The Synonym for Oil Care

Transcription

1 The Synonym for Oil Care The tool for predictive maintenance Fine Filter Systems for applications in the industry sector

2 Applications Applications CJC Fine Filter systems - one solution for many applications Forming Machining Drop forging hammer / -presses Rolling mills Upsetting machines Rotary swaging machines Round bending machines Flanging machines Wire-drawing machines Lathes Grinding machines Cutting machines Milling machines Pressing Quenching Automotive industry Press brakes Screw presses Excenter presses Wedge presses Vulcanising presses Chamber filter presses Flanging presses Annealing ovens Closed quench oil baths Open quench oil baths Wash water Reconditioning of skimmed oil Hydraulic presses Die casting machines Injection moulding machines Machine tools Wash systems Quench oil baths / furnaces Conveyor belts Coal mills Blast furnaces Slag granulation Converters Casting plants Rolling mills Band steel production Manipulators Shearing and slitting lines Straightening machines Welding machines Balancing and bending systems Feeders and feed units Steering and servo-systems Conveyor belts Transformers Turbines Spreaders and scrapers Casting Compressors Paper industry Timber industry Casting machines Trimming presses Screw compressors Piston compressors Turbo compressors Paper machines Calenders Refiners Packing machines Turbines Block band saws Saw mills Round timber feeder lines, sorters, conveyors Engines / Generators Thermal oil systems Plastic industry Cement works Food industry Pharmaceutical industry Injection moulding machines Blow moulding machines Extruder machines Crushers Raw mills Coal mills Cement mills Rotary kilns Cement mixers Concrete mills Storage tanks / Reservoirs Mobile machinery Further applications Earth-moving machines Tunnel boring machines Agricultural machines Road building machines Street sweepers Industrial trucks Cranes (Un)Loaders Hydraulic roller coasters Hydraulic flight simulators Hydraulic control systems Vacuum pumps Labelling machines Gas engines Diesel engines Generators Test benches Component test benches Endurance test benches 2 CJC Fine Filter systems - one solution for many applications Oil reservoirs Intermediate bulk containers Waste / Recycling industry Scrap shears Baling presses Crushers Extruder drives Shredders (Un)Loaders, Cranes Karberg & Hennemann, Your Partner for Oil and Fluid Maintenance - for more than 65 years! Steel works 3

3 Particles, Water and Oil Ageing 80 % of all breakdowns in hydraulic and lubrication systems are the result of contaminated system fluids Cellulose - The Ideal Filter Material CJC Depth Filter inserts simultaneously remove particles, water and oil degradation products Grooving through abrasion (bearing ring) Particles Particle contamination of the oil can only be reduced, not avoided. The contaminants enter the system from the environment (e.g. through venting, oil refilling or repairs), but they are also generated inside the system (abrasion). Every particle in the system can generate more contamination (sand blasting effect). Erosion Small particles in a high velocity oil flow come in contact with metal surfaces and edges, breaking off more particles (sand blasting effect). Particles Solid particles are permanently retained between the cellulose fibres. 75 % of the insert volume forms a structure of cavities. Each insert has a filtration degree of 3 µm absolute and 1 µm nominal. Especially developed CJC Fine Filter inserts offer a filtration degree in the submicron range. Capacity: several kilogrammes Wasser Cellulose fibres absorb water by capillary attraction. Even if only a few ppm of water are in the oil, the fibres dry the oil. Capacity: several litres Oil ageing / Oxidation Oxidation products, resins, varnish and sludge residues deposit permanently, with a combination of adsorption and absorption, on the polar sites of the cellulose fibres. Cellulose fibres have an inner surface of 120 to 150 m² per 1 gram. Capacity: several kilogrammes Corrosion (shaft) Varnish (valve) Abrasion Hard particles jammed between moving parts destroy the surfaces (abrasive wear). Water It is very difficult to avoid water contamination in the oil. Humid air enters the system via air vents and is absorbed by the oil. Varying temperatures enhance this process. Cooling water leakages and similar water ingress are also common sources of oil contamination. Cavitation Water droplets in the oil