Construction Company Doubles Oil Life With Shell Tellus

COMPANY – Powermech Project Limited

LOCATION – Hyderabad, India

APPLICATION – Escort Hydra pick and carry cranes

KEY EDGE – Shell Tellus S3 M 68

SIGNIFICANT – Increase in Oil Life

CHALLENGE – Powermech was using a fleet of Escort Hydra pick and carry cranes -­ featuring Simpson S433 engines – under high loads and in hot and dusty conditions. The company wanted to improve equipment reliability and extend oil life in order to boost productivity.

SOLUTIONS – The Shell Lubricants team recommended a switch to Shell Tellus S3 M 68 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.

Based on reduced maintenance time and oil consumption across its fleet of 221 cranes, the company reported an annual savings of ₹ 24,15,040.

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

COMPANY – Dhansar Engineering

LOCATION – Rajasthan, India

APPLICATION – Komatsu HD 785-100 Thaul trucks

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

IMPORTANT – 75% Reduction in scheduled maintenance downtime

SAVINGS – ₹ 88,91,280 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 53 V220C 2 .

OUTCOME – The new re-greasing protocols and application of the new product reduced grease consumption from 1Okg 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 saving ₹ 88,91,280 .

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.

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.