil-drain interval of 350 hours and wanted a lubricant with a longer oil drain interval, ideally 500 hours, to increase equipment availability and production time.

The mining company worked with Shell Lubricants to identify a solution and decided to change to Shell Rimula R4. The company also chose to take advantage of Shell LubeAnalyst’s service to monitor the oil’s condition. After trials, it was established that the new lubricant could be used for up to 600hrs, providing the equipment was well maintained.

As a result of changing to Shell Rimula R4, the mining company has increased its oil drain interval by 70% from 350 to 600 hrs. Because fewer oil changes are required, the company has reduced its lubricant consumption and extended the maintenance intervals, which has resulted in lower maintenance costs. There is also a benefit from increased production time and a lower lubricant inventory. The company recognizes the value of Shell’s lubricant solution and has estimated a total annual saving, across numerous machines of ₹3,18,33,768.

16Nov

Sasan Power-Shell Rimula

November 16, 2021 admin

Shell Rimula MW 15W-40 (MGR00299-5) Mining copy

Sansar power maximizes swing gear life with Shell LubeExpert

COMPANY – Sasan Power Ltd.

LOCATION – India

APPLICATION -CAT 7495 excavator shovels

KEY EDGE – Shell Rimula MW 150W-40 & Shell LubeExpert

SAVINGS – ₹ 15,64,594 total reported annual customer saving

SIGNIFICANT – Reduction in maintenance cost

CHALLENGE – This mining company was running a fleet of CAT 7495 excavators & wanted to monitor lubricant performance to maximize the life of its swing gear & pinions in order to increase equipment availability and productivity.

SOLUTION – Following a Shell LubeExpert test, the shell lubricants team made recommendations to improve the lubrication system and ensure consistent delivery to the shovel gears.

OUTCOME – After acting on the device to replace jammed spray nozzles and tighten the injectors, the company was able to restore the flow of grease to the pinions and gears, protecting the components from wear.

VALUE – The improvements to the lubricants system helped to reduce maintenance and loss of productivity, with the company reporting estimated ammual savings of ₹15,64,594.

08Nov

Dhansar Engineering Optimises Production With Shell Gadus

November 8, 2021 admin

Shell Gadus S3 V460D 2 (GRE-00474-5) Mining copy

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

SAVINGS – ₹ 46,68,741 total reported annual customer saving

SIGNIFICANT – Upto 4x Longer Re-Greasing Interval

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.

SOLUTION – Shell Lubricants recommended switching to Shell Gadus S3 V460D 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.

VALUE – With fewer stoppages for re-greasing improving productivity and reducing operating costs, the company has reported estimated annual savings of ₹ 46,68,741.

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