evaporate under high pressure, implode and rip particles off the metal surfaces. Corrosion Water or chemical contaminants in the oil cause rust or chemical reactions, which deteriorate the component surfaces. Oil ageing (formation of resins, varnish, sludge and acids) Degradation products resulting from oil ageing occur in both lubrication and hydraulic systems. This is mainly influenced by oxidation (oxygen), hydrolysis (water) and pyrolysis (thermal decay at high temperatures). In most cases, all of these three factors combined are at play. The degradation products lead to formation of sludge and / or resin-like deposits. Additionally, an acidification of the fluid occurs during oil ageing process. Oil degradation products The resin-like degradation products are deposited on the metal surfaces and form a sticky layer to which particles adhere. The created sand paper effect accelerates wear and tear. Depth filtration - extremely high dirt holding capacity and long filter lifetime CJC Fine Filter inserts are depth filters, i.e. compared to surface filters contaminants are retained in the depth of the filter material. This implies an enormously high dirt holding capacity and extremely long filter lifetime. Due to the slow pace of the oil flow only possible in an own circuit (offline filtration) and the extremely long filter paths of a depth filter, CJC Fine Filter inserts are particularly effective. The longer the fluid has contact with the filter material, the more effective is the fine filtration. The filter efficiency is basically a function of the fluid s contact with the filter material. Flow direction See product sheets for further information. Download: clean oil Cross-section of a CJC Depth Filter insert - The oil flows through the CJC Depth Filter insert radially from the outside to the inside For each application a suitable solution Cross-section of a used CJC Depth Filter insert With more than 20 various types of filter inserts we offer the optimal solution for each application. Mineral oils and synthetic pressure fluids and lubricants up to ISO VG 460 / 40 C, also biodegradable oils Aqueous oils and fluids Oils and fluids with extremely high dirt ingress Oils and fluids with high potential to generate acids, e.g. HFD fluids, gas engine oils Oils and fluids with high water content that has to be minimised in short time, e.g. insulating oils Oils and fluids with high potential to generate acids or high water content and simultaneous contamination with particles and oil degradation products Only clean oil is able to loosen already deposited particles and degradation products in the oil system and to hold them in suspension until these are also filtered out. 4 5

4 Offline Oil Maintenance Independent of the machine's operation for highest possible oil cleanliness Your Advantages Reduce costs, increase machine reliability and avoid oil changes Inline filtration in comparison with offline filtration Small investment, large effect Good for you - good for our environment! Bypass filter (inline) Only a part of the inline fluid flow is filtered Dependent on the operation of the machine Pressure filter (inline) Housings and filter elements are expensive, because they have to be designed for max. system pressure High energy costs (the higher the filtration degree, the higher the costs) High operation pressures and high flow rates lead to an extreme load (material fatigue, damage of the pore structure) Release of already filtered particles due to highly fluctuating pressure surges Short contact time between fluid and filter material due to the high flow rate Low dirt holding capacity Frequent filter replacements Dependent on the operation of the machine Only solid particles are filtered out, no protection against cavitation, corrosion and oil ageing Suction filter (inline) Only protection against large solid particles No protection against caviation, corrosion, oil ageing and wear caused by fine particles Oil is drawn from the surface; contaminants in the oil sump are not captured Big filter sizes necessary Dependent on the operation of the machine Oil system Tank Return filter (inline) Big filter sizes in some cases necessary, because the return flow rate is often bigger than pump flow rate Short contact time between fluid and filter material due to the high flow rate Dependent on the operation of the machine Only solid particles are filtered out; no protection against cavitation, corrosion and oil ageing Offline