What is Proactive?

Proactive maintenance is a cost saving trend toward a maintenance program that targets the root causes of machine wear and failure. Proactive methods are currently saving industries of all sizes thousands, even millions of dollars on machine maintenance every year. By 1 micron Filtration and 100% water removal, the sand blasting effects of dirty oil under pressure, is eliminated. Increase life of pumps, seals, etc.

Laboratory and field tests show that more than any other factor, fluid contamination is the number one culprit of equipment failure. Even the most microscopic particles can eventually grind a machine to a halt. No discipline has previously taken a micro view on machine damage, concentrating on the causes instead of the symptoms of wear. Proactive maintenance is that discipline, and it is quickly being recognized worldwide as the single most important means of achieving savings unsurpassed by conventional maintenance techniques. Proactive maintenance is presented as an important means to cure failure root causes and extend machine life.

Fluid contamination control through the installation and management of improved filtration systems for all lube, gear, hydraulic and turbine oils has been established as an essential method to implementing proactive maintenance. Substantial savings are based on case studies involving the installation of improved filtration applications.

Numerous examples of 10-fold maintenance cost improvements are given. Extend the life of your plant equipment, and save money doing it! Heat, moisture, air and particles literally rob fluids and lubricants of life. But with rigid contamination control practices, these fluids and lubricants can last indefinitely which, in turn, prolongs the life of the machine’s components and keeps the machine running at the highest level of efficiency. Plus, the costs to begin a proactive contamination control program are quickly absorbed in maintenance cost savings.

Proactive “Life Extension” Maintenance

Proactive maintenance has now received worldwide attention as the single most important means of achieving savings unsurpassed by conventional maintenance techniques. The approach supplants the maintenance philosophy of “failure reactive” with “failure proactive” by avoiding the underlying conditions that lead to machine faults and degradation. Unlike predictive/preventive maintenance, proactive maintenance commissions’ corrective actions aimed at failure root causes, not just symptoms. Its central theme is to extend the life of mechanical machinery as opposed to (1) making repairs when often nothing is broken, (2) accommodating failure as routine and normal, or (3) preempting crises failure maintenance in favor of scheduled failure maintenance.

While the root causes of failure are many, or at least presumed to be, it is generally accepted that 10 percent of the causes of failure are responsible for 90 percent of the occurrences. Most often, the symptoms of failure mask the root cause or they are presumed themselves to be the cause. For example, a sudden bearing failure is often blamed on poor quality or a bad lubricant. The root cause, on the other hand, is often contamination in the lubricant (bad filter) or faulty installation of the bearing.

When a machine is well designed and well manufactured, the causes of failure can generally be reduced to machine misapplication or contamination. And, among these two, contamination is clearly the most common and serious failure culprit. A great deal of laboratory proof and field confirmation now are available to support this fact. Therefore, the logical first-approach to proactive maintenance is the implementation of rigorous contamination control programs for lubrication fluids, hydraulic fluids, coolants, air, and fuel. The appropriateness and veracity of this maintenance strategy is emphasized below:

A. According to the bearings division of TRW, “contamination is the number one cause of bearing damage that leads to premature removal.”
B. Machine Design Magazine reports that “less than 10 percent of all rolling-element bearings reach the fatigue limit because contamination usually causes wear or spalling failure far earlier.”
C. According to Caterpillar, “dirt and contamination are by far the number one cause of hydraulic system failures.” J. I. Case states that “one thing holds true about hydraulic systems: the systems must be kept clean — spotlessly clean — in order to achieve the productivity they’re capable of.”
D. Protractive studies by the U.S. Navy show that the cost of contamination on marine and aviation equipment per operating hour exceeds 60 percent of the cost of fuel per hour on the same equipment.
E. Massachusetts Institute of Technology states, “six to seven percent of the gross national product ($240 Billion) is required just to repair the damage caused by mechanical wear.” Wear occurs as a result of contamination.
F. Oklahoma State University reports that when fluid is maintained 10 times cleaner hydraulic pump life can be extended by 50 times.

For more detail, please download this PDF article.

GF2 BURN RATE MODIFIER AND LUBRICANT IMPROVES ENGINE EFFICIENCY AND REDUCES EMISSIONS

GF2 Fuel Enhancer is an engine fuel oil package containing organometallic compounds as well as other materials. It is designed to be completely soluble in fuel oils and can be added directly to the fuel in storage.

