E h i ThE h i ThEnhancing The Enhancing The Quenchant PerformanceQuenchant PerformanceQuenchant PerformanceQuenchant Performance

ByByP.K.DevalP.K.DevalP.K.DevalP.K.Deval

HardcastleHardcastle Petrofer Pvt. Petrofer Pvt. LtdLtd

ContentsContentsContentsContentsAboutAbout HardcastleHardcastle PetroferPetroferAbout About HardcastleHardcastle PetroferPetroferQuenchant Quenchant Performance Performance -- CriteriaCriteriaRestoration/RepairRestoration/RepairRestoration/Repair Restoration/Repair

of Degraded Quenchantof Degraded QuenchantU d ti fU d ti f Q h t P fQ h t P fUp gradation of Up gradation of Quenchant PerformanceQuenchant PerformanceMethodologyMethodologyCase StudiesCase Studies

ABOUT ABOUT HARDCASTLE PETROFERHARDCASTLE PETROFER

Joint Venture with Petrofer, GermanyJoint Venture with Petrofer, GermanyM f t i F iliti tM f t i F iliti t G j tG j tManufacturing Facilities at Manufacturing Facilities at Gujarat Gujarat and J & Kand J & KISO 9001 and ISO 14001 certified ISO 9001 and ISO 14001 certified companycompanycompanycompanyWide Wide Product RangeProduct Range

Product Rangeg

Fire Resistant Hydraulic

Heat Treatment Drawing Rolling Hot Hydraulic

FluidsProducts

Cutting Coolants

Compounds

Rust Preventives

Oils

Cleaners

Forging

Die-Casting ProductsPreventives Products

Our Focus…

…..…To provide …..…To provide Quality Solutions to the Quality Solutions to the Customers through our Customers through our P d t d S iP d t d S iProducts and ServicesProducts and Services

Our ServicesOur Services…

Selection of the Right ProductSelection of the Right ProductDevelopment of customized productsDevelopment of customized productsp pp pInIn--situ modification of quenchants situ modification of quenchants Technical support on system related aspectsTechnical support on system related aspectsTechnical support on system related aspectsTechnical support on system related aspectsApplication supportApplication supportCondition monitoring of our productsCondition monitoring of our productsDesign support for quench systemsDesign support for quench systemsg pp q yg pp q yFiltration of used oilFiltration of used oil

Types Of QuenchantsTypes Of QuenchantsTypes Of QuenchantsTypes Of Quenchants

WaterWaterWaterWaterWater Quenching AdditivesWater Quenching AdditivesQ hi OilQ hi OilQuenching OilQuenching OilPolymer QuenchantsPolymer QuenchantsMolten Salt BathsMolten Salt BathsMolten Metal BathsMolten Metal BathsMolten Metal BathsMolten Metal BathsGasesGases

Quenchant PerformanceQuenchant PerformanceQuenchant PerformanceQuenchant PerformanceCriteriaCriteria

Achievement of desired propertiesAchievement of desired propertiesMetallurgical and Dimensional Metallurgical and Dimensional

Achievement of desired finish Achievement of desired finish Longer service life Longer service life Less dragLess drag--out or consumption costsout or consumption costsConsistency of quenched resultsConsistency of quenched resultsAbsence of quench cracksAbsence of quench cracksReduced rework or rejection costsReduced rework or rejection costsjjOptimum cycle time Optimum cycle time

Performance EnhancementPerformance EnhancementPerformance EnhancementPerformance EnhancementRestoration / Repair ofRestoration / Repair ofRestoration / Repair of Restoration / Repair of

Degraded QuenchantDegraded Quenchant

Up gradation Of Up gradation Of Quenchant PerformanceQuenchant Performance

Quenching Oil DegradationQuenching Oil DegradationQuenching Oil DegradationQuenching Oil Degradation

IndicatorsIndicatorsIndicatorsIndicatorsSludge FormationSludge FormationContamination by scales, water, sootContamination by scales, water, sootIncrease in acid value /Increase in acid value / saponificationsaponificationIncrease in acid value / Increase in acid value / saponificationsaponificationvaluevalueDepletion of additivesDepletion of additivesDepletion of additivesDepletion of additivesIncrease/ decrease in viscosity / Flash Increase/ decrease in viscosity / Flash PointPointPointPoint

Quenching Oil DegradationQuenching Oil DegradationQuenching Oil DegradationQuenching Oil DegradationEffectsEffectsEffectsEffects

Poor FinishPoor FinishLoss of Quench SeverityLoss of Quench SeverityLoss of Quench SeverityLoss of Quench SeverityInconsistent ResultsInconsistent ResultsDistortion and Distortion and CrackingCrackingggPoor Poor CleanabilityCleanabilityHigh Drag OutHigh Drag Out

Quenching Oil DegradationQuenching Oil DegradationQuenching Oil DegradationQuenching Oil DegradationRemediesRemediesRemediesRemedies

SettlingSettlingFiltration / CentrifugingFiltration / CentrifugingFiltration / CentrifugingFiltration / CentrifugingOil RefiningOil RefiningAddition of additivesAddition of additives

Quenching Oil DegradationQuenching Oil DegradationQuenching Oil DegradationQuenching Oil DegradationCorrective / Preventive ActionsCorrective / Preventive ActionsCorrective / Preventive ActionsCorrective / Preventive Actions