filter Particles, water and oil ageing products are simultaneously reduced to a minimum Fine filtration to a range of < 1 µm (submicron range) Continuous fine filtration (24/7), independent of the operation of the machine Oil is drawn from the lowest point of the system tank, meaning the highly-contaminated oil in the bottom of the tank (sediments) is filtered too - the clean oil is returned to the tank close to the suction point of the main system pump Its own pump enables an application-specific adjustment of the pump flow Efficient fine and depth filtration due to the long contact time between filter material and fluid For filter replacement it is not necessary to stop the machine No high pressures, flow rates or pressure surges and the related problems Extremely high dirt holding capacity and long lifetime of the filter elements The constant high oil cleanliness level permanently achieved by offline fine filtration prolongs the lifetime of system components and oil by a factor of 2 up to >10 and more! Less maintenance, increased productivity Approx. 60 % lower maintenance costs Less wear and tear and therefore less unscheduled downtimes and production losses Improvement of the process stability Longer lifetime for system components and oil Longer lifetime for filter elements of inline filters Lower energy consumption Less frictional loss Less pressure build-up by system pump necessary as for pressure filters, a lower filtration degree can be selected as due to the longer lifetime, the filter elements of pressure filters are saturated much slower Short amortisation time > 75 % of the installed CJC Fine Filter systems have a payback time of less than one year of operation Protect the environment As a result of the longer lifetime of oil and components the energy and resources consumption necessary for production and disposal of spare parts and operating material (new oil etc.) decrease Improvement of the carbon footprint by oil conditioning Thermal disposal of waste oil causes approx. 2.6 kg of the harmful greenhouse gas CO 2 per 1 litre Filter material consists to 100 % of renewable raw material No additional impact on the environment during disposal of the filter material CJC Fine Filter inserts can be disposed of according to the (German) Waste Product Key and thus, they also comply with the requirements of DIN EN ISO 4001:2005 "Environmental Management System" and the life-cycle resource management Highest possible oil cleanliness can only be ensured by continuous offline fine filtration - in conjunction with the inline filter. Easy installation: Profit from the advantages of the CJC Fine Filter systems! The oil is drawn and returned at the system tank. 6 7

5 CJC Fine Filter units Installation sizes and modular build-up Further CJC Oil Maintenance Systems Especially for oils and fluids with very high content of free or dissolved water Principle: Fine and depth filtration CJC Filter Separators 62 cm Applied for following contaminants: Particles Water Oil ageing products (resins, varnish, sludge) Acid compounds Design size 15/25 36,3 cm 31,5 cm 25 cm Ø 15 cm , ,5,5 cm CJC Depth filter Design size 27/- 50 cm 70 cm 108 cm 81 cm 54 cm 27 cm Ø 27 cm 146,9 cm See product sheets for technical data. Download: Design size 38/ cm 57 cm 100 cm Ø 38 cm Fine and depth filtration in combination with a coalescer-filter for removal of larger amounts of free water from oils and fuels. Applied for the following contaminants: Free water Particles Oil degradation products (resins, varnish, sludge) Principle The coalescing principle is ideal for the separation of free water from mineral and synthetic oils with a good demulsification time (< 20 minutes). For optimal coalescer efficiency the solid and soft contaminants contained in the oil (particles and oil ageing products) have to be removed by fine filtration before the coalescing process starts. Contaminations negatively influence the demulsification capability, clog the coalescer and reduce the coalescer efficiency. In a subsequent coalescer filter, the water droplets are carried by the laminar oil flow through the coalescing element and attach to the coalescer fibres due to the larger adhesion forces. The flow pushes them along the coalescer fibres and lets them coalesce with other droplets at the intersections. Finally, due to gravity and the higher density, the larger droplets are released and separated in a discharge area. CJC Fine Filter insert CJC Coalescer-filter Flow