Factory Wide Central Hydraulic Power Unit
One Steel have been operating a pipe mill at Kembla Grange for many years, manufacturing pipe for the Oil & Gas industry, as well as structural sections for the construction industry. When CMA was first introduced to the plant in 1995, 15 different hydraulic power units were located around the plant, with a full load power of ~700kW. Oil consumption due to leaks exceeded 50,000 litres per year, and hydraulic failures were the single largest cause of reduced plant availability.
The plant’s management team chose to adopt a CMA recommended plan to replace all local power units with a central system and distribution pipework in a similar manner to compressed air systems. The system was designed, built, and installed in July 1996. Since that time the plant has never had a loss of hydraulic oil supply, maintenance costs have been dramatically reduced, and oil consumption reduced to a minimum.
System Description.
- 4 x 75kW pump sets, each comprising a 120 Bar @ 140l/min pump, and a 210 Bar A 70 l/min pump.
- 3 pump sets operating, and 4th turned off as system standby. Full load running power is 225kW, as opposed to > 700 previously.
- Boosted suction/ recirculation system to provide main pumps with cooled, and filtered fluid.
- 6000 litre reservoir with multiple level and temperature sensors.
- Fully welded 1.25″, 2″ and 2″ (return line) distribution pipework. Approximately 3000 lineal metres throughout plant.
- Oversized boost and pressure line filtration. No return line filtration.
- Powers ~ 70 actuators through all parts of the plant, typically 24hrs x 6 days per week.
- 1 pump of 11 installed changed out in 11 years.
- Oil cleanliness consistently NAS 5 (ISO 11/8).
- 17 servo-valve based actuators in plant. No servo valve failures since 1996.
