Why Pay More for Pump Repair?

Many of today’s sophisticated construction and oilfield hydraulic systems utilize servo controlled Piston style hydraulic pumps.  

These servo’s are mounted on the pump and use an electric signal to port servo or pilot pressure to stroke the pump to a desired position in order to obtain optimum flow and pressure.  

These valves are extremely dirt sensitive and when contaminated will cause a perfectly normal pump to perform as if it is no longer capable of producing optimum flow or pressure.  As the problem may appear to be a general pump failure and not a specific servo problem the complete pump will often be sent in for repair.

When the repair facility evaluates the pump they are bound to rebuild it to function at factory new specs up to their stated warranty period which may be 12 months depending on the shop. Therefore the repair shop will replace or rebuild any components which may possibly fail during the warranty period; not just the offending servo.

So a pump that failed due to a contaminated servo valve which may cost between $500.00 and $1,200.00 to replace new could cost upwards of $5,000.00 to rebuild.

Obviously this is just the tip of the iceberg as downtime can be a much greater expense than the repair.

Rubber and metal particles from a seemingly innocuous “NEW” hose assembly can foul a servo immediately and put a piece of equipment on the maintenance board for a week to 10 days unnecessarily.  New hose assemblies are contaminated and must be cleaned properly in order to protect expensive downstream components.

The McCormick and Associates team is proud to represent Ultra Clean. For more information, contact us at (302) 521-0125 or mike@mcassoc.com

Three Easy Steps to Improve Cleaning Process

Things that you can do right now to make your cleaning process more effective!

If you are already using the Ultra Clean System then you already know the importance of cleaning your hydraulic lines. But did you know that you can maximize your efforts without spending a penny more? Just take a look at these three simple suggestions:

1. Do you really need that chop saw?

When assembling a hydraulic hose, the very first step is to cut it to the correct length. Obviously this step is necessary but it is also the biggest contributor of contamination to your new hydraulic line. Abrasive wheeled chop saws are the worst offenders. Try switching to a metal blade whenever possible to reduce the amount of debris generated by the cutting process.

Take it a step further: Try implementing a “clean cut” saw or blade that is specifically designed to minimize the ingress of contamination. Some saw-manufacturing companies that are worth investigating are Marken Mfg., Specialty Saw, or O+P[1].

2. Use clean air

Firing a projectile with dirty air is like mopping a floor with muddy water. It simply defeats the purpose. Wet air is even worse. Water particles will adhere to the walls on the inside of hose or tubing, capturing and retaining airborne dust particles and polluting the hydraulic oil on the equipment.

Using clean, dry air is one of the best ways to avoid recontamination. We recommend installing a 5-micron filter at the point-of-use to reduce contamination.

Take it a step further: Implementing a compressed air dryer like the UC-D1 Super Dry will eliminate most common headaches by absorbing oils and water and filtering out solid air particles. Click here to learn more and request a quote!

3. Sweep your workshop

 Keeping your workshop clean seems almost too mundane to mention but you’d be surprised at how few people give it any thought. All that grime gets kicked up and circulates around your shop, settling all over the place. It’s what we warn about when we mention “airborne particles”. It’s also the same air that will settle into your new hydraulic lines if not cleaned and capped correctly.

Take it a step further: Try using a vacuum instead of a broom to avoid stirring up the dirt.

It’s important to note that putting these tips into practice is not a substitute for an effective cleaning process like the Ultra Clean System. These tips are a supplement for giving your system an edge, not a replacement procedure. In fact, ISO cleanliness tests show that only giving your hydraulic lines an air-blow – even with clean air! – doesn’t provide you any significant advantages.

The McCormick and Associates team is proud to represent Ultra Clean. For more information, contact us at (302) 521-0125 or mike@mcassoc.com

Small Things Have Big Consequences

How a tablespoon of dirt can cost mines millions of dollars!

It isn’t easy working in the Mining Industry.

Mines are the backbone of the economy, providing raw materials to meet every day needs of consumers and businesses. But they also have to contend with a tough economy, environmental and regulatory requirements, workplace safety, and skyrocketing costs. In addition to this, reports indicate that mining companies are also facing labor shortages!

Never before has maximizing productivity become such a critical issue.

Mining is a huge and expensive business and one of the most significant contributors to operational costs is the heavy machinery that is used in the mines each day. Haul trucks, shovels and other similar equipment that move the raw materials can have operational costs of up to $500 per hour! But if you think that’s bad, the cost of taking just one of those machines offline is staggering. In his article, Extending Mining Equipment Life, David Fisk reports that, “On average, a truck that is taken offline for a shift has a financial production impact of $35,000 and, for a shovel, it can be many times that…The ability to extend the operating life of a $5,000,000 haul truck or a $17,000,000 shovel is significant with respect to the success of a mine.”

Mining shovel & truck on worksite

But how can you extend the life of such expensive equipment?

One way is to examine the health of the machine’s hydraulic lines. Hydraulic hoses and tubing are the bloodline of your equipment and the worst enemy of this hydraulic circulatory system is contamination. MachineDesign.com cites hydraulic component maker Muncie Power Products as saying that up to 80% of all hydraulic system failures can be attributed to contaminated oil. Furthermore, they report a Canadian study that found particle-contaminated hydraulic oil accounted for 82% of all equipment wear.

Perhaps the most disturbing thing about this contamination issue is that the dirt that is causing all the damage to your equipment wouldn’t fill a bottle cap. Once dirt, gunk, contamination, – or whatever you want to call it! – gets into the hydraulic system, it stays there and wreaks havoc on all the precision components that makes your system run.

There is a solution!