switch and solenoid valve Dirt Water Size Dirt Water Dirt Water 1,1 kg 0,5 l 27/108 8 kg 4,8 l 27/81 6 kg 3,6 l 15 kg 7,2 l CJC Desorber 27/54 4 kg 2,4 l 27/27 2 kg 1,2 l Desorption for removal of larger amounts of dissolved water from mineral, synthetic and high-viscosity oils - even from stable emulsions and oils with a density > 1. Design size 427/108 Design size 727/108 Applied for the following contaminants: Free and dissolved water Particles (only in combination with a CJC Fine Filter unit) Oil degradation products (only in combination with a CJC Fine Filter unit) Ø 27 cm Ø 27 cm 159,7 cm 120 cm 85 cm Dirt Water 108 cm 161,6 cm 140 cm 110 cm 108 cm Dirt Water Principle With desorption it is possible to separate both free water and dissolved water from the oil unaffected by additive packages and viscosity. Mineral and synthetic fluids with a poor demulsification time (> 20 minutes) and stable emulsions can be dried even with very high water content - up to 30 % ( ppm). The desorption process is based on the principle that heated air can effectively hold large quantities of water. In the desorber, the warm oil is met by a counter flow of cold, dry air. The air, heated very quickly by the warm oil, absorbs any water present until saturation is reached. During the subsequent air cooling process the water condenses and the dry air is used again for drying of the following oil flow. Desorption removes only H 2 O. In the case that the oil is contaminated with particles and oil ageing products too, it is possible to connect a CJC Fine Filter unit upstream of the CJC Desorber. 32 kg 19,2 l 56 kg 33,6 l Fluid volume, viscosity, type and amount of dirt ingress, operating temperature and other parameters influence the dimensioning. For optimal dimensioning customised for your fluid system, please contact us! 8 9

6 Particle Content and Oil Cleanliness Analyse and evaluate oils Water Content and Varnish-Potential Analyse and evaluate oils Classification according to ISO 4406 (International Organization for Standardization) The ISO 4406/1999 method for coding the level of contamination of solid particles is a classification system that converts the numbers of counted particles into an ISO class (oil cleanliness level). According to ISO 4407, counts at 5 and 15 µm from the manual particle counting are equivalent to the counts at 6 and 14 µm when using an automatic particle counter calibrated in accordance with ISO Amount of particles > specified size more than up to ISO Code 8,000,000 16,000, ,000,000 8,000, ,000,000 4,000, ,000,000 2,000, ,000 1,000, , , , , , , ,000 64, ,000 32, ,000 16, ,000 8, ,000 4, ,000 2, , (Extract from the currently valid ISO 4406 standard.) Automatic particle count From a 100 ml sample of the fluid to be examined, the quantity of particles > 4 μm, > 6 μm and > 14 μm is determined. The quantities of particles are then categorised in class codes, indicating the oil cleanliness level. Example - ISO Code 19/17/14 (typical for new oil): 250,000 up to 500,000 particles 4 μm, 64,000 up to 130,000 particles 6 μm and 8,000 up to 16,000 particles 14 μm are contained in 100 ml of the tested oil. Microscopic analysis Only the quantity of particles 5 μm and 15 μm is determined. Example - ISO Code 17/14 (typical for new oil): 64,000 up to 130,000 particles 5 μm and 8,000 up to 16,000 particles 15 μm are contained in 100 ml of the tested oil. ISO 11/10/6 ISO 13/12/7 ISO 15/13/8 ISO 18/17/15 ISO 20/18/13 ISO 24/23/20 Photos of test membranes of various contamination degrees Karl-Fischer-Titration With the Karl-Fischer-Titration it is possible to determine the water content in oils. Basis for water determination is the reaction of iodine with water in a dissolution. Two different methods exist: Volumetry: This method is used for detection of larger amounts of water in oil. The measuring ranges from 0.01 % up to 100 % water in oil. Coulometry: This method is used for exact detection of smallest amounts of water in oils. The measuring ranges from % up to 5 % water in oil. MPC-Test (Membrane Patch Colorimetry) 50 ml of the oil to be tested and 50 ml filtered heptane are mixed and vacuum-filtered through the test membrane. The colorimetric analysis is conducted after the subsequent drying of the membrane. The residuals on the membrane are analysed by the spectral sensor. The deposits absorb or reflect the light completely or partially. The differences between sent and reflected light as well as the colour