Volkswagen 31280 Truck Engine
With monitoring by predictive analysis, were found some problems of external contamination and solved safely before causing more costly issues.
ALS performs fluid analysis so that major damage is avoided, and also to generate savings through predictive maintenance.
Result
The cost of replacing the turbine plus the value of specialized labor was
$1,134.00. If the monitoring was not carried out with the predictive maintenance and necessary changes, this problem with external contamination and
wear would not be detected and the lubrication of the system would be impaired, causing serious damage to the system and its failure, with an estimated
repair value of $7,315.00, without mention loss in production
84.50%
COST AVOIDED
94,35%
Cost avoided
94,35%
Cost avoided
Analysis
The reports signaled high concentration of iron, a moderate concentration
of silicon and a slight concentration of aluminum. Thus, the results indicated
external contamination and marked engine wear.
Diagnosis
It was recommended to stop the equipment as soon as possible to inspect the entire air intake system: such as damaged air filters, seat cover and tightening of the clamps. In addition to checking the oil level in the sump and possible sources of wear particles in the oil filter.
Solution
The client reported that the technician identified that the turbine shaft was bent, rubbing against the compressor housing and thus causing contamination in the system.
Result
The cost of replacing the turbine plus the value of specialized labor was $1,134.00.
If the monitoring was not carried out with the predictive maintenance and necessary changes, this problem with external contamination and wear would not be detected and the lubrication of the system would be impaired, causing serious damage to the system and its failure, with an estimated repair value of $7,315.00, without mention loss in production.
The savings generated by predictive maintenance were $6,181.00 (or 84.5%)
Risks without analysis and predictive maintenance:
- Total fuel contamination
- The compromise of the lubrication system
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.
ALS performs fluid analysis so that major damage is avoided, and also to generate savings through predictive
maintenance.
- Worsening wear of the compartment
- Compromising the lubrication system
- Accelerated engine wear
