steel mills/works oil maintenance - filter equipment...steel mills are often suffering from large...

Steel Mills/Works

Oil Maintenance

Preliminary Version

Draft

Internal Use Only

Steel Production There are many different processes in steel making, and much of it is performed at high temperatures in order to have the steel deformable. Depending on the size of the steel plant there will be different number of production lines and there will be different amounts of the different product possibilities.

There are typically several different oil systems in steel mills/rolling mills. Normally there will always be a gear & lubrication oil system and hydraulic oil systems for auxiliary hydraulics and steering systems. There will often be more applications where oil cleanliness is an important factor, e.g. in sintering plants, coke oven and furnaces.

Steel mills are often suffering from large contamination and water problems. Water is a huge problem for any oil system, and since water in used a lot, to cool, in the production process, this problem will unavoidably occur. The production of steel generates many particles which end up in the oil. The metal particles does much damage to both the oil and the machinery. Water problems are severe and there have been cases where the oil contained up to 35 % water. Steel mills often use high viscosity oils, where it can be hard to separate water from oil.

Due to high operating temperatures in the production heat related problems, shown as vanish and sludge and condensed water in the oil will most probably occur.

Key Decision Figures for CJC™ filters: • Oil Volume • Oil Viscosity • Oil temperature under operation • Environment (Installation)

Steel Work Questions Introduction examples of investigating questions to use for steel works:

• Which machine do you have issues with (Most critical machine in production) • How do you do oil maintenance today? Oil changes based on oil analyses,/intervals/color/smell

etc.? can I see an oil analysis? • Have you calculated the total cost of an oil change? Including downtime, manpower etc. • How does downtime affect your production? Cost/h? Use case studies

• How often do you service/change oil on your machines? • How do you experience the environment in your production process? (Metal dust & water ingress)

Steel Mills and CJC™ Overview of CJC™ applications in steel mill production.

Steel Mills – Main Gear Lubrication System There are many different gears at a steel plant. Many of these needs to be lubricated in order to function in the production. The lubrication system lubricate gearboxes for roller feed, screw down and more. The production is run at high temperatures to keep the steel where it is possible to deform it and this environment is harsh on production components and the lubrication oil. Further the deformation of the steel also creates metal particles which goes into the components. Finally there are also water problems, as water is used in the production, and this also finds the way into components and the oil.

The Problem • Contamination from particles – especially metal particles, residues from the production process.

The particles go in and cause wear on components. • Sludge and varnish, creating sticky surface on components • Water ingress, creating wear on components

Consequences:

• Short lifetime on components • Unscheduled downtime, associated with high costs

All these increase maintenance costs and production costs.

The Solution By doing oil maintenance on the lube system it is possible to prolong the lifetime of both the oil and the components in the system. The installation of a CJC™ Steel Works Lubrication Combi Filter will both remove particles, sludge, varnish and large water contents. The filter increases the reliability of the system and reduces downtime.

Filter Selection The filter selection is based on the following parameters:

Oil type ISO VG 220 Ambient temperature (oC) Min. 0 Max. 40 Operating temp. oil (oC) Min. 60 Max. 90 Circulation ratio (l/h) Flow % of volume Pressure Inlet (bar) Max. 0,5 Design pressure (bar) Max. 4

If these parameters are not met then a specific selection is required. Then at a higher price.

Filter Name HDU plus plus D40 Base product HDU27/108 D 40 No. of Inserts + type 4xBLA 27/27 System Volume (l) <14.000 < 14.000 Pump flow (l/hr) 960 1.400 Power consumption (kW)

0.55 13

Pump Type MZ-16-4 Dirt Capacity (kg) 16 Operational weight (kg) 100 920 Dimensions 575x434x1439 1522x1400x1750 Item No. 604002397 FA7402103-X

The filters are multivoltage and are for most voltages. Special voltages on request.

Steel Mills – Central Bearing Lube There are many different components at a steel plant. Many of these needs to be lubricated in order to function in the production. The lubrication system lubricates e.g. the roll-neck bearings on roller tables. The production is run at high temperatures to keep the steel where it is possible to deform it and this environment is harsh on production components and the lubrication oil. Further the deformation of the steel also creates metal particles which goes into the components.

