Fixed Centrifuge Oil Filtration Assemblies Save Crusher At Quarry
Date: Thursday, May 30, 2013
A local quarry came to us for assistance after their crusher suffered a catastrophic failure. Which resulted in a very expensive ($500,000) rebuild. The crusher is a critical part of their plant which breaks the rocks down into 3 different sizes of aggregate. When the crusher is out of action. The quarry stops production completely. Ongoing proactive preventative maintenance strategy require to prevent further unplanned downtime, and preventable costly repairs.
Oil Sampling
We commenced a scheduled oil sampling program. To determine and monitor the wear and contamination levels in the lube system after the rebuild. 1st round of samples, high residual levels wear particles, failure debris found. Despite traditional cleaning methods. Utilised throughout rebuild process.
Problem
This problem was rectified by running a Lubemaster OS600 Oil Filtration Unit on the system. To completely clean any residual particle and moisture from the entire system while the system remained in operation. This effectively cleans the whole compartment. Oil flows through Lubemaster. The system agitated as the equipment operates.
To maintain the oil cleanliness levels. Clean Oil Services custom-built and attached a permanent centrifuge oil filtration assembly to each of the lube systems (3). Which continually filter the oil and keep it in pristine operating condition. By removing any particulate contamination while ever the crusher is working.
Rexroth system with OS060 Centrifuge fitted, driven by auxiliary pump
The oil sampling and analysis continues on a monthly basis. Check that peak condition maintained. Conducted promptly after the monthly programmed maintenance completed. One occasion identified elevated wear particles indicated thrust bearings overloaded. An area worked on just prior to sampling. Investigation determined bearings over adjusted. Identifcation via oil analysis. Failure imminent with repair costs estimated at over $100,000. Significant loss of production due to the down time would also have resulted.
Benefits
Additional benefit, oil change intervals now determined by oil condition. Not by a set number of hours. This has provided substantial savings in gear oil purchases. Confidence in performance the oil maintained by regular oil sampling.
The management and maintenance staff at the quarry now have confidence. That the plant is operating at optimum levels and no further unplanned breakdowns have occurred.
The following note of thanks was sent by the Quarry Manager (name withheld by request).
“Since we have gone down the road of using your company. Setting up regular oil sampling with analysis, having installed the centrifuge cleaning systems to our crushers. The outcomes speak for themselves. This has finally given me confidence that we can now follow the trends. Act before we endure costly equipment rebuilds that have taken place in the past. I want to take the time to thank you and your people. For your efforts in helping us toward getting a very important part of our preventative maintenance under control. We look forward to an ongoing working relationship between our Quarry, and Clean Oil Services.”
Contact Clean oil Services today and see how they can help you with your oil analysis or cleaning solution https://cleanoilsservices.com or https://Lubemaster.com.au
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