Cracking down on contamination before it blows your bottom line is the most effective way to increase the productivity of your critical equipment. And there is no better leader in contamination control than Ultra Clean Technologies Corp.

Founded in 2001 to replace traditional, expensive flushing methods, our method quickly dominated the hydraulic hose, tube, and pipe cleaning market becoming the preferred supplier to the world’s top 5 mobile equipment manufacturers. Our unique, patented, pneumatic, projectile delivery system has helped hundreds of companies reduce contamination, extend equipment warranties, and increase productivity and profits. Mikko Rysa, Vice President of John Deere Worldwide Forestry Sales & Marketing, explains:

There is a new technology…called the Ultra Clean System that scours hydraulic systems by shooting a rapid-fire projectile through hose and tube assemblies. The projectile strips out internal contamination as it travels through couplings and around bends, forcing the contamination out in front of it. So oil stays clean as it reaches expensive components, which extends system and filter life.

A Small Price to Pay to Eliminate a Catastrophic Failure

So how does it work?

During the assembly of the hydraulic lines, Ultra Clean Projectiles are fired through the lines to strip out contamination caused by the cutting, crimping, bending, or flaring processes. Then the assembly is sealed off against atmospheric debris using the innovative Clean Seal System – a unique heat-shrinkable capsule that makes traditional screw-on caps look antiquated and cumbersome by comparison. This ensures that only clean assemblies are placed onto your equipment.

SMALL IDEA, BIG IMPACT

By cleaning and sealing the assemblies prior to installation you eliminate the introduction of new contaminates to your equipment and reduce the risk of system failures or lost productivity.

And we aren’t just blowing smoke. Independent lab reports show achievable cleanliness ISO codes as low as 18/16/13! That’s cleaner than any other comparable system on the market today.

With proven technologies, patented equipment, practical education and world-class customer service, Ultra Clean Technologies is focused on providing companies with cost effective tools to maximize profitability by extending equipment life.

The McCormick and Associates team is proud to represent Ultra Clean. For more information, contact us at (302) 521-0125 or mike@mcassoc.com

Why Choose Ultra Clean?

Ultra Clean Tech specializes in contamination control technologies for industries that require contamination-free hoses and tubes in order to prevent costly equipment downtime or failure.

We lead the way with practical education and innovations that set the global standard for cost beneficial contamination control.

When you choose Ultra Clean Tech to control your fluid power contamination, you can be sure that your company is not only choosing the world’s most technologically advanced and comprehensive contamination control solutions but also dealing with some of the most highly knowledgeable sales and customer service representatives in the industry.Ultra Clean Hose and Tube Cleaning

Many of today’s sophisticated construction and oilfield hydraulic systems utilize servo controlled Piston style hydraulic pumps.  These servo’s are mounted on the pump and use an electric signal to port servo or pilot pressure to stroke the pump to a desired position in order to obtain optimum flow and pressure.  These valves are extremely dirt sensitive and when contaminated will cause a perfectly normal pump to perform as if it is no longer capable of producing optimum flow or pressure.  As the problem may appear to be a general pump failure and not a specific servo problem the complete pump will often be sent in for repair.

When the repair facility evaluates the pump they are bound to rebuild it to function at factory new specs up to their stated warranty period which may be 12 months depending on the shop. Therefore the repair shop will replace or rebuild any components which may possibly fail during the warranty period; not just the offending servo.

So a pump which failed due to a contaminated servo valve which may cost between $500.00 and $1,200.00 to replace new could cost upwards of $5,000.00 to rebuild. Obviously this is just the tip of the iceberg as downtime can be a much greater expense than the repair.

Rubber and metal particles from a seemingly innocuous “NEW” hose assembly can foul a servo immediately and put a piece of equipment on the maintenance board for a week to 10 days unnecessarily.  New hose assemblies are contaminated and must be cleaned properly in order to protect expensive downstream components.

The McCormick & Associates team is proud to represent Ultra Clean. For more information, contact Mike McCormick at mike@mccassoc.com or (302) 521-0125.

Citric or Nitric Passivation at OmegaOne

Passivation is the chemical treatment for protecting metal from corrosion. The process of passivation is actually a corrosive process in which corrosion occurs on the surface, forming a thin layer over the surface, creating a natural seal.  The process of passivation is something that accelerates the process, which (passively) occurs over time, thus the term “passivation.”

Why Do We Passivize Our Fittings?

Industry standards require that all stainless-steel fittings are passivated. Though there are multiple methods of passivation, OmegaOne passivates our stainless-steel fittings in compliance with ASTM A967. 

ASTM A967 discusses two, nitric or citric.  Both methods of passivation are intended to remove free iron particles from the surface of the metal.  Iron particles or other contaminants may be present from the machining process when the fitting is manufactured.  Nitric and citric passivation both make stainless steel more resistive to oxidation (rust-resistant).

OmegaOne uses the citric method of passivation, performing a copper-sulfate test to confirm that free iron and other potential contaminants have been removed from the surface.  OmegaOne selected the citric method of passivation as this method because it is environmentally friendly.  However, the citric method of passivation may not be acceptable for certain applications.

Working with Our Customers

Some specifications, such as Aerospace Material Specification (AMS), require the nitric method for the fittings. If you have a customer that’s requiring nitric passivation per the SAE AMS 2700, contact our sales team. We can provide you with information to educate your end-user and possibly get them to accept the citric method products. If that’s not possible, we can have the nitric done per request. 

We make finding the right fittings easy!

The McCormick and Associates team is proud to represent OmegaOne. For more information, contact us at (302) 521-0125 or mike@mcassoc.com