GF2 Fuel Enhancer
-Improves combustion efficiency
-Reduces particulate emissions
-Demulsifies fuel
-Stabilizes fuel
-Inhibits fuel tank corrosion
-Reduces combustion system wear

GF2 Fuel Enhancer gives you greater fuel efficiency. In comparative tests the additive decreased combustible carbon residue 60 to 90 percent. These results are evidence of more complete combustion. Also, the resulting lower carbon residue indicates more BTUs (power) per pound of fuel. Thus the effect of GF2 Fuel Enhancer Combustion Catalyst is two fold. More complete combustion produces more useful energy while reducing soot and smoke.

GF2 Fuel Enhancer contains a dispersant to stabilize fuel in storage. Fuel oil begins to repolymerize as soon as it is refined. Polymerization forms submicronic particles. As the process continues, particles become larger and agglomerate forming macroscopic sludge that plugs filters and injectors and eventually renders the fuel unpumpable. GF2 Fuel Enhancer disperses existing macroscopic sludge, retards further polymerization, and permits fuel to be combusted efficiently.

GF2 Fuel Enhancer contains a corrosion inhibitor to mitigate internal tank corrosion and a detergent to help keep lines, filters, and atomizers clean. Increased combustion efficiency and less maintenance provide the economic justification for GF2 Fuel Enhancer Combustion Catalyst.

Combustion Catalyst
Enhancer Burn Rate Modifier & Lubricant

GF2 Fuel Enhancer is a burn rate modifier. It is a unique, proprietary fuel treatment package containing an oil soluble organometallic compound. The enhanced stability and dispersant/detergent package allows GF2 to be the additive of choice when dealing with problem fuels or fuels in storage. It is designed to be completely soluble in fuel and can be added directly to fuels in storage. Features include:

-Combustion Catalyst- Improves combustion efficiency

-Polymerization Retardant- Keeps diesel fuel pumpable and combustable

-Dispersant- Eliminates filter plugging and injector scoring

-Corrosion Inhibitor- Retards internal corrosion and fouling of fuel tanks

-Demulsifier- Effective in separating water from fuel

-Lubricant- Lubricates the fuel system

-Detergent- Cleans injectors and the entire fuel metering system

-Reduces fuel consumption while increasing horsepower and performance

-Reduces emissions

-Permits perpetual fuel storage

GF2 Fuel Enhancer provides you with greater fuel efficiency. In comparative tests, the additive decreased combustable carbon residue 60-90 percent. These results are evidence of more complete combustion. Also, the resulting lower carbon residue indicates more BTU’s (power) per pound of fuel were produced. Thus the effect of GF2 Fuel Enhancer is two fold. More complete combustion produces more useful energy while reducing soot and smoke.

GF2 Fuel Enhancer includes a superior formula to stabilize fuel in storage. Fuel oil begins to depolymerize as soon as it is refined. Polymerization forms submicronic particles. As the process continues, particles become larger and agglomerate forming macroscopic sludge which plugs filters and atomizers and eventually renders the fuel unpumpable. GF2 disperses existing macroscopic sludge, retards further polymerization and permits fuel to be stored indefinitely.

Other ingredients include a biocide which effectively controls the growth of a broad spectrum of micro-organisms; a corrosion inhibitor to retard internal tank corrosion; and a detergent to help keep lines, filters and atomizers clean.

Application

GF2 Fuel Enhancer is formulated to be completely soluble in fuels and is designed to be added directly to fuels in storage at a rate as necessary based on scientific testing.

Treat Ratio:
1:10,000

1 Gallon treats 10,000 Gallons of Fuel (Any Hydrocarbon based fuels)

Note: 1 Gallon treats 5,000 Gallons of Bunker C Fuel

THE EFFECTIVENESS OF GF2™Fuel Enhancer

Carbon Mass Balance testing can be used to evaluate the effectiveness of GF2™. The Carbon Mass Balance test measures carbon leaving the engine in the form of exhaust. The only source of carbon the engine has is its fuel. Mass cannot be created or destroyed; so the amount of fuel entering the engine can be determined. If the amount of fuel used is reduced under a given load, the effectiveness of a fuel treatment can be measured. This procedure is ideal for determining whether the addition of a fuel treatment has any effect on fuel efficiency and exhaust emissions that pollute the environment.