intensity in the respective spectral range allow an MPC value to be calculated. The higher the MPC Index, the heavier the colour change on the membrane and the greater the potential of the oil to generate deposits Normal Monitor Attention Critical Problematical Oil change System purification Normal oil ageing Critical value for formation of deposits is achieved soon Many soft contaminants, start of deposits on sleeve bearings and cooler spots in the lubrication system Extremely high amount of soft contaminants, formation of deposits in bearings, valves or tanks Hydraulic oil samples with various water content. From left: 0.01 % % % % % - 2 % water in oil Additive degradation, oxidation, high oil temperatures and long use of the oil can generate further particles, which deposit Additive degradation and oxidation well advanced, deposits in bearings, valves and tanks Oil no longer useable, deposits in the whole system Categorising cleanliness levels 22 / 20 / / 17 / / 15 / / 14 / / 12 / 10 MPC index 2 MPC index 19 MPC index 35 MPC index 41 MPC index 49 MPC index 53 MPC index 60 Depending on the application, specified oil cleanliness levels for oil systems (ISO 4406) are recommended. The adjacent table shows these minimum requirements in an overview. (Source: Noria Corporation) The of hydraulic and lubrication system components varies distinctly according to the cleanliness level (ISO 4406). heavily contaminated not useable in oil systems 50 % of medium contaminated e.g. new oil* low and medium pressure systems 75 % of lightly contaminated hydraulic and lubrication systems 100 % of clean servo and high pressure systems 150 % of very clean all oil systems 200 % of *) Up to 0.05 % of insolubles are permissible in new oil. (DIN , Part 2) Further important analysis options: Viscosity determination Acid content: Detection of neutralisation number or base number Element analysis Particle Quantifier index Read more about the topics of classification systems, oil analysis and correct oil sampling in our brochure "Ratgeber Öl". Download: Ensuring a longer lifetime for machine, system components and oil is a must to sustainably reduce the content of particles, water and oil degradation products to a minimum! 10 11

7 Hydraulic Oil - Application Examples Minimise downtime and failures, reduce maintenance costs and prolong oil lifetime Lubrication Oil - Application Examples Reduce costs by fine filtration instead of oil changes and simultaneously optimize protection against wear Problem: Water and particles Ring rolling machine 1,500 litres hydraulic oil HLP-D 68 Ingressing condensed water regularly led to an extremely high water content of 2,900 up to 3,900 ppm and an accelerated oil ageing process. Additionally, the contamination with solid particles was so high that the oil cleanliness class could not be detected by particle counter. The already installed offline filter could not achieve the recommended oil cleanliness for hydraulic systems. Permanent low water content after start-up of the CJC Fine Filter system: After 6 days: 200 ppm After 7.5 months: 117 ppm Oil cleanliness level improved with finally ISO Code 14/13/9 - significantly cleaner than new oil Optimum protection against abrasive and corrosive wear and tear as well as cavitation ISO Code 4406 )* Water, ppm New oil reference 18/16/13 < 1,000 Without CJC not measurable 3,900 AFTER 6 days of fine filtration with CJC 18/16/ AFTER 7.5 months of fine filtration with CJC 14/13/9 117 *) Further information on cleanliness classes see page 10 Chief of technical services: The achieved oil cleanliness is notable. We have tried out a lot of filters but only with the filters from CJC did we reach the desired oil cleanliness. In the meantime we have retrofitted four further machines in our production with CJC offline filters. Problem: Particles Compressor 4,200 litres lubrication oil, type Shell Turbo T 46, ISO VG 46 Due to the operating conditions the oil contaminates within a very short period of time. Oil cleanliness of the new oil is already poor - despite filtration before filling it into the tank and flushing of the whole oil system (filter of the oil supplier was used). Only continuous offline fine filtration ensures a permanently high oil cleanliness level (see results on the right). As a result of the prolonged oil lifetime, costs and time are saved (costs per compressor and oil change: approx. 