Machinery Lubrication magazine published by Noria Corporation
Issue link: https://www.e-digitaleditions.com/i/136253
HYDRAULICS with less time to cool, release heat and disperse foam. The end result is a tendency to create materials within the system that can cause varnish, ultimately leading to valve sticking. End-User Research Of course, knowing the issues isn't enough. Only by talking with end users can real needs and problems be identified. A recent survey of end users found three key needs regarding hydraulic fluids: productivity, extended equipment life and reduced downtime. The survey also enabled the identification of the top operational problems end users were experiencing with hydraulic valves. This was further explored to determine which benefits end users considered most important. Reducing valve sticking not only would improve the operational economics but also help the environment by maintaining operational efficiency and maximizing the use of power. Following are a few real-world examples of how additive technology that prevents varnish can deliver real cost savings. Plastic Injection Molding Plastic injection molding is a very common method of massproducing parts, so when valves stick and hydraulic systems need to be shut down for unscheduled maintenance, there are several impacts on the company's financial bottom line. In the example above, a plastic injection-molding company with 50 machines (four valves per machine) saw potential savings of $45,695 per year with the right hydraulic oil. Survey participants included representatives from a number of industries including plastics, government, construction, general manufacturing, waste disposal, civil engineering, specialty production, agriculture, forestry, marine, and oil and gas. The research revealed that the cost of valve replacement, which is the response to varnish formation, is an important issue for end users. Hydraulic equipment operators, like everyone else, are concerned about economy. In many cases, slow or failed valve actuation means valves are routinely changed or cleaned, which costs time and money. Failure to respond to valve sticking can result in: • Decreased production (most operators only respond when slow actuation is obvious) • Unscheduled downtime • Increased costs • Safety concerns Effects (Varnish) Varnish occurs as oil ages. In addition to the natural process of additive consumption, hydraulic fluid degrades as a result of oxidation and thermal decomposition. The ideal solution is a hydraulic fluid that does not deposit varnish on surfaces. This would lessen or eliminate the need for valve replacement. 22 May - June 2013 | www.machinerylubrication.com Gas Turbine Power Generation Peaking turbines, which supply power only when demand is high, are another good example of how the right fluid can deliver a better economic result. The presence of varnish can lead to a turbine trip, which means the turbine will not deliver power when needed. The potential cost of a turbine trip can be $5,000 to $120,000. Off-Highway Excavators In the construction industry, pulling a piece of equipment out