The Problem • Contamination from particles – especially metal particles, residues from the production process.

The particles go in and cause wear on components. • Sludge and varnish, creating sticky surface on components • Condensation water, creating wear on components

Consequences:

• Short lifetime on components • Unscheduled downtime, associated with high costs

All these increase maintenance costs and production costs.

The Solution By doing oil maintenance on the lube system it is possible to prolong the lifetime of both the oil and the components in the system. The installation of a CJC™ Steel Works Lubrication Fine Filter will both remove particles, sludge, varnish and moisture contents. The filter increases the reliability of the system and reduces downtime.

Filter Selection The filter selection is based on the following parameters:

Oil type ISO VG 460 /MorgOil Ambient temperature ( oC) Min. 0 Max.40 Operating temp. oil ( oC) Min. 60 Max. 90 Circulation ratio (l/h) Flow % of volume Pressure Inlet (bar) Max. 0,5 Design pressure (bar) Max. 4

If these parameters are not met then a specific selection is required. Then at a higher price.

HDU plus plus D40 Base product HDU 427/81 2 x D 40 No. of Inserts + type 12xBLA 27/27 System Volume (l) 40.000 Pump flow (l/h) 2.600 2x1.400 Power consumption (kW)

1,1 2x13

Pump Type GP-33-4 GP-26-4 Dirt Capacity (l) 48 Operational weight (kg) 2x929 Dimensions (lxwxh) 2 times

1522x1400x1750 Item No. FA7402193-X

The filters are multivoltage and are for most voltages. Special voltages on request.

Steel Mills – Oven hydraulics The blast furnace

The Problem • Contamination from particles – especially metal particles • Degradation • Oxidation • Condensed water

Consequences:

• Short lifetime on gears • Downtime

All these increase maintenance costs, production costs and enhance the risk of the employees.

The Solution With good oil maintenance it is possible to extend the life time on both the oil and the machine components considerably.

The oil maintenance system (HDU and Desorber) will remove all three contaminants – particles and oxidation residues and water.

All this will reduce down time and increase reliability.

Gear OilSlewing Gear Drives, Ore Bucket Digger

ASIN5078-UKSteel & Aluminium + Mining

24.03.2009

CJC™ Application Study

C.C.JENSEN A/SLøvholmen 13 DK-5700 Svendborg DenmarkPhone: +45 6321 2014 Fax: +45 6222 4615

[email protected] www.cjc.dk

Twin executed slewing bearing gear drive.

The Filter Separator in the box.

The Filter Separator PTU 2 27/27PV.

Oil sample BEFORE filtration. Oil sample AFTER filtration.

Application Study written by:

Ivan PartonoC.C.JENSEN A/SThe Netherlands

In cooperation with:

Erik van SchagenMaintenance Manager

Special thanks to:

Gerard BrammerTechnical Department

2006

CUSTOMERCORUS IJmuiden, the Netherlands GSL (Grond Stoffen Logistiek)

THE SYSTEMA ‘Delattre-Levevier’ ore bucket digger, with slewing bearing gear drives and twin executed gear drives, each powered by Electromotor with 110 kWatt power output. A reduction gear box (4-stages) serves as pro-pulsion to rotate the bucket dig-gers along the azimuth. Each gear box contains 100 litres of Total Giran L 220 (ISO Vg 220).

THE PROBLEMAs the outdoor application is working under extreme con-ditions, fine ore particle dust and huge amounts of water have accessed the system. Condensation, precipitation and cleaning of the application with high pressure cleaners lead to very high water content in the gear oil. These contamina-tion sources were not beneficial for the life time of the gear oil, the spherical roller bearings, the gear-teeth and the in-ner gearbox. Periodical inspections showed rust formations and severe wear of the components. The only remedy was frequent oil changes which proved labourious and expensive.

