Why is oil maintenance so important?

Why is oil maintenance so important?

Machine hydraulic components often need to be reconditioned, an indication of when this needs to occur is dirty oil. This case by the forging press of the Leiber Group, shows that the existing filtration system is not sufficient, but the solution is so close.

70 to 80% of the breakdowns caused by dirty oil in the hydraulic systems, shows that oil is the most important component inside lubricating oil systems. Permanent cost intensive machine breakdowns need prevention and therefore, the operator has to know what happens to the oil itself and what is affecting a dirty oil condition permanently in contact to the machine components.

Here is an example:

Fresh oil requires the DIN 51524 for minimum requirement to fulfill the purity class (ISO 4406) 21/19/16. Again, well-known manufacturers of proportional valves demanding a purity class of minimum 16/14/12 respectively 20/17/14 depending on manufacturer and operating pressure.

When filling with fresh new oil, damage or malfunction could happen to the proportional valves. There are various sources of contamination: by assembling the plant, filling errors with fresh oil, environmental influences, refilling process, repair and maintenance work, process-related wear and some others. Contamination is when particles, water, mix of different lubricating oil grades and additives result in adverse effects like:

  • Reduction of lubricating effect and oil lifetime, therefore increased wear of the system components.
  • Unplanned machine downtime by defective components like valves, pumps and others.
  • Unstable production process.
  • Rising costs for overhaul, repair, machine downtime, losses at production by less quality and quantity.

There are several preventative measures to avoid contamination of oil. Some good advice – first check the condition of the system oil by sampling. Only a detailed test report offers data about oil condition and gives a hint for the next action.

Machine hydraulic components often need to be reconditioned, an indication of when this needs to occur is dirty oil. This case by the forging press of the Leiber Group, shows that the existing filtration system is not sufficient, but the solution is so close.

Our good client Leiber, a specialist for lightweight components made of aluminium, with 2 production sites in Europe, offers a complete process chain.

They provide everything from research and development up to serial production and assembly of complex modules with bionic designs and in-house alloys. Leiber is using, among others, a 40-tonforging press by Schuler. The hydraulic oil systems take 1,250 litres of hydraulic oil HLP46.

During the forging process the forging die is sprayed with graphite and contaminates the surrounding air (particles of dust, dirt and others) and finally infiltrates the hydraulic system.

Despite the existing particle filtration, the whole system is contaminated and hydraulic components are then expected to wear and cause final machine down time.

The company decided on a test period with a filtration unit of Greenoil Standard ApS from Denmark promising to resolve the problem. Also, in operation is the WP1-P1-100, flow-rate: 100 ltrs./hr with filter element type 2102T.

Oil samples were taken before and after the test run and were analysed to show a clear test result: on 11.07.2019 the oil condition and purity class before the test run was poorer than manufacturer
specification.

The expected lifetime of the components would decrease. Now in operation, the GreenOil filter unit, after an 8-week test trial, the whole oil systems undergoes an enormous improvement of the purity class. All relevant disadvantages for components are gone and the long plant availability secures the production process.

Purity class (ISO 4406) increased from 18/17/13 to 16/14/11 respectively from 8A to 6A (SAE AS 4059). Greenoil recommends installing a fixed filtration unit for permanent operation.

Timo Kästle, Head of Maintenance explained “We are more than satisfied with the results, highlighting the particle capacity of the filter element. Further tests to follow on other plants and we are convinced to have made the right investment.”

Website: www.schuhmacher-tech.de
Email: lars.benk@schuhmacher-tech.de
Phone: +49 7424 9495663

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