Equipment reliability is the primary cost consideration for mining operations. Mobile equipment costs are ever increasing from operation, labour requirements, and capital investment of replaceable fluids, filters and failed components. OEI cleanable magnetic filters are proven to maximize equipment uptime and operating life to improve business impact.
Feature Case Study
ROI: Engine Rebuild Preventions, $1,450,000
Papua New Guinea / 2018 – Ongoing
CAT 739D Haul Trucks
The CAT 789D haul trucks being used at a gold mine in Papua New Guinea were experiencing frequent engine failures due to wear contamination damaging tight-tolerance engine components. The mine required a solution for equipment downtime and lost productivity.
Begin a 2 year trial deploying OEI ADD-Vantage 9000 engine oil filters on 6 haul trucks.
The results were so compelling that after only 1 year the mine outfitted an additional 36 haul trucks with the OEI ADD-Vantage 9000 filters.
In 1 year, the OEI filters saved the mining operation $1,450,000 in engine rebuild preventions and extended oil intervals.
The mine intends to outfit their full fleet of CAT 789D haul trucks with OEI filters to protect their coolant systems, engines, hydraulics, wheel motors and fuel systems.
36 Haul Truck Engines & 1.5 Million Dollar Savings
The challenge was to extend engine oil change interval and rebuild times. The CAT 785D haul trucks at a gold mine were experiencing frequent engine failures due to wear contamination. The mine required a solution for equipment downtime and lost productivity.
Argentina Cement Plant Maag Drive
The challenge was to decrease the amount pf contamination in the MAAG drive. As a solution, the customer installed 4 OEI magnetic filter elements into an existing T-strainer on the return line.
Haul Truck Front Wheel Hub Roller Bearings
The mine site was experiencing premature outer taper roller bearing failures on the front wheel hubs of their Komatsu 860 E and 960 E haul trucks.
The site operates 92 haul trucks, and the expected operating life of front wheel hubs is 20 000 hours; the site however, was experiencing 1-3 failures per week at a cost of 1 million South African Rand per failure.
The mine started investigating in May of 2015. Oil analysis determined that during operation, contamination was wearing heavily on the outer taper roller bearings which was, in turn, causing premature wheel hub failure.
Dragline Gearbox Testimonials
The challenge was to lower the ferrous contamination levels in dragline #5 gearboxes, and improve ISO fluid cleanliness levels.
Exceeding Hydraulic Fluid ISO Standard Within a 3 Hour PM Period
A diamond mine in the North West Territories of Canada was challenged with hydraulic system failures that were causing frequent unschedule downtime. The maintenance manager required a filter skid capable of improving the Komatsu Shovel’s hydraulic fluid ISO rating 25/24/16 to the standard 18/16/13 within the three hour pm period.
Preventing Break Failure on a 16H Grader
Rio Tinto Iron Ore Group was experiencing frequent grader chain case downtime due to wear contamination prematurely wearing the chain case, sprockets, bearings, and gears.
Predictive Maintenance on a 930E Haul Truck Wheel Motor
The challenge was to find a more effective predictive maintenance tool than OEM ceramic-magnetic plugs to monitor and identify premature wear of the haul truck wheel motors.
Prevent Final Drive Failure fo a C10 & C11 Dozer Fleet
A leading coal producer in Australia’s Bowen basin wanted to extend the service intervals of their dozer fleet from 250 hours to 330 hours. The OEM CAT magnetic filter plugs were unable to remove enough wear contamination from the dozer’s final drives to protect them from premature failure, and the mine required a more effective magnetic technology. If the service extension could be achieved, the cost savings would be significant in terms of reducing transport (float hire), unscheduled downtime, equipment replacement, and maintenance.
Cancelling the Rebuild of a CAT 3508 Haul Truck Engine
The challenge was to extend the life of a Kress coal haul truck 3508 CAT engine; these engines have an expected operating life of 16,000 hours. At 13,000 BMA Blackwater performed an oil analysis and found high levels of wear contamination (PQ 12) which resulted in a rebuild diagnosis.
ColoWyo Mine Protecting Tier 3 and 4 Engines
Out of concern for the new tier 3 and 4 engine tolerances, Colowyo wanted to improve their diesel fuel engine cleanliness to minimize ianjector and pump wear.
Filtering Heavy Lube Oil in Drums to Save Thousands
A cement mine consumed 6 drums/year of Molub-Alloy 8031-3000 open gear oil-base gel, > 78,000 cPs, at a cost of $12,000 USD/year. Traditional filtration is unable to sufficiently filter this oil gel at the necessary flow rate; also, insufficient filtration results in a one time product life. The gel was disposed of as a waste grease which has a significant environmental footprint. The challenge was to clean the oil when it is transferred to a clean drum.
Consol Energy Corp Diesel Fuel Dispensing
The challenge was to protect mining equipment from wear contamination under 4 microns that would damage close tolerance fuel system components; filter the diesel fuel coming out of the tanks, prior to dispensing.
IOCC High Flow Diesel Fuel Line Filtration
IIOC was concerned with their diesel fuel meeting higher-tier engine fuel cleanliness requirements. Existing fuel cleanliness aligned with North American fuel delivery standards, however, IOCC wanted to improve on the cleanliness in order to minimise on injector and pump component wear.
OEI magnetic filters are designed for 95+% efficiency: they are optimized for fluid viscosity, flow volume, flow rate, temperature, mobility, and mounting requirements.
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One Eye Industries Inc. does not directly offer or supply engineering services. Our final designs and products are approved through qualified and legally authorized companies and individuals, including third parties, when appropriate.