Keeping off road vehicles running
One of the USA’s largest and best-known dealers for Caterpillar off- road vehicles, Whayne Supply, asked Magnom, to help solve problems with operational efficiency and downtime of heavy-duty off-road vehicles.
Purpose designed Magnom filtration units are now used to remove ferrous particles. Working in conjunction with traditional barrier techniques, they provide unmatched levels of filtration on the vehicles. These filters are now commercially available to Caterpillar dealers across North America.
Truck mounted lift gates
Leading hydraulic lift gate manufacturer Waltco wanted to reduce the risks of component failure caused by fluid contamination. The efficiency and small size of the Magnom CP In-Line Circuit Protection Units provided the ideal solution , and were specified as standard components.
Pedinghaus is a leader in steel fabrication technology and its machines are used throughout the world. Our customer, a user of its drilling machines user wanted to pre-empt problems with magnetic contamination.
Four days of testing was all it took to demonstrate the sheer amount of contaminant that Magnom In-Line Midi unit could extract, ranging from 1 to 40 microns in size, and the Magnom units were specified for use throughout the plant.
Off shore trawling
Magnom was asked to find a solution for a trawler owner who had been having problems with the hydraulic winches his crew – and livelihood – relied on and which were virtually impossible repair while at sea.
We suggested fitting a Magnom stainless steel module in the hydraulic line to remove contaminants. We went back to check after five months and the system had proved to be trouble free since the Magnom unit has been installed.
A car manufacturer’s wash system was performing poorly and the frequency of breakdown was unacceptable. An analysis of the hydraulic oil showed high levels of ingressed contamination from the factory environment and debris from welding, grinding and sandblasting during the building of the cars.
The answer, delightfully simple, proved to be Magnom Midi In-Line units, fitted to the main hydraulic systems.
Martin Marietta produces construction aggregates in North America, and challenges its fleet off road vehicles with hydraulic systems with just about the toughest working environment possible.
Maintaining a vehicle fleet that can be relied on, no matter what, is critical and so our dealer recommended standard Magnom In-Line units. Used on Caterpillar haul tricks and loaders, they protect hydraulic and transmission systems.
The Schuster Building
The Schuster Building is Louisville, Kentucky is listed on the US National Register of Historic Places as a “significant example” of Colonial Revival architecture as applied to commercial buildings,
After single hydraulic failure resulted in a $30,000 bill – mostly from loss of building revenue while the plant was out of use – inspectors traced the failure to contaminants building up, damaging seals and destroying the pump.
Now a Magnom Midi In-Line unit cleans the fluid of magnetic contaminants to prevent a repetition.
Heavy duty excavator
Hydraulic contamination was causing breakdowns on a heavy-duty Atlas Copco L12 Scoop excavator and leading to excessive downtime in Anglo Platinum’s South African mining operations.
Engineers fitted a standard Magnom In-Line unit and, on the next routine 125-hour service, found it to be heavily laden with contamination that would otherwise have been left circulating in the system. Site engineers reported longer oil and barrier life and the potential for longer service intervals.
A large Midwestern US hydraulic repair company is using a Magnom filters on their Schroeder Brothers testing machine.
They had realised that the standard 25 micron canister filter was not able to remove ferrous contamination that is introduced when they first start up and test the units after refurbishment. Now, a Magnom Midi, easily installed In-Line, eliminates contaminants and debris before refurbished units are returned to the customer. Post-rebuild start up wear is greatly reduced and refurbished pumps have longer life.
Protecting critical drive components
After a top bearing in a large gearbox had overheated, a large US paper plant called on Magnom to find a way to keep the plant running. The fault had been caused by an oil pump failing which had in turn overheated the bearing, causing it to gain ¼” in endplay. The plant had been uncomfortably close to a catastrophic failure!
Engineers installed Magnom technology upstream of conventional coalescing filters. After a week the fluid was completely clean – and Magnom was being specified throughout the plant to filter diesel and water lines.