THE SOLUTIONA CJC™ Filter Separator PTU2 27/27 PV-DE2H1PWY on a drip-tray, with electric preheaters (2x1650 Watt), au-tomatic water discharger and with a pump yield of 60 L/h was installed, using a CJC™ Filter Insert BLAT 27/27 (3 micron absolute). Due to a harsh working environment the CJC™ Filter is in-stalled in a stainless steel protective box with hatches for easy access and maintenance. By means of change-over valve the single CJC™ Filter Sepa-rator is servicing both the left and the right gearbox at regu-lar intervals.

THE RESULTWithin 40 days, water content was reduced from 62,970 ppm to 29.9 ppm. Particle contamination was reduced dramatically and the condition of the oil recovered. Resin content and oxidation by-products in the oil were removed, adsorbed by the CJC™ Filter Insert BLAT 27/27. The first filter insert was saturated within 4 weeks and had a gross total weight of more than 10 kg. The automatic water dis-charger empties water from the Filter Separator and thereby maintains the condition of the oil.The purpose of installing the CJC™ Filter Separator was to continuously maintain a low water content and remove solid particles and oxidation residuals (resins).

Bucket Digger Application.

Gear Oil Steel Mill Screw Down Gear System

ASIN5037-UKSteel / Aluminium

24.03.2009





Bryan HoldenC.C.JENSEN LtdUnited Kingdom

In cooperation with:Charlie Mcginty

Corus United Kingdom

2001

CUSTOMERCORUS, Dalzell Works PLC, Motherwell, United Kingdom. (Formerly known as British Steel PLC.)

THE SYSTEMSystem A is a Mill Screw Down Gear Lube Sys-tem (oil = ISO VG 150). System B is Main table gearboxes and Roller tables (oil = ISO VG 320). The steel passes through the tension rollers backwards and forwards, continuously until the plate is formed. While passing through the roll-ers, the steel is quenched with water.

THE PROBLEMThe system suffered from large water and par-ticulate ingress, causing a large number of gear-box failures. Water level 35.5 % and an uncount-able ISO code.Over the years the amount of contamination cannot be quantified, but it is known to have a damaging effect upon components and the life time of the oil.

THE SOLUTIONA CJC™ Desorber Unit D38 was installed to operate between 2 systems (A and B). In ad-dition a CJC™ Fine Filter was installed upon each system. System A with HDU 3 x 27/108 GP, with pump flow rate = 2400 L /h. System B with HDU 427/108 GP, with pump flow rate = 3100 L/ h. Both Fine Filters were installed with CJC Fine Insert type BLA 27/27 (3 μm absolute).

THE RESULTSince the installation of the CJC equipment, the gearbox failures have ceased saving component cost and plant downtime. 35,5% of water, was reduced to 112.7 ppm, and from uncountable ISO code, down to 18/15.

Oil drained from the bottom of the oil tank before startup. The water content was as high as 35%

The CJC™ Fine Filters.

Oil Test before CJC-filter Oil Test after CJC-filter

Gear Oil Steel Strip Rolling Mill


24.03.2009





Joe Downes C.C.JENSEN LtdUnited Kingdom

In cooperation with:Peter Skates

Senior EngineerBritish Steel plc.

2002

CUSTOMERCORUS, Shotton Works, United Kingdom. (Formerly known as British Steel plc.)

THE SYSTEMThe 5 Stand Tandem Mill has 5 stands, each driven by Davy gearboxes coordinated to pro-duce steel strip by cold reduction process. Oil system capacity 28,000 litres. Shell Omala 460, ISO VG 460.

THE PROBLEMThe costs incurred with a recent replacement gearbox led to a full inspection of the other gear-boxes by the Engineering Dept. as part of their predictive maintenance program. There was evi-dence of gear tooth wear and blocked lubricating jets - resulting from contamination. Further dam-age had to be avoided by improving oil quality and oil cleanliness, which led to upgrading filtra-tion. A replacement gearbox was estimated to cost around £ 200,000.

THE SOLUTIONA CJC™ HDU Fine Filter 427/108 GP was installed temporarily for trial purposes. After achieving a positive result, the trial unit was replaced by the CJC™ HDU Fine Filter 5 x 27/108 GP as a permanent solution.

