A major steel plant in Belgium experienced severe servo-valve sticking, rapid filter plugging, and high varnish levels after switching to ashless hydraulic oil without flushing the system. MPC values exceeded 50 and oil contamination reached 290 mg/kg, causing reliability problems and costly downtime. Fluitec applied DECON at a 3% treat rate to solubilize and remove deposits. Within four months, MPC values dropped below 18, contamination levels fell to 30 mg/kg, and sticking valves were fully resolved. Filter life increased significantly—delivering a remarkable 10,667% ROI for the customer.
Problem
In a steel manufacturing plant in Belgium, the operators noticed sticking of the servo valves and accelerated filter plugging on the hydraulic systems. This occurred after they switched to an ashless type of mineral hydraulic oil without flushing the system. High MPC values within the range of 50 and high contamination values of 290mg/kg were also observed.
Solution
Fluitec’s DECON was added to the system to decontaminate it at a treat rate of 3%. Within the next four months, the MPC values stabilized and the contamination levels decreased.
Results
MPC levels have significantly declined to the normal range (less than 18) and the contamination levels went to 30mg/kg. Additionally, the mechanical challenges of valves or pumps sticking have been eradicated. Filter elements are also not changed as frequently as before.