Nissan Motor Company was experiencing regular failures of the lubricant recirculation pumps on grinding machines at their UK crankshaft production shop. Each failure resulted in direct costs of c £1000 and uncalculated costs associated with machine downtime.
The solution provided by Magnom distributor Linden Group was to install 2 Magnom Clear 20 Units in parallel. These were immediately capturing in excess of 8kg of contaminant every 2 to 3 days, delivering savings in overhaul and downtime costs as well as improved product quality.
Cleaning heavy duty transmissions
Rugeley’s coal fired power station produces approximately 1,000 megawatts of electricity for the UK grid. It had been experiencing up to 6 failures per annum of the gearboxes on their coal crushing mills before fitting Magnom filters on all 15 coal crushers’ gearboxes.
The highly -viscous lube oil used in the gearboxes precluded the use of barrier filtration, so engineers had been relying on strainers and bar magnets until they discovered Magnom technology and were able virtually to eliminate failures.
Cleaning heavy duty transmissions
Ricomix Oy who manufacture parts for Wartsilla diesel engines were already using Magnom Clear 5 and Clear 10 units to filter the cutting fluid in an Okuma CNC lathe with excellent results when they identified a problem with a Sunnen single stroke honing machine. Replacing paper filters weekly was proving to be very expensive .
They therefore approached Magnom’s Finnish distributor – Rotec Engineering – who fitted a Magnom Clear 20 Unit. Such were the results that Ricomix have had the confidence to do away with the standard filtration all together and rely solely on the Magnom technology.
Reducing bearing failures
While still owned and operated by Corus, Lackenby Steel Works Beam Mill had experienced several bearing failures on the static and mobile hot saws, all due to ferrous contamination.
A UK Magnom distributor, Linden Group, installed a Magnom unit on the main drive lubrication system to help improve the cleanliness of the circuit. The service life of the oil was increased and, should a bearing begin to fail, engineers had the reassurance that the Magnom unit would protect the rest of the circuit components from being damaged by the debris. Magnom was also installed on all the works’ power packs.
Protecting hydrostatic systems
With all-too-frequent repair bills for a hydrostatic system in a small Bobcat excavator running at around $1000.00 for parts alone, there was a pressing need to resolve this customer’s issues.
The failures were consistently contaminant related, and fitting a standard Magnom filter has effectively reduce failure and wear, enabling the customer to rely on a key piece of on-site plant to keep working for them.
Protecting hydraulic systems
Having already ordered a Magnom Midi In-Line filter for an older machine used in its underground operations, Martin Marietta engineers were quick to realise that it would also be the solution for a brand new Fletcher roof bolter that had gone down very early in its service life.
Given its working environment, it was no surprise to find that the problem was due to contamination of hydraulic valves and our dealer was quick to supply another Magnom filter, which resolved the problem.
Allison commercial transmissions are relied on as real workhorses, and often used in hostile environments and without breaks. In this case, Site & Pipe in the US were using a heavy duty excavator; and they were aware of the need to protect the gearbox from even the smallest wear metals that enter into valve bodies and can cause poor performance and failure.
Their choice of a Magnom Midi has resulted in trouble free operation.
Protecting hydraulic pumps and valves
Mi-Tech Metals’ reputation for providing the best tungsten metal products on the market is based on quality, service and reliability. The installation of a Magnom Clear 5 filter to protect the pump in a hydraulic press both extends the life of the pump and increases the reliability of the press.
It was estimated that savings reaped from the extended life of the Parker Hannifin filters had paid back the cost of installing Magnom technology in less than 6 months.
United Water was investing in new SEW-Eurodrive helical gear motors and specified Magnom protection from day 1.
In-Line Magnom Midi unites were chosen and they provide protection for all bearings, gears, seals, and pumps. Equipment life is extended, breakdowns avoided and productivity optimised. A key factor in choosing Magnom was how easy its filters are to check and clean.
Having spent $8,000 on the rebuild of a 740 HT Allison transmission, American Concrete engineers decided to protect their investment with Magnom filtration, and so avoid the lost revenue that would result from future breakdowns.
