AHS Hydraulic Consulting Solves Your Problems and Saves You Money

 
 

Solving Problems, Every Time

When companies hire us to consult, they’re usually looking to increase the performance of their hydraulic equipment, decrease unscheduled downtime, and reduce operating costs. In all our years of supporting our clients, we’ve never failed to deliver a solution.

AHS has completed numerous projects for us and we have the upmost confidence in their abilities to finish on schedule and within costs.
David Garney, Schnitzer Steel Industries, Inc.

AHS Consulting services are customized to meet our clients needs. Some of our most commonly requested consulting projects include:

In-plant Hydraulic System Analysis

These types of projects help you provide a deeper understanding of your current system design and specifications as well as potential targets for worthwhile system improvements. Investing in a system analysis helps you plan for future system expansion and resource allocations more effectively.

Preventive Maintenance Schedule and Guide

The AHS team delivers or directs maintenance to address problems before they become emergencies. It’s been estimated that a lack of preventative maintenance is responsible for 75% or more of hydraulic component failures each year.

Hydraulic Design

Clients regularly hire AHS to create retrofit designs for their hydraulic systems. These projects result in increased machine performance, reduced failure points, simplification of system design, usage of common parts across various systems in the plant.

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Case
Studies

The Compressor Housing Project

Customer was determined to have an antiquated air compressor system with a lot of wasted energy. A study was conducted that showed that 43% of the capacity of their 1400HP air compressor system was being as lost as wasted energy due to poor system design and antiquated controls. A system was designed to increase the air capacity of the plant to 1850HP while saving roughly 500HP of energy used 24/7 by upgrading controls and fixing design issues. The 1.5 million dollar project was completed in less than 4 weeks. Estimates show a roughly $160,000/year reduction in energy consumption by the plant air system.

  • Ye Old Compressor House

  • 2. Construction Site
  • 3. New Compressors and Tanks
  • 4. Piping and Wiring
  • 5. Tents Covering Compressors
  • 6. Building Being Constructed
  • 7. Attaching Walls to the Building
  • HPU and Fluid Conditioning - After
  • HPU and Field Conditioning - Planning
  • HPU Before_1
  • Valves and Filtration - After
  • Valves and Filtration - Before
  • HPU-Before_2
  • HPU - After
  • HPU Before_3
  • HPU Room Overview - Planning

Caster Billet Pusher/Weigher

When it became time to add weighing capability to the existing billet pusher hydraulic system, the decision was made to greatly expand the hpu room and build a new expanded power unit as well. AHS was tasked with designing the new power unit and associated valving. In addition, we were asked to draw floor plans to ensure that all of the equipment and piping would fit in the new building, with room to spare. The project came off without a hitch, and has been up and running ever since.

Electric Arc Furnace

One of our steel mill clients asked us to redesign their electric arc furnace hydraulic system, and to manage the project. The challenge was to get all materials and components on-site before work was scheduled to be started, and then to manage the many contractors necessary to make it all happen. It was completed on-time and under-budget, the first charge was fired on New Year's Eve.
  • EAF HPU - After_1

  • EAF HPU - Before_1
  • EAF Valves - After_1
  • EAF Valves - Before
  • EAF HPU - After_2
  • EAF HPU - Before_2
  • Caster Strands - After_1
  • Caster Strands - Before_1
  • Caster Strands - After_2
  • Caster Strands - Before_2
  • Caster Strands - After_3
  • Caster Strands - Before_3

Caster Strands

Originally the system was designed with proportional valves and European valve patterns that made sourcing parts difficult and expensive. While documenting the system, Advanced Hydraulic Solutions, Inc. discovered that only two pressures were needed to maintain full system functionality. We went to work changing the system to a dual pressure circuit, with standard valve patterns that are in stock locally. In addition, we designed and built custom ductile iron manifolds that would accept standard replacement parts. This streamlined maintenance and made inventory management a breeze for the customer.

Automated Coil

The mill at customer location came with an automated coil entry positioning system when the mill was constructed in 2002 that would never operate due to poor system design and misapplication of technology. Over the years several attempts we made by various contractors to make the system work but no one was successful. In order to make the line run an operator would need to be continuously measuring and adjusting position the entire time the mill was in operation. AHS was brought in to redesign the system and implement an auto-feed function for the coil entry into the working line of the mill. By simplifying the circuit from a poorly designed 8 valve circuit to a correctly designed 2 valve circuit with a delta controller, and removing the laser positioning system that was poorly applied in this environment and instead opting for a camera guided system AHS was able to create a well-functioning, simplified, auto-loading coil entry system. By implementing this design the line now takes one less operator to run, produces greatly improved product quality and is the job is expected to increase component life to due smoother operation. Estimates show the job will pay for itself in less than two years.
  • Coil After_1

  • Coil Before_1

  • Valve After_1

  • Before Valve_1

  • Valve After_2

  • Valve Before_2