OnOn--line filtration / centrifugingline filtration / centrifugingOnOn line filtration / centrifugingline filtration / centrifugingPeriodic cleaning of heat exchangerPeriodic cleaning of heat exchangerPeriodic cleaning of tanksPeriodic cleaning of tanksPeriodic cleaning of tanksPeriodic cleaning of tanksControl of Oil TemperatureControl of Oil Temperature

Polymer Quenchant Polymer Quenchant DegradationDegradation

IndicatorsIndicatorsIndicatorsIndicatorsFoul SmellFoul SmellReduced pHReduced pHChange ofChange of colourcolourChange of Change of colourcolourIncrease in Solution HardnessIncrease in Solution HardnessIncrease in electrical conductivityIncrease in electrical conductivityIncrease in electrical conductivityIncrease in electrical conductivityChange in Change in refractometerrefractometer factorfactorIncreased tramp oil contentIncreased tramp oil content

Polymer Quenchant Polymer Quenchant DegradationDegradation

EffectsEffectsEffectsEffectsIncreased Quench SeverityIncreased Quench SeverityInconsistent ResultsInconsistent ResultsInconsistent ResultsInconsistent ResultsCorrosion of tank / quenched partsCorrosion of tank / quenched partsStickinessStickinessDistortion and crackingDistortion and cracking

Polymer Quenchant Polymer Quenchant DegradationDegradation

RemediesRemediesRemediesRemediesTank Cleaning / Tank Cleaning / SanitisationSanitisationAddition of additivesAddition of additivesAddition of additivesAddition of additivesCorrection factor for Correction factor for refractometerrefractometerMaintain higher concentrationMaintain higher concentrationggChange the bathChange the bath

Polymer Quenchant Polymer Quenchant DegradationDegradation

Corrective / Preventive ActionsCorrective / Preventive ActionsCorrective / Preventive ActionsCorrective / Preventive Actions

OnOn--line filtrationline filtrationOnOn line filtration line filtration Installation of oil skimmerInstallation of oil skimmerPeriodic cleaning of tanksPeriodic cleaning of tanksPeriodic cleaning of tanksPeriodic cleaning of tanksControl of water qualityControl of water qualityAgitation when not in useAgitation when not in useggRegular monitoring of bathRegular monitoring of bath

UpgradationUpgradation of Performanceof PerformanceUpgradationUpgradation of Performanceof Performance

To ImproveTo ImproveTo Improve….To Improve….Quench SeverityQuench SeveritySurface AppearanceSurface AppearanceDistortion ControlDistortion ControlMetallurgical PropertiesMetallurgical Properties

MethodologyMethodologyMethodologyMethodology

Lab Analysis of Tank SampleLab Analysis of Tank SampleReview Review & Analysis of Data& Analysis of DataDevelopment WorkDevelopment WorkDevelopment WorkDevelopment WorkProduction TrialsProduction TrialsFormulation For TopFormulation For Top--upsupsControlControl & Monitoring& MonitoringControl Control & Monitoring& Monitoring

Case StudiesCase StudiesCase StudiesCase Studies

II it U d tiit U d tiInIn--situ Upgradation situ Upgradation Of QuenchantOf QuenchantOf QuenchantOf Quenchant

BackgroundBackgroundBackgroundBackground

Customer :Customer :Manufacturer & 100% Exporter of Gears Manufacturer & 100% Exporter of Gears for Trucks and Tractors.for Trucks and Tractors.for Trucks and Tractors. for Trucks and Tractors. Process :Process :

C b i i iC b i i iCarburising in Carburising in Sealed Quench FurnaceSealed Quench Furnace

QuenchantQuenchant ::Medium speed Quench OilMedium speed Quench Oil HQ MHQ MMedium speed Quench Oil Medium speed Quench Oil HQ MHQ M

Problems FacedProblems FacedProblems FacedProblems Faced

Low Core HardnessLow Core HardnessLow Core Hardness Low Core Hardness & Surface Bainite& Surface Bainite

In case of some In case of some

Heavy Sectioned GearsHeavy Sectioned GearsHeavy Sectioned GearsHeavy Sectioned Gears

Root Cause AnalysisRoot Cause Analysis

Data Collected FromData Collected FromProduction Log BooksProduction Log BooksProduction Log BooksProduction Log Books

Inspection ReportsInspection Reports

Microstructure StudyMicrostructure Study

Cooling Curve Analysis of Quenching OilCooling Curve Analysis of Quenching Oilg y Q gg y Q g

Development WorkDevelopment WorkDevelopment WorkDevelopment Work

Additive PackageAdditive PackageAdditive Package Additive Package DesignedDesignedCooling CurveCooling CurveCooling Curve Cooling Curve Analysis Analysis

Before & AfterBefore & After•• Before & AfterBefore & After

ResultsResultsResultsResults

Additive Package Added InAdditive Package Added In--situsituAdditive Package Added InAdditive Package Added In situsituAdditive Addition Under SupervisionAdditive Addition Under SupervisionQ h R lt S ti f tQ h R lt S ti f tQuench Results SatisfactoryQuench Results SatisfactorySpecial Product developed for Special Product developed for

TopTop--upsupsS ti fi d C tS ti fi d C tSatisfied CustomerSatisfied Customer

Case Study ICase Study IBright Quenching OfBright Quenching Of Marquenched Partsq

Case StudyCase Study

BackgroundCustomerCustomerReputