Hydraulic Security Gate System Retrofit
Hydraulic security gate system redesign reduces failures from weekly to Zero failures in 3 years!
Customer:
Oil RefineryIndustry:
OilEquipment:
Hydraulic Security Gate SystemServices Provided:
Provided: Hydraulic Troubleshooting, Redesign and Retrofit, and Creation of Hydraulic SchematicResults:
ZERO hydraulic failures in 3 years, spares inventory reduced by 60%, component OEM costs reduced by 50%
Summary (Problem)
A newly installed (by manufacturer) hydraulic security gate system (7 remote gate locations) was experiencing repeated failures (2-3 day duty cycle), creating terrible traffic backups. The previous manufacturer’s and the customer’s relationship was terminated. The customer was left with a multimillion-dollar system that was not dependable and the existing bill of materials contained substitute part numbers that made component procurement very difficult and very expensive.
The equipment was observed in operation, and IRG performed hydraulic troubleshooting procedures. Production and maintenance personnel were also consulted as correct operation sequence functions were determined.
Process and Outcome
A course of action was then planned which included:
- Identification of failed components
- An upgrade in filtration
- An upgrade of hydraulic cylinders
- Circuit redesign
- Creation of a complete hydraulic schematic, including a bill of material containing full manufacturer information and complete model codes.
- Maintenance and production personnel were trained in the function, proper maintenance and troubleshooting procedures of all components.
Results:
- Three years of operation with ZERO hydraulic system failures
- Spares inventory was reduced by 60%
- Identifying component OEM reduced costs by 50+%