CJC presentation-OFFSHORE sector

CJC Presentation - OFFSHORECLEAN OILBRIGHT IDEAS

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C.C.JENSEN A/S, CJC Presentation - OFFSHORE, Jesper Skov Moeslund, April 2008

C.C.JENSEN A/S is the ideal consultant for both owners and staff

who wish to increase the reliability and lifetime of their equipment

• Mud pumps

BOP Unit

Draw Works

Cantilever

Deck Cranes

Lubrication Oil

(gen set)

Diesel Fuel

Etc…

OFFSHORE APPLICATIONS


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C.C.JENSEN A/S – CCJ

General Presentation –

June 2007

Page 2

A Drop of Success

Presentation of

C.C.JENSEN A/S


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• A limited company, family owned –established in 1953.

• 184 employees in Denmark.

• 10 subsidiaries + 2 sales officeabroad, with 60 employees.

• Production of:

• Ship windows – 10%

• Casting of ship propeller – 25%

• Oil Filtration – 65%

• Sale: 30 mill Euro in C.C.JENSEN A/S.

• Export: 70%.

Briefly about C.C.JENSEN A/S


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• Total Solutions• Minimum Energy Consumption• Maximum Space Utilization• Fire-proof Windows (945oC)

The Ship Window Division


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The Metal Casting Division

Propeller blades: Raw casting weight: Max. 3,000 kg Raw casting dimensions: Height 1,800 mm

Width 2,100 mm

Propeller bosses: Raw casting weight: Max. 2,500 kg Raw casting dimensions: Diameter appr.

1,200 mm

Other castings: Boss cylinders, covers, lids etc. Raw casting weight: Max. 2,000 kg


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Off-line Filtration Systems

The Filter Production


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Oil Related Problems

Moisture - waterOxidation by-products:

Resins, sludge and varnish

Particles

Essential for proper lubrication:

Clean, dry oil at the recommended temperature

10 mm

5 mm

2 mm

Catalysts for oil degradation


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Particles in Bearings and Gears


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Particles and Water in Oil

Where do the particles in the oil come from?• Built-in - assemply or transport• Delivered in new oil and fuel• Generated – from wear and oxidation• Ingress – from the environment

Where does the water in the oil come from?• Condensation – temperature changes and humidity• Ingress – leakage from seals / cooler or accidents• Delivered in new oil / fuel (MGO etc.)• Faults in oil handling


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1. Manufacturing of components

2. Unit assembly

3. New oil

4. Dust 5. Wear

From where comes the Particles?


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Particles Create Wear

Erosion - sand paper effect (Sand Blasting)


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Particles Create Wear

Abrasion - seizing (Grinding)


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Water in Bearing Lube Oil

Cavitation and Hydrogen-embrittlement

(Formation of rust)


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Human hair: 70 mm

3 mm

Smallest visible particle

for the naked eye:

40 mm

1 mm


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The figure on the

right shows that

particles less than

5 µm is more than

66% of the total

numbers of

particles.

Particle Size

Distribution


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Test on Roller Bearing


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The Impact of

Small Particles


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LEM – Rolling Element Bearings

Current Machine

Cleanliness (ISO)

Life Extension Factor

2 3 4 5 6 7 8 9 10

24/22/19 20/18/15 18/16/13 16/14/11 15/13/10 14/12/9 13/11/8 13/11/8

23/21/18 19/17/14 17/15/12 15/13/10 14/12/9 13/11/8 13/11/8

22/20/17 18/16/13 16/14/11 15/13/10 13/11/8

21/19/16 17/15/12 15/13/10 13/11/8

20/18/15 16/14/11 14/12/9

19/17/14 15/13/10 13/11/8

18/16/13 14/12/9

17/15/12 13/11/8

16/14/11 13/11/8 1)

15/13/10 13/11/8 2)

14/12/9 13/11/8 3)

Source: Noria Corp.

1) Life Extension Factor = 1.8 ● 2) Life Extension Factor = 1.5 ● 3) Life Extension Factor = 1.3


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1% water = 10,000 ppm. ● Estimated life extension for mechanical systems utilizing mineral-based fluids.

Example: By reducing average fluid moisture levels from 2500 ppm

to 156 ppm, machine life (MTBF) is extended by a factor of 5.

LEM - MOISTURE Level

Current Moisture

Level, ppm

Life Extension Factor

2 3 4 5 6 7 8 9 10

50,000 12,500 6,500 4,500 3,125 2,500 2,000 1,500 1,000 782

25,000 6,250 3,250 2,250 1,563 1,250 1,000 750 500 391

10,000 2,500 1,300 900 625 500 400 300 200 156

5,000 1,250 650 450 313 250 200 150 100 78

2,500 625 325 225 156 125 100 75 50 39

1,000 250 130 90 63 50 40 30 20 16

500 125 65 45 31 25 20 15 10 8

260 63 33 23 16 13 10 8 5 4

100 25 13 9 6 5 4 3 2 2

Source: Noria Corp.


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ISO Standards


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Evaluation of Particle Count


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Test membranes and microscopic photographs of various contamination levels

Examples of ISO Codes


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Application: Wind Turbine600 kW

Oil type: Tribol 1710/320Oil volume: 220 liters

CJC Off-line Oil Filter Application

BeforeFiltration

Filtration time0

hours

48

hours

1

month

Particles 2 µm 1,443,178 29,975 6,774

Particles 5 µm 298,681 14,652 2,204

Particles 15 µm 17,893 1,549 356

ISO 4406 Code 21/19/15 15/14/11 13/12/9

Water content *1,240 109 76

Colour of membrane

filter discBlack Light White

AfterFiltration

* High water content due to long standstill period

Oil Analysis of Wind Turbine Gear


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Cavitation and hydrogen-embrittlement

Water in Bearing Lube Oil


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Ref: Noria Corporation

Water Results in Micropitting

Bearings

Gears


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Filtration

and products


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Surface Filtration

Typical Surface Filter

for In-line Installation

Element housingEnd cap seal

Core

Medium support

Pleat

support band

End cap

Filtered oil returns

to the oil circuit

Unfiltered oil enters

under pressure

Function

CJC™ Depth Filter

for Off-line Installation

Depth Filtration

Two-disc filter sandwich

Filtered oil returns

to the oil circuit

Unfiltered oil enters

under pressure

Function


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Varnish/resins are falling out on surfaces

Oil Degradation / Oxidation


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Degradation products or soft contaminants are a widespread problem in all industries. They are the precursors of deposit (varnish)

on components causing machine problems.

Most notable in close tolerances and sensitive control systems

Plunger from directional control valve



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Oil degrades changing its composition and functional properties. When the oil deteriorates a number of unwanted products are formed:

• Acid compounds

• Polymerized compounds (long-chain molecules)

• Sludge (insoluble compounds)

• Varnish (deposit formation)



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Oxidation process

Base-oil oxidation


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Varnish will result in:

• ”Sandpaper surface effect”

• Increased component wear

• Reduced machine performance

• Ineffective heat exchangers

• Small tolerances clogging

• Filter blocking and valve sticking

• Restriction of oil flow

• Increased maintenance resourcesVarnish on steering gear

Consequences of Oil Degradation


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Electrostatic filterCellulose filter

Fine filter

BCA technology

Removal of Oil Degradation


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What happens inside the fiber

Step 1: Film diffusion

Step 2:Macro diffusion

Step 3:Micro diffusion

Cellulosemolecule


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Before

Cut-down in a used

CJC Filter Insert

type A27/27

Cut-down in a new

CJC Filter Insert

type B27/27

Filter Inserts

After


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CJC presentation-OFFSHORE sector

Technology

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