THE RESULTA target cleanliness was set at ISO 18/16/14 (new oil). Starting with a high figure ISO 22/19/16, the target was reached in less than 7 weeks. With continuous filtration the contamin-ation fell to 17/15/11. The first set of filter in-serts lasted 14 months. System cleanliness had improved and confidence in the equipment was secure following another gearbox inspection.

The 5 Stand Tandem Mill.

Before CJC filter After CJC filter

Date 2 μm 5 μm 15 μm ISO

08.10.96 3,462,830 473,380 52,320 22/19/16

11.10.96 1,750,385 265,896 17,548 21/19/15

24.10.96 1,598,443 131,088 10,774 21/18/14

31.10.96 355,795 54,821 4,607 19/16/13

05.11.96 298,753 48,317 3,812 19/16/12

21.11.96 216,888 24,627 1,667 18/15/11

05.12.96 86,960 30,784 1,443 17/15/11

THE RESULT

Particle content per 100 ml oil.

Hydraulic Oil Aluminium Injection Moulder


24.03.2009




Before CJC™ filtration After CJC™ filtration


Stefan MolborgC.C.JENSEN Ibérica,

S.L.

In co-operation with:Mr. Medir Lecha PuigMaintenance Chief

RUFFINI, S.A.

2000

CUSTOMERRUFFINI, S.A, a company making moulding of pressure cast pieces made of aluminium alloys, mainly intended for the car industry.

THE SYSTEM24 Injection machines, makes ITALPRESSE, PRETRANSA and IDRAPRESSE, from 500 up to 2,500 tons.

THE PROBLEMRUFFINI, S.A. wanted a suitable oil quality for the hydraulic system, general servo systems and critical systems of these machines that would be within category ISO 16/14/10.

RUFFINI, S.A. also wanted to reduce break- downs and unplanned stoppage hours, as well as to make longer the life of the oil that was replaced every year and avoid the complicated cleaning of the tanks of the injection machines, too.

THE SOLUTIONCJC™ Depth Fine Filters LG 15/25 L with CJC™ Filter Inserts BG 15/25 of 3 μm abso-lute were installed. Thanks to the qualities of these Filter Inserts water and particles up to 1 μm were removed, and water and resins were absorbed, which are the end products of oxida-tion of oil.

THE RESULTIn 1 month the contamination level was reduced by 90% and in 3 months by 99%, getting an ISO code twice under the recommended level, what helped to make life of hydraulic parts longer. Contamination of injection machines resulting from obstruction was reduced, as well as that of servo valves that from 18 stoppages has been reduced down to 2 stoppages per injection ma-chine yearly.

The process removed not only abrasive particles, but also resins and moisture. As it is no longer necessary to clean the tank, and as the oil life time has been prolonged, the customer has ob-tained a saving of € 17,424 yearly.

Mr. Medir de RUFFINI With a CJC™ Fine Filter LG 15/25 L.

BeforeFiltration

After1 months

After3 months

Solid particles > 565,924 50,024 5,684

ISO Code 20/17/12 16/15/9 13/12/8

Water 40 ppm 26 ppm 19 ppm

Resins (oxidation) Brown White White

OIL CHANGE

Before Filtration Each year

After filtration No change in 4 years

THE RESULT

COMMENTS

Mr. Medir Lecha, Maintenance Chief of RUFFINI, S.A.:“...After knowing C.C.JENSEN Filters and having installed them on our injection machines, we have got the suitable oil quality and reduc-tion of yearly unplanned stoppages from 18 to 2 times. At present we are certain to work with oil in very good conditions and suitable at all times for our facilities. The investment to install CJC™ Filters was a right decision and a pro-assets good maintenance tool...”

Hydraulic Oil Steel Rolling Mill, Roll Force System


24.03.2009





Jan FogedC.C.JENSEN A/S

Denmark

In cooperation with:Eric Kuijs

Project EngineerCorus Packaging Plus

The Netherlands&

Rinco VoorripsProject Engineer

Fluid Power & Lubrica-tion

Corus Strip Products IJmuiden

The Netherlands

2001

CUSTOMERCORUS Packaging Plus, IJmuiden, Netherlands. (Formerly known as Hoogovens IJmuiden.)

