Turbine
Through predictive monitoring, it was possible to detect recurrent entry of solid contaminants and eliminate their entry points, preventing further damage to the system.
Through fluid analysis, ALS promotes predictive maintenance to prevent damage and inconvenience to your equipment.
Result
The cost to replace the heat exchanger, engine oil, and filter was USD 1,629.
Without predictive maintenance monitoring and the necessary replacements, radiator fluid would have continued to leak, impairing proper cooling and potentially leading to engine failure and equipment shutdown. Damage to this magnitude would require a complete engine overhaul, costing USD 21,053, not including downtime losses. The savings generated by predictive maintenance totalled USD 19,401, equivalent to 92.3%.
60%
cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports signaled a large amount of suspended solid particles from various sources, with a high ISO class for the application.
Diagnosis
It was recommended to perform a micro filtration to reduce the solid contaminants, and to check the condition of the filters and seals, in order to identify the point of entry of contamination and eliminate it.
Solution
With the checks and inspections at the entry points, the client identified an overheating and a lack of shielding. As a result, a new heat exchanger was added to the system, replacing the oil filters and turbine plug-in. His team also cleaned the reservoir and changed the oil.
Result
The cost of these inspection actions was USD 3,943.86.
If predictive monitoring was not performed, the recurrent contamination would not be identified and could cause greater damage, totaling a cost of USD 9,859.65.
The savings generated by predictive maintenance were USD 5,915.79 or 60%.
Risks without analysis and predictive maintenance:
- Locking of the lubrication system
- Reduction in the useful life of components
- Unexpected plant stop
EPIROC DM30 Drill Engine Analysis
The reports indicated to the customer the presence of external dust contamination due to high silicon concentration, as well as increased levels of Iron, Chromium, and the PQI index, suggesting possible wear on the piston rings, pistons, and cylinder liners.
94,35%
Cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
EPIROC DM30 Drill Rig Motor Diagnosis
It was recommended to identify the source of contamination ingress by inspecting the air filters, checking the seating/integrity of the cover and the tightening of the clamps, verifying the oil level in the crankcase, and assessing possible power loss.
Solution – EPIROC DM30 Drill Rig Engine
The customer reported that inspections were carried out and, based on them, signs of exhaust gases were found in the intake coming from the cylinder head return. The cylinder head was removed, allowing the detection of valves and seats with poor sealing. The engine was repaired and the seals were replaced.
94,35%
Cost avoided
94,35%
Cost avoided
94,35%
Cost avoided
EPIROC DM30 Drill Rig Engine Video
EPIROC DM30 Drill Rig Engine Result
The cost to replace the heat exchanger, engine oil, and filter was USD 1,629.
Without predictive maintenance monitoring and the necessary replacements, radiator fluid would have continued to leak, impairing proper cooling and potentially leading to engine failure and equipment shutdown. Damage to this magnitude would require a complete engine overhaul, costing USD 21,053, not including downtime losses. The savings generated by predictive maintenance totalled USD 19,401, equivalent to 92.3%.
Through predictive monitoring and oil analysis, recurring ingress of contamination with abrasive potential and increased wear was observed.te.
Through fluid analysis, ALS promotes predictive maintenance to prevent damage and inconvenience to your equipment.
- Higher contamination
- Compromising the lubrication system
- Accelerated engine wear
