Construction Company Increases Oil Life With Shell Rimula R4 15W-40

COMPANY – Dilip Buildcon Ltd

LOCATION – India

APPLICATION – CAT haul trucks

KEY EDGE – Shell Rimula R4 15W-40 & Shell LubeAnalyst

IMPORTANT – 100% INCREASE IN OIL DRAIN INTERVAL

SAVINGS – US $32,000 total estimated annual customer saving

CHALLENGE – This road building company was operating a fleet of CAT haul trucks in hot (45-50C), dusty environments with high operating hours. It wanted to analyse its oil use and machinery condition with a view to extending the interval between oil drains.

SOLUTIONS – The Shell Lubricants team worked closely with the construction company, providing the Shell LubeAnalyst service to give a clear picture of oil condition.

OUTCOME – Based on the Shell LubeAnalyst reports, the company was able to confidently extend its ODI from 250 to 500 hours for its CAT machines. These savings are expected to be replicated across the full fleet and at different sites.

The reduction in manpower, maintenance and consumables costs associated with extended oil life has seen the company identify, at the test site, estimated annual savings of US $32,000.

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 15W-40, Shell LubeAdvisor, Shell LubeVideoCheck

IMPORTANT – 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.

SAVINGS – US $2,444 total reported annual customer saving

CHALLENGE – An Indian haulage company operates trucks 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.

SOLUTIONS – Shell suggested that the company should trial Shell Rimula R4 15W-40 and also offered the Shell LubeAnalyst oil condition monitoring service and Shell LubeVideoCheck, a fibre-optic tool that enables operators to inspect key internal engine components.

OUTCOME – As a result of using Shell Rimula R4 15W-40, the trucks’ oil-drain interval increased from 18,000 to 36,000 km.

The company reported a total annual saving of US$2,444 per annum for 18 vehicles.

Road Construction Company Extends Oil-Drain Interval By 50% With Shell Rimula R4

COMPANY – Road construction company

LOCATION – India

APPLICATION – Heavy-duty diesel engines

KEY EDGE – Shell Rimula R4, Shell LubeAnalyst

IMPORTANT – A road construction company wanted to determine the best lubricants for equipment it would use on a new project in Indore, India. The equipment included heavy-duty machinery from Komatsu, MAN and Greaves. After considering different lubricant suppliers, the company chose shell lubricants. Shell recommended Shell Rimula R3 x 15w-40 for all the engines, which gave an oil-drain interval of 300 hours.

SAVINGS – US $40,000 total reported annual customer saving

CHALLENGE – A road construction company in Indore, India, was using Shell Rimula R3 X 15W-40 for all its engines and wanted to increase its oil-drain interval of 300 hours.

SOLUTIONS – Shell Lubricants offered Shell Rimula R4 15W-40 after using the oil condition monitoring service Shell LubeAnalyst service to measure oil performance and identify the correct oil-drain interval.

OUTCOME – By switching to Shell Rimula R4 15W-40, the company was able to extend its oil-drain interval by 50% from 300 to 450 hours. The company reduced its lubricant consumption and extended its maintenance intervals because fewer oil changes were required.

The reduced lubricant consumption and extended maintenance intervals resulted in lower maintenance costs. The company reported a total annual saving of US $40,000.

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

IMPORTANT – 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.

SAVINGS – US $427,428 estimated annual customer saving

CHALLENGE – A leading Indian mining company operating heavy-duty equipment in challenging working conditions wanted an engine lubricant that would give it a longer oil-drain interval to increase equipment availability and production time.

SOLUTIONS – The company decided to change to Shell Rimula R4. It also took advantage of the Shell LubeAnalyst service to monitor the oil’s condition. After trails, it was established that the new lubricant could be used for up to 600 hours.

OUTCOME – By changing to Shell Rimula R4, the company has increased its oil-drain interval by 70% from 350 to 600 hours. Fewer oil changes are required and the company has extended the maintenance interval and increased production time.

As a result of reduced lubricant consumption and lower maintenance costs, the company has reported a total estimated saving of US $427,428 per year.

Factory Extends Equipment Life With Shell Omala S4 WE 320

COMPANY – Heubach Colour Pvt Ltd

LOCATION – Gujarat, India

APPLICATION – Elecon gearboxes

KEY EDGE – Shell Omala S4 WE 320

IMPORTANT – 500% EXTENSION IN GEARBOX LIFE

SAVINGS – US $31,000 total estimated annual customer saving

CHALLENGE – Heubach Colour is a pigment and paint manufacturer; it was operating a number of Elecon gearboxes working under maximum load on its conveyor system. The company wanted to assess its lubrication set-up to improve reliability and streamline maintenance.

SOLUTIONS – The Shell Lubricants team recommended Shell Omala S4 WE 320, as its compatibility with the soft metal of the worm gears would reduce wear. Being synthetic, it also enabled lower operating temperatures and reduced energy consumption.

OUTCOME – Following the switch, operating temperatures dropped along with noise and vibration levels. Importantly, unplanned downtime has also been eliminated, extending the life of the gearboxes by five times.

Based on the longer gearbox life alone, the company has identified estimated annual savings of US$31,000.

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.