THE SYSTEM(270 bar) A hydraulic servo system for the roll force operation used on the cold rolling mill no. 11. System capacity: 6,000 litres of Hydran BE 32 oil.

THE PROBLEMPrior to the installation of the CJC™ Filter, a vacuum purifier had been connected to the sys-tem. However, the water content in the oil was still 0.37% (3,700 ppm), thus causing serious prolems to the hydraulic system. Furthermore, the system suffered from a high particle contam-ination (ISO code 18/17/15), 45% of which had been formed through oxidation of the oil.

THE SOLUTIONA CJC™ Filter Separator PTU3 27/108 MZ-EPW with a pump flow rate of 960 L/h was in-stalled for continuous circulation of the oil tank. The unit utilizes 4 of CJC™ Filter Insert BLAT 27/27 (3 μm absolute) and a CJC™ Coalescing element for water separation.

The purpose of installing the CJC™ Filter Sepa-rator was to continuously maintain a low water content, and remove solid particles and oxidation residuals (resins).

THE RESULTThe CJC™ Filter Separator reduced the water content down to 74 ppm and diminished the solid particles content to ISO code 12/11/6. The incidental damage of a leaking cooler was also neutralized as the separator removed the water as soon as it entered the tank.

Date Water Content PPM ISO Code

05.10.00 3,650 18/17/15

24.11.00 1,041 15/14/10

08.12.00 *) 3,462 15/14/11

20.12.00 810 14/13/10

03.05.01 74 12/11/6

THE RESULT

CJC™ PTU3 27/108

*) Leaking cooler

Hydraulic Oil Steel Strip Mill, Exit System


24.03.2009




Before CJC Filter After 136 days


Joe DownesC.C.JENSEN LtdUnited Kingdom

In cooperation with:Chris Hawley, Pickle Line

EngineerBritish Steel plc.

2001

CUSTOMERCORUS, Shotton Works, United Kingdom. (Formerly known as British Steel plc.)

THE SYSTEMThe Exit system operates the Coil Traversing Beam, which transports heavy steel coils weigh-ing up to 30 tonnes from the Pickle LineBay. Oil system: 4,500 litres, Shell Tellus 1800, ISO VG 32, hydraulic oil.

THE PROBLEMHistorically, the system suffered from various hydraulic problems, such as pump failures fre-quently not coming on load, loading valves stick-ing, hydraulic shock, cooler failures, sub- sequent water ingress and contamination of the system. Plans to upgrade the system with proportional valves were progressing, but first a solution to control the contamination had to be decided.

THE SOLUTIONCJC™ Filter Separator PTU3 27/108 P-EPW, 2/speed motor and pump flow rates of 600 and 1,200 L/h. Installed with 4 of CJC™ Filter In-sert BLAT 27/27 (3 μm absolute), and water separation with CJC™ Coalescing element.

THE RESULTWithin two weeks, improvements to system oil cleanliness were apparent, both visually and from analysis resulting in better hydraulic per-formance. In-line filter life had increased by a factor of 8. Water / moisture was under control, which permitted their Engineering Department to upgrade the system.

CSM, Pickle Line - BWG Exit.

Lubrication OilCan Manufacturing - Steel/Aluminium Rolling Machines

ASIN5008-UKFood Industry02.09.2008




Before filtration After filtration


Jan FogedC.C.JENSEN A/S

Denmark

and

Reimar LarsenC.C.JENSEN A/S

Denmark

In cooperation with:Paul Moeling

Ball Packing EuropeThe Netherlands

2001

CUSTOMERBall Packaging Europe, NL (formerly Continental Can Benelux BV).

THE SYSTEMMachine lubrication oil for Wall Ironing Machines (manufacturing of cans by means of rolling steel plate). Machines: Alcoa/Ragsdale type CR24 & CR26,5. Oil: Mobil Vactra Extra Heavy.

THE PROBLEMPrior to the installation of CJC™ equipment oil cleanliness levels were typically 22/20/17 (ISO) and >2% water content causing a water oil emulsification.