25,000 EUR). Asset Manager: I hadn't thought that we would achieve such a clear result! We will use the CJC Fine Filters also for our other sites so that those compressors will also be supplied with clean oil. Number of particles in 100 ml Particle content according to ISO ,200,000 1,000, ,000 > 4 µm 600,000 > 6 µm > 14 µm 400, ,000 0 New oil After 9 days with After 2.5 month without After 1.5 months with (initial sample) CJC fine filtration CJC fine filtration CJC fine filtration Compressor not in Compressor in Compressor in operation operation operation ISO Code *) New oil 20/18/13 WITH CJC Fine Filter 15/14/10 WITHOUT CJC Fine Filter 21/19/15 WITH CJC Fine Filter 16/15/12 *) Further information on cleanliness classes see page 10. Problem: Oil ageing and particles 60 hydraulic presses (80 up to 500 tons) Average 1,500 litres hydraulic oil Problem: Oil ageing, water and particles Wire-drawing machines 500 litres lubrication oil, type Fuchs Ratak TRP 170 / 2.300, 400 cst WITHOUT CJC offline fine filter AFTER approx. 4 months with CJC fine filter Particles > 1 µm % * % * Oil system was heavily contaminated with particles and oil degradation products - despite an inline filter with a filtration degree of 8 µm. Increased wear and tear due to abrasive particles and resin- and varnish-like deposits on the system components Enormous maintenance costs caused by daily oil related failures Particle content was decreased by > 99 % within shortest time and due to the simultaneous removal of oil degradation products, the potential to generate deposits was reduced to a minimum. The drastic drop of oil related failures and downtimes led to an appreciable reduction of costs and to significantly higher machine reliability and productivity. Submerged pump of a hydraulic press with resin- and varnish-like deposits (oil ageing) With inline filter filtration degree 8 µm With CJC offline fine filter filtration degree 3 µm Particles > 4 µm 1,443,178 6,774 Due to the production process the oil is heavily contaminated with particles and water. Additionally, the thermal stress of the oil during the drawing process causes formation of oil degradation products. Resin- and varnish-like deposits adhere to the final product, blocking the wire nozzles in the soldering machines and considerably reducing the useful life of the lubricant. The formation of deposits on the surface of the wire is avoided as a consequence of the contamination removal. Due to the permanent high oil cleanliness the oil lifetime has been prolonged drastically. Particles > 2 µm % * 0.0 % * Water 22,000 ppm 874 ppm Membrane color black white * Weight of the particles in the oil in percent Maintenance Manager: [...] The CJC Filter has given us some very satisfactory results. It is a very beneficial installation that provides us with clean oil, something crucial for good lubrication. Our final product, the stainless-steel wire, has also been improved and is no longer stained by oxidation of the lubricant. [...] It's for this reason that we have installed offline fine filters in 13 systems. Particles > 6 µm 298,680 2,204 Maintenance Manager: The installation of CJC Filters at our hydraulic presses was an excellent decision. From now on CJC Filters are part of the technical specification, and all new machines are fitted with CJC as original equipment. Particles > 14 µm 17, ISO Code *) 21/19/15 13/12/9 *) Further information on cleanliness classes see page In total more than 100 application studies from different industries verify the success of CJC. Please feel free to contact us or visit our website for more information! 13

8 Gear Oil - Application Examples Avoid unnecassary oil changes and thus, protect resources and environment Other Oils and Fluids Improve processes and increase productivity Problem: Particles Cement mill 2,000 litres gear oil, type Addinol Eco Gear 320 M Although the oil was changed 2 years ago, the oil was heavily contaminated especially with metal particles and swarf. Oil cleanliness 25/22/16 (ISO 4406). The use of such an extremely contaminated oil reduces the lifetime of components by 50 %. (Source: Noria Corporation) Number of particles in 100 ml 18,000,000 16,000,000 14,000,000 12,000,000 10,000,000 8,000,000 6,000,000 4,000,000 Particle content according to ISO 4406 > 4 µm > 6 µm Problem: Particles and oil ageing Casting machine 7,000 litres HFC fluid, type Houghto Safe 620 Comparatively frequent failures at casting machine no. 5 due to the poor fluid condition. HFC fluid was loaded with solid particles (metal particles