Need To Optimise Machine Productivity?
Installation of a Graco Automatic Lubrication System
and Wiggins Non-Pressurised Fuel System.
Mining operations rely heavily on efficient, well-maintained machinery to maintain productivity. The downtime caused by mechanical failures can lead to significant losses. For a coal mine in Mpumalanga, past issues with hydraulic grease pumps and overfuelling had resulted in machine failures, including two incidents where equipment burned down due to overfuelling. These issues were costly both in terms of repairs and lost production.
Frequent Hydraulic Lock and Overfuelling
The colliery had experienced frequent hydraulic lock issues with their grease pumps, a situation where pressure builds up in the hydraulic system, causing the pump to seize or lock up. Hydraulic lock occurs when the pump cannot release excess pressure preventing it from dispensing grease properly. This condition can arise due to factors such as contamination, air bubbles in the system, or improper maintenance, leading to interruptions in the lubrication cycle.
For the mine, this meant that critical lubrication points were not receiving the necessary grease, resulting in increased friction and wear on vital machine components, such as pins and bushings. Over time, insufficient lubrication can lead to component damage, expensive repairs, and, most critically, unplanned downtime.
DID YOU KNOW:
Each instance of hydraulic lock can have a direct impact on productivity and overall operational efficiency.
Overfuelling was also noted as a significant concern, with two machines burning down as a result thereof. These persistent problems resulted in unnecessary downtime, costing both time and money.
In August 2023, the mine sought to install a more reliable system on their excavator before it went into operation. FloSolve provided a tailored solution to address the mine’s concerns related to costly downtime caused by hydraulic lock and overfuelling.
Project Details
DATE
August 2023
CLIENT
Coal Mine
PROJECT TYPE
Graco Automatic Lubrication and Wiggins Refuelling System Solution
The installation included:
- Graco Electric Dyna-Star Pump for automatic lubrication, ensuring continuous and efficient lubrication for all lube points.
- Wiggins non-pressurised refuelling system to prevent the risk of overfuelling incidents.
- Wiggins R-series couplers for reliable connections during fuelling operations.
Additionally, the JVXFL breather, JNX86-25 shut-off valve, and JNC2A fuel receiver were installed to optimise the machine’s overall performance.
Proven Results: A Year of Operation Without Failures
The excavator has operated for 6 430 hours over the past 12 months, using approximately 130L of diesel per hour. This means that the Wiggins fuel system has efficiently handled over 835 900L of diesel without breakdowns. The Graco Electric Dyna-Star Pump has cycled about 77 160 times, moving roughly 15 000kg of grease to keep all pins and bushes lubricated. No failures or unplanned downtime due to lubrication or refuelling have occurred since the installation.
This high level of reliability has not only eliminated past issues but also helped optimise machine productivity. By using FloSolve’s lubrication and refuelling solutions, the mine has reduced both downtime and the risk of expensive component failures.
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FloSolve is the official supplier of Graco Auto Lubrication and Wiggins Refuelling Solutions. Contact us for more information on +27 (0)11 389 5300 or sales@flosolve.co.za
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