To address Leakage & reduce the consumption,it will help us

1. A Hydraulic Survey Report
By, Abhishek Kumar
Engineer-Technical Services

2. Index
Sl No. Topics Covered Page No.
1 Objective of Survey Report 03
2 Survey Analysis 04-08
3 Suggestions 09-10
4 Cost Benefit Analysis 11

3. Objective of Survey Report
The major objective of report are as follow:-
a. Reduce the Consumption of Hydraulic Lubes.
b. Suggestion-Key areas to improve.
c. Reduce Maintenance Downtime

4. Survey Report
Our survey report is based on the areas of CRM(Cold Rolling Mill) &
CGL(Continuous Galvanizing Line).
We found few reason behind the high consumption.
A single hydraulic leak of one drop per second/minute/hours can
lead to heavy consumption of the lubricants in a 12 month period.
This volume adds up fast. In economic terms the cost of this waste
is staggering. Besides high oil consumption, the economic effects
of hydraulic system leakage include following also:-
a. Inefficient machinery operation
b. Environmental damage,
c. Safety and accident liability,
d. Premature machine component failure,
e. Poor manufacturing quality
f. Increased capital costs.

5. Why Leakages happen!! Case Study
Oxidation caused by overheating and contamination by
dirt, moisture and wear metals are two of the biggest
causes of hydraulic system failure and can lead directly
to leakage problems and high consumption.
In this pictures, you
can clearly see that
there is lots of dust
and dirt

6. Contamination of Oil
In all the pictures, the
Breathers are not at its
place,
Due to these there is
huge chances of
contamination of oil
which ultimately leads to
leakages at various
points.
Breather not
available
Breather not
available
Breather not
at its place

7. Filtration of Oil
Filter Paper
change date-
21 feb 2014
In this picture, the filter
paper change date of the
filtration machine is 21st
Feb 2014,
As per the discussion we
got to know the filtration
machine is regularly
connected to the
Hydraulic tank, but as the
filter not being changed,
the filtration is not
optimum.
Filtration
machine is
connected from
the inlet of the
Tank , no
Breather
available

8. ”Visible Leakages during study”
SL
No
Area Leakage point Type of Leakage Reason
1 CRM-1 Table-Up & Down- Primary Cylinder Minor Oil seal damaged
2 CRM-1 Mandrel Expand & Collapse Major
3 CRM-1 Control valve table Minor Valves
4 CRM-2 Mandrel Minor
5 CRM-2 Auto Centric hydraulic tank Minor Valves
6 Trimmer-1 On the Tank surface Minor Valves
7 Pickling Squeeze role Hydraulic Major
8 CGL-1 Exit power Pack-Valve unit table Major
9 CGL-1 Edge Guide-Ferrule Fitting Minor
10 CGL-1 Steering Unit-Valve Leakage Minor
11 CGL-1 SPM LP- Butterfly Valve Minor
12 CGL-2 LP Power Pack(Entry),Main Cylinder Minor Oil seal damaged
13 CGL-2 Entry Edge Guide Cylinder leak Major Oil seal damaged

9. Suggestion to reduce the Leakages & Consumption
Sl No To do Suggestion After Effect
1. Keep the Area clean and
free from dust/dirt.
a. Use Breathers.
b. Lock it after using.
a. Contamination
control.
b. Reduction of
chances of
leakages,
c. Reduction in
premature
failure.
2. Test Sample of the Used
Oil.
Routine analysis should
cover aspects of
lubricant health,
wear debris, and
solid contamination
a. To help judge
the true
severity of the
wear debris.
b. To understand
the premature
failure

10. Sl No To do Suggestion After Effect
3. Use
Filters/Strainers
a. Hydraulic filters can be
installed in pressure, return
and, sometimes, in suction
lines, depending on the
application, circuit design and
degree of protection needed.
a. Contamination
control.
b. Reduction of
chances of
leakages,
c. Reduction in
premature
failure.
4. Filtration of
Tank
a. The Filter paper should be
change regularly to get the
optimum performance of Oil.
b. Connect it through quick
connectors , to avoid
contamination.
a. To prevent the
system from
wear debris.
b. Prevent oil
seal from leak.
5. Arrest the
Minor
Leakages.
a. Start the arresting of leakages
from minor type such as
tightening/Changing of valves.
a. Reduce the
Consumption.

12. Role of Lube Supplier
SL No. Services
1. Reduce the Consumption of Hydraulics and reduce maintenance
downtime cost. Hence Increase productivity.
2. Oil Sampling & Condition Monitoring of Critical machines.
3. Control and Continuous Improvement.
4. Periodic review.
5. General technical Consulting for Lubes.

13. THANK YOU!!!