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.

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..