The high volume of emulsified oil made it unfit for further use. The high surrounding tempera-ture also accelerated bacteria growth.

The yearly oil consumption was approximately 80,000 litres.

THE SOLUTIONA purpose built unit was installed consisting of a dual tank Desorber D38 along with a CJC™ Fine Filter HDU 2x27/54 P with a flow rate of 1,400 ltr/hr, fitted with CJC™ Filter Insert B 27/27. The filter was also fitted with an auto-matic water content monitor.

Oil is collected in drip trays and pumped to a storage tank (1,000 ltr.) The oil is then pumped through the Desorber D38 to remove the water. Once the water monitor indicates <300 ppm the oil is transferred through the Fine Filter for particle and resin removal.

THE RESULTDue to the success of the CJC™ equipment Ball Packaging Europe reduced the net consumption of oil to 30,000 ltr/year, thus saving 50,000 ltr. of oil/year. Depending on the oil price typical sav-ings can be EUR 68,340.

The CJC treatment unit at Ball Packaging Europe

THE RESULTParticle countAcc. ISO 4406 Water content Appr. annual

cost Euro

Before 22/20/17 >20,000 ppm 134,320

After 17/15/12 52 ppm 65,980

Lube OilStainless Steel Wire Manufacturing

ASIN5069-UKSteel & Aluminium

24.03.2009





Mr. Thomas K Jensen, C.C.JENSEN IBÉRICA, S.L.

In cooperation with:

Mr. Xavier Brugues (Head of Maintenance)

andMr. Victor Motis

(Head of Purchasing)

of the group

2005

CLIENTInoxfil, S.A., founded in 1990, is dedicated to the manu-facture of stainless steel wire and is the biggest factory in Europe. Inoxfil is part of the group Acerinox, S.A. group, internationally recognized as the world’s most competi-tive company in the manufacture of stainless steel.

THE SYSTEMConsists of a system for lubricating the machine for drawing stainless steel wire under the PLEUGER brand name. Each tank holds between 300 and 500 litres of FUCHS, RATAK TRP 170 / 2.300 lubricating oil. The oil’s viscosity at operating temperature is 400 cSt.

THE PROBLEMThe drawing process heats the oil, accelerating the age-ing process and generating resins. When introduced into the machine, the stainless steel wire is covered with dust. This generates particles that contaminate the oil. The level of water is high. This mixture of contaminants adheres to the surface of the final product (the wire), blocking the wire nozzles in the soldering machines and seriously reducing the useful life of the lubricant.

THE SOLUTIONA CJC™ HDU 27/54 PV Fine Filter with a CJC™ Filter Insert FA 27/27 was installed so that the oil at the bot-tom of the lubrication system tank would be continuously cleaned and dried. The volume of flow is 45 l/h, elimi-nating sludge and particles of 3 μm absolute size, and absorbing the water.

THE RESULTTests on the “distribution of particles”, in which oil sam-ples were taken before and after the installation of the CJC Filter, show a significant reduction of particles, res-ins and water.The level of particulate contamination was lowered by a factor of approximately 12. The resins were eliminated and the water level was lowered. The wire no longer displays stains from the drawing process that had been caused by the temperature and the contamination. The life of the oil has been prolonged.

The INOXFIL, S.A. plant (Igualada - Barcelona)

Josep Musons (Head of the Mechanical Workshop) and the installation of the CJC™ Off-line Filter.

Weight of particles, %(in the oil)

Size of the Membrane:

BEFOREAFTER

(approx. 4 months)

1 μm 2.819 % 0.241 %

2 μm 2.747 % 0.0 %

5 μm 2.298 % 0.0 %

10 μm 1.276 % 0.0 %

Water 22,000 ppm = 2.20 % 874 ppm = 0.08 %

Level of resins (oxidation) black white

Results of tests on the CJC™ off-line filter at the Inoxfil plant

COMMENTSComments by Xavier Brugués(Head of Maintenance):“...The CJC unit has given us some very satisfactory results. It is a very beneficial installation, and assures us of a 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 Off-line Fine Filters in 13 systems.”

steel mills/works oil maintenance - filter equipment...steel mills are often suffering from large...

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