etc.) and especially with oil degradation products - so-called soft contaminants - from oxidation and degradation processes. Number of particles in 100 ml 35, , , , , ,0000 5,0000 Particle content according to ISO 4406 > 2 µm > 5 µm > 15 µm Particle content reduced by 50 % within the first 6 days and by 99 % within 18 days. Oil cleanliness improved to 17/15/11 (ISO 4406) - cleaner than new oil. 2,000,000 0 Initial Sample After 6 days After 18 days After 46 days Oil samples - membrane filter test Within 8 days the number of particles > 2 µm decreased by 86 % - abrasive wear and tear was minimised. Simultaneously, also the amount of soft contaminants was visibly reduced (compare membrane colours). 0 Initial sample After 8 days fine filtration Oil samples - membrane filter test Optimum protection against abrasive wear and tear as well as longer oil change intervals reduce costs and preserve the environment. Significantly less failures, less production downtime and less maintenance resulting in decreasing costs and increasing process reliability and productivity. Manager metalworking shop: The extensive oil analyses from OELCHECK have convinced us. They clearly show the improvement of the oil cleanliness. Because of the excellent results the gear boxes of the other four cement mills as well as of the raw mill were also equipped with CJC Offline Filters. BEFORE fine filtration, AFTER 18 days fine filtration Additionally, the customer profits from the longer lifetime for fluid and system components. Due to the brilliant results, all three die casting machines were equipped with CJC Offline Filters. In future, CJC Fine Filters are part of the technical specifications. BEFORE fine filtration, AFTER 8 days of fine filtration Problem: Oil ageing, water and particles Gear box hot rolling mill, steel work Gear oil Gear box breakdowns, high component wear and short oil lifetime caused by an enormous amount of dirt and water in the oil. Water content approx %. Water accelerates oil ageing and therefore the oil was not only contaminated with solid particles, but also with reaction products caused by the oil ageing. Since the installation of the CJC Oil Maintenance system no oil related breakdowns and production downtime occured. Spare part and maintenance costs were significantly reduced. Water content was reduced to 0.01 %. 40% 35% 30% 25% 20% 15% 10% 5% 0% Water content Water content in % Oil samples - membrane filter test Problem: Particles and asphaltenes IPSEN discontinuous chamber furnace 2,400 litres mineral oil based quenching oil Black deposits on the small hardened parts (valve covers). Despite extensive after-treatment not removable. High scrap quantity due to these optical defects. After only 1 1/2 weeks the surfaces of the hardened parts were significantly cleaner without black deposits. No sand blasting during after-treatment necessary. Minimised scrap. Work amount and costs considerably reduced. Oil samples - membrane filter test BEFORE fine filtration, Test membrane: 0.45 µm AFTER fine filtration Test membrane: 0.45 µm After fine filtration particle content was measurable, oil cleanliness 18/15 (ISO 4406) was achieved. Simultaneously, the amount of soft contaminants was immensely reduced (Compare membrane colours). BEFORE fine filtration, AFTER fine filtration Maintenance Manager: We have clearly seen the efficiency of the CJC Fine Filter on the quenched parts. This result has convinced us. Hardened parts: on the left with unfiltered, on the right with filtered quenching bath 14 In the industry, marine or mining sector, in power plants or in wind turbines CJC offers the optimal oil maintenance systems for any problem! 15

9 - worldwide Karberg & Hennemann GmbH & Co. KG Marlowring 5 D Hamburg Germany Phone: +49 (0) Fax: +49 (0) filtration@cjc.de History Founded in 1928 and located in Hamburg, we develop and manufacture CJC Fine Filter technology since With substantial know-how and in-house analysis and test facilities we are experts when it comes to the maintenance of oils and fuels. Quality Competent advice and individual solutions, even for the most difficult filtration problems of our customers - that is our daily claim. The certification of our company according to DIN EN ISO 9001:2008 provides us with assurance and motivation. CJC worldwide CJC Fine Filter systems are available worldwide through subsidiaries and distributors. Find your nearest distributor on our website - or give us a call! MPIe 12.16