Taking the advice of an Allison rebuild specialist with 35 years experience, they chose a standard Magnom Midi filter.
Three Magnom units were installed on a workhorse Cat loader used by Martin Marietta – one on the hydraulic pump and two on the transmission. In each case, standard Magnom units fitted the bill, illustrating just how versatile the patented Magnom concept is.
The customer was amazed by the amount of contamination removed by Magnom technology , compared conventional filtration, and asked for Magnom to be fitted on other site equipment straight away.
Cleaning high risk, large scale transmissions
Engineers at an international steel company producing both hot and cold rolled coils in Malaysia were shocked when Magnom dealer Sense Services demonstrated the level of residual ferrous contamination the transmission lubrication circuit on their cold rolling line – despite the plant’s use of both primary and secondary conventional filtration.
A trial installation quickly demonstrated the effectiveness of Magnom Inline Process Units, and they were quickly installed on lines throughout the plant.
Cleaning furnace fuel
Towngas, a Hong Kong based utility company was having problems with contamination in the naphtha fuel (a hydrocarbon) used to fuel a large furnace. The system’s resin type filters were allowing fine rust to pass through.
A Magnom Inline Process Unit was installed downstream of the filters and inspected after 6 weeks. It was found during inspection that only the first 2 of 20 Magnom cores in the unit were full of rust. This proven efficiency enabled operators to schedule an extended service interval of 6 months, resulting in significant savings.
Truck mounted lift gates
The UK Sugar Beet Industry’s intensive processing season, between September and March, depends on the reliability of machines that are now protected by a Magnom In-Line Process Unit.
Following initial extraction by diffusion, residual material is mechanically pressed to extract as much remaining sugar as possible. The pulp press gear boxes driving the process are absolutely critical during this continuous operation and it is essential that they remain reliable due to the high costs of downtime.
Portable filter system
Industrias Del Envase, a plastics processing plant in Peru fitted a Magnom Clear 5 to a portable dialysis filtration system to remove ferrous contamination to below one micron.
This system was able to reduce running costs and prolong service life of the hydraulic systems of 8 plastic process machines.
Protecting industrial transmissions
Magnom’s Inline Process Core design was chosen to remove contaminants from large transmissions driving the hot rolling mills at Bridgenorth Aluminium in the UK.
Installation followed oil analysis that identified significant ferrous contamination and other wear elements within lubrication circuits of transmissions driving hot rolling mills, and a visual survey had indicated that there was already significant and progressive wear presenting a real risk of catastrophic failure.
Extending service life of heavy duty crushers
Reduced downtime and consumption of barrier filter elements repaid an investment in Magnom technology in less than a month for European Metal Recyclers in Manchester, UK.
A Magnom In-Line Process Core was fitted to protect the pump on a hydraulically operated scrap metal crusher. Because it could be fitted in any position – in this case vertical – the core is easy to access for cleaning and installation was straightforward without any major alteration to the system. An order for Magnom units to protect other pumps in the plant was quickly placed.
Maintaining end-of-life equipment
Didcot is one of the UK coal fired power stations scheduled for decommissioning and engineers are charged with keeping aging equipment running and meeting environmental targets without any significant maintenance expenditure during these final years.
A major challenge has been keeping the vertical axis coal crushing mills running, and the installation of Magnom Inline Core units has eliminated expensive transmission failures and demonstrated the suitability of Magnom technology to protect the similar open gear transmissions used in the vertical axis coal mills across the globe.
Truck-mounted lift gates
HydraForce is a UK firm offering high quality hydraulic cartridge valves for the mobile and industrial equipment market, catering for flow rates of 0.4 to 530 lpm. State-of-the-art preparation and assembly equipment enables it to meet critical tolerances for more efficient hydraulic circuits.
It chose Magnom Midi In-Line Unit for the 10 micron return line filters on two test rigs. Having found that they were so effective that results were visible to the naked eye, Hydraforce put plans in place to roll this technology out to its other test rigs as quickly as possible.