Gear flushing to ISO 17/15/12 in under 2 hours
Chongqing Gearbox had tried both domestic and international gear flushing suppliers but none could meet the required ISO code 17/15/12, resulting in long, electricity-consuming flushing processes. A test with the CJC™ Gear Flushing Unit (GFU) reduced contamination by a factor of 60 in less than two hours and reached the objective faster than promised.
Application Snapshot
Industry:
Wind
Country:
China
Oil type:
Mobil SHC XMP 320
Executive summary
Chongqing Gearbox required a documented flushing result of ISO code 17/15/12, but previous gear flushing equipment from both domestic and international suppliers could not reach this requirement. The outcome was very long flushing processes with high electricity consumption, without achieving the wanted cleanliness level.
Due to poor experiences in the market, Chongqing Gearbox was reluctant when C.C.JENSEN presented the CJC™ Gear Flushing Unit (GFU). A test on sale-on-return conditions was agreed, with the objective to reach and document ISO 17/15/12 in 3 hours. The flushing started at a contamination level of 3,000,000 particles per 100 ml (>4 micron) and was reduced to below 50,000 in less than 2 hours, achieving the objective faster than promised.
Cleanliness target achieved faster than promised
The test objective of ISO 17/15/12 in 3 hours was achieved faster than promised, with ISO 16/15/12 reached after 2 hours.
Lower cost per gearbox
The CJC™ GFU cleaned more than 300 gearboxes on the first set of filter inserts, resulting in a filter insert cost per gearbox as low as 32 USD.
Major particle reduction
Contamination at >4 micron dropped from 3,000,000 to 50,000 particles per 100 ml in 2 hours, a reduction by a factor of 60.
Reduced electricity consumption
The reduced flushing time delivered an electrical cost saving equivalent to 160 USD per gearbox, with break-even in less than one year.
Measured oil condition development
Before flushing, particle levels were measured at 3,000,000 (>4 micron), 375,000 (>6 micron), and 6,000 (>14 micron) particles per 100 ml, corresponding to ISO code 22/19/13.
After 2 hours of flushing with the CJC™ GFU, particles were reduced to 50,000 (>4 micron), 25,000 (>6 micron), and 3,000 (>14 micron) particles per 100 ml, corresponding to ISO code 16/15/12.
Results and operational impact
The test objective was reached faster than promised, with contamination reduced by a factor of 60 in less than 2 hours. The reduced flushing time increased production capacity and enabled automatic flushing processes with documented results.
Documentation to Chongqing’s customers became automatic, whereas it had previously been performed using labour-intensive oil samples. The lifetime of the flushing oil was increased, delivering oil savings.
“Not only flushing the gearbox to be at a required cleanliness in a short time, but we also saved electricity for more than 160,- USD for each gearbox due to the high efficiency using the CJC™ GFU.”
-Mr. Zhang Li, Chongqing Gearbox
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