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

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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.

Factory Extends Equipment Life with Shell Omala S4 WE320

CHALLENGE – To access its lubrication set-up to improve reliability and streamline maintenance.

Solution – Shell Lubricants team recommended Shell Omala S4 WE 320, as its compatibility with the soft metal of the worm gears would reduce wear.

Outcome – Unplanned downtime has also been eliminated, extending the life of the gearboxes by five times.

Use of the shell lubeanalyst oil and equipment condition monitoring service helped an integrated steel plant save an impressive on lost production.
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Mining Company Increases Productivity With Shell Gadus S3 V 460

CHALLENGE – To increase equipment availability and control maintenance costs

SOLUTION – A change to Shell Gadus S3 V 460D was recommended for its high base oil viscosity, lithium complex-based thickener technology.

OUTCOME – increases its re-greasing interval from 12 to 36 hours, Reduction in downtime and labour costs.