Carbon Mass Balance Test results of GF2™Fuel Enhancer shows that harmful emissions are significantly lower.

GF2™’s interaction with fuel can be explained using a chemical formula.The basic principles behind the benefits and catalytic effects of GF2™are easy to understand. Today’s engines leave some amount of fuel unburned on each piston stroke. GF2™makes it easier for your engine to burn more of the fuel in the cylinder. Since more of the fuel is being burned, more power is being generated. Since less of the fuel is being wasted, you will have fewer emissions and better economy which saves money.

Chemistry

An engine converts fuel into energy by the following chemical processes:

CxHy + O2 → ( CO2 + H2O ) + ( CO + HC + C ) + ΔH

The ΔH is known in chemistry as enthalpy and represents the energy created from the thermodynamic process taking place inside an engine. The CxHy represents the fuel, for example gasoline is C8H18 and diesel is C12H26. The CO2, H2O, CO, HC, and C on the right side of the arrow represent products that are released in the engine exhaust.

There are no exothermic (i.e. energy producing) reactions that could yield more energy out of the CO2 or H2O, so we’ve grouped those components together in the equation above. However, there are exothermic reactions that can extract additional energy from the second group: the CO, HC, and C.

When GF2™is introduced into the engine; it acts as a catalyst and lowers the activation energy needed to further break down the unburned products in the above reactions. Specifically, when GF2™is used the following additional chemical processes take place in the engine:

CO + O2 → CO2 + ΔH

HC + O2 → CO2 + H2O + ΔH

C + O2 → CO2 + ΔH

The ΔH’s in the three above equations are how GF2™increases your engine’s output. These ΔH’s add to the ΔH produced by the engine’s standard process to deliver more output energy from the engine. This extra energy can be used to either increase engine output power (if the amount of fuel input is kept constant) or reduce the engine’s fuel intake (if the amount of output power is kept constant).

Customer Highlight

Because of the data available and results monitored over a period of 15 years including the awards granted, one speciGic company will be used to show the success of GF2 fuel treatment in that company’s equipment.

We will outline four primary areas of benefit.
• Operational:
• Maintenance:
• Economic:
• Environmental: Significantly Reduced Emissions.

Fuel economy and engine efficiency.

Reduced costs and extended engine and component lifespan. Overall net savings directly impacting bottom line profits.

These categories have been evaluated using one of the largest and most successful mining contractors in the world PT Pamapersada (PAMA) based in Jakarta, Indonesia.

PAMA’s founder and former President Mr. Sudiarso Prasetio, became lifelong friends with HHG’s supplier whose products have contributed to PAMA’s success and profitability with annual double digit growth Gigures since they began Girst using the GF2 Formulation.

Operational

GF2TM is unique compared to other fuel treatments on the market. Instead of having to use several one off treatments, GF2TM is completely self-contained with everything the fuel needs, to allow the engine to run smoothly and efGiciently for a very long time extending the life of expensive components such as injectors, pumps, liners, valve system etc. It is highly concentrated containing the following essential components below but without the Gillers other manufacturers use making it the most cost effective fuel treatment on the market today.

Normal Treatment ratio is 1:10,000, 1 gallon treats 10,000 gallons, or 1 liter treats 10,000 liters. This is the original product and not a copy.

In Ship and Power Generation Engines using Bunker Fuels the Treatment ratio is 1:5,000 for 1st 800 hours of use then 1:7,500 for regular usage.

1.Combustion Catalyst made up of complex organometallic compounds including ferrocene which helps lower the initial burn rate of the fuel in the cylinder, allowing more time for the fuel closest to the piston to burn more completely. This also helps reduce sulfur by products. The engine has a limited amount of time to burn all of the fuel in the combustion chamber before it is swept out to the exhaust.

Without GF2TM, fuel is ignited from only one point in the chamber. Normally the Glame burns from the top down to the piston head.

With GF2TM multiple Glames occur in your engine's combustion chamber propagating from all of the GF2TM molecules in the fuel. More of the fuel in the chamber is burned on each stroke and less is wasted in the exhaust. This allows more of the BTU’s in the fuel to be released and used in the form of energy to deliver more power to the transmission providing better overall fuel economy, using less DEF Gluid and saving on regen systems and catalytic convertors. If unburnt fuel is entering the exhaust system that means you lost money.

2.Cetane is vastly improved in diesel engines with the use of GF2TM allowing for most of the diesel fuel to be consumed in the cylinder, increasing horsepower and performance and reducing smoke/soot.

3.Octane: By adding GF2TM to the lowest grade of gasoline fuel, it will provide the performance of the higher grade fuels but with more BTU’s available for the power band. High performance engines can use the lowest grade gasoline fuels with GF2TM and not be subject to pre-ignition knock which previously required them to use the more expensive gasoline fuels. It all has to do with getting more oxygen molecules around the fuel.

4.Lubrication additive, recent legislative changes to reduce sulfur content in fuels and eliminate all lead, have meant a decrease in the inherent lubricity of diesel fuel as well as gasoline (petrol). Experts estimate that as much as 50 percent of today’s ULSD (ultra-low sulfur diesel) pool will need a lubricity improver to meet engine manufacturer’s speciGications and that up to 75 percent of the diesel pool could require treatment as reGiners convert to ULSD production in 2006 and beyond.

GF2TM includes a synthetic lubricity agent that addresses the Engine Manufacturers Association (EMA) preferred diesel fuel lubricity speciGication, the FQP-1.

The ASTM D-6079 diesel lubricity speciGication test balances input from engine makers, standards ofGicials, and fuels producers. It says that a “wear scar” no larger than 520 μm (microns) in diameter should result from a standardized wear test. The lubricity agent in GF2TM, when analyzed under the ASTM D-6079 test speciGications produced a wear scar of less than 440 μm, far exceeding the requirements for lubricity speciGications required by engine manufacturers.

5.Water Demulsifier which separates water from fuel making it more efGicient in the combustion process, eliminating harmful acids which are by products of the combustion process in water contaminated fuels and which cause pitting and component failure.

6.Polymerization Retardants which stop the fuel from breaking down and returning to its natural state as crude oil which is what fuels begin to do typically 30 days after being “cracked” at the reGinery.

This polymerization process starts to form submicron-sized particles. As the process continues, particles become larger and eventually agglomerate, forming macroscopic sludge. These particles can score injectors and eventually plug Gilters and the very small openings in the injector’s nozzles and over long periods of time render the fuel un-pumpable. Equipment left for long periods of time without being used such as seasonal equipment like boats, lawn movers, tractors, off road vehicles, trucks etc. become very hard to start because of this polymerization process.

GF2TM disperses existing macroscopic sludge and retards further polymerization, permitting the fuel to Glow and burn more efGiciently making it ideal for use in heavy fuels such as No 6 diesel or bunker fuel, which is used in ships and power generators.

GF2TM is perfect for long term fuel storage especially emergency generators which are vital and need to start when utility power goes down. Companies can purchase large quantities of fuel when the price has dropped and can store that fuel for very long periods of time keeping it fresh and alive with the use of GF2TM.

7.Oxidation stabilizer. All fuels are subject to oxidation. Oxidation creates in-soluble by products which cause injector deposits like a varnish. These deposits can slow response or cause sticking of moving internal parts and lead to injector failure. GF2TM contains a dispersant that stabilizes fuels, preventing oxidation.

8.Corrosion inhibitors. Many parts of an engine are made up of ferrous metal components, aluminum and plastics. Many fuels today contain Ethanol which is alcohol and highly corrosive to fuel lines and engine components. GF2TM contains a corrosion inhibitor in order to mitigate corrosion in tanks, engines and fuel lines and a detergent to help keep engines, fuel lines, Gilters, pumps and injectors clean. This will result in increased efGiciency, less breakdowns and less maintenance for your equipment.

9.Detergents which keep the fuel system components clean and within original design tolerances for precise fuel delivery to the combustion chamber.

All of the above provide better running equipment, less breakdowns, more profits and a cleaner environment, all in one simple, effective, treatment.

Maintenance

When PAMA Girst began using the GF2TM formulation their engines were being overhauled at 12,000 hour intervals on average. Using the GF2TM formula the engine life was extended to over 18,000 hours of operation as there was much less wear in cylinders, valves, and fuel delivery systems especially injectors and fuel pumps and this required fewer personnel for repairs.

(Typical costs of overhauling these engines are $250,000 - $500,000) They have reduced their maintenance budget by 40%.

This is unheard of in an industry which is the harshest environment for equipment on the planet.

Economic

Q. How effective is GF2 in providing a Return on Investment for heavy industry?

A. The GF2 formulation treats over 300 million gallons of diesel fuel (over 1 billion liters) for PAMA each year with the GF2TM formula. This saves PAMA in excess of $50 million dollars per year in fuel consumption alone.

The GF2TM formula provides PAMA with up to 8% fuel savings in addition to what they save not having to purchase equipment replacement parts.

By using the GF2 formula , PAMA's return on investment (ROI) with this fuel treatment is over 600% providing a huge proGit margin for the company.

GF2TM is the most cost effective Fuel treatment for all commercial equipment including the general public’s personal vehicles. Remember PAMA, is one of the largest mining contractors in the entire world and the largest purchaser and user of Komatsu mining equipment as well as the largest purchaser and user of Volvo articulating trucks worldwide.

PAMA annual revenue is $4 Billion dollars and annual proGit is $900 million. PAMA attributes over $300 million of those profits to GF2TM formulation

Environment

Q. Is GF2TM proven to reduce pollution?

A. Yes! Once again let’s use PT Pamapersada (PAMA) as the example.

PAMA received ISO 14064-2 award which is an International Standard related to the reduction of Greenhouse Gas Emissions, on March 10 2014. They received this award as a direct result of using GF2TM . By using this product they eliminated 516,912.2 tons of CO2 emissions in 2012 compared to 2011. That is the equivalent of removing 116,000 full size automobiles off the road in one year.

PAMA is the 1st and only mining operation worldwide and the only company in Indonesia, to have won such a prestigious award all thanks to the GF2TM formula .

Carbon Credits. PAMA continues to sell their carbon credits for considerable proGit each year.

The result of PAMA’s use of the GF2TM formula is the people of Indonesia have a cleaner environment in which to live and the huge economic gains that a large company such as PAMA provides the country.

COMBUSTION CATALYST OF GF2 Fuel Enhancer ™

GF2™ Fuel Enhancer contains organo- metallic compounds, as well as other materials, that optimize the combustion process by creating a more efficient use of fuel. The treatment is engineered to lower the ignition point of fuel and provide a longer residence time for the combustion process.

By lowering the ignition point, GF2™Fuel Enhancer optimizes the combustion process of hydrocarbon-based fuels, minimizing carbon deposits, soot, smoke and particulate matter. This results in less carbon and smoke emitted from exhausts due to unburned fuel, which helps protect the environment. GF2™improves the burn rate by lowering the ignition point. This in turn burns lower-end BTUs in the fuel that are normally expelled out of the exhaust.

DETERGENTS

GF2™keeps fuel system components clean and within design tolerances for precise fuel delivery to the combustion chamber.

OXIDATION STABILIZER

Biodiesel is prone to oxidation. When biodiesel oxidizes, insoluble by-products are created that cause injector deposits. These deposits can slow response or cause sticking of moving internal parts and lead to injector failure. GF2™Fuel Enhancer contains a dispersant that stabilizes fuels, thereby preventing oxidation.

WATER DEMULSIFIER

GF2™Fuel Enhancer completely separates fuel from water, thus reducing injector and fuel pump failure.

POLYMERIZATION RETARDANT

Fuel naturally begins to break down as soon as it is refined, eventually returning to its original state as crude oil. This polymerization process starts to form submicron-sized particles. As the process continues, particles become larger and eventually agglomerate, forming macroscopic sludge. These particles can score injectors and eventually plug filters and injectors, and over long periods of time, render the fuel unpumpable. GF2™ disperses existing macroscopic sludge and retards further polymerization, permitting fuel to burn more efficiently.

CORROSION INHIBITOR

GF2™contains a corrosion inhibitor to mitigate internal tank corrosion and a detergent to help keep lines, filters, and injectors clean. This results in increased efficiency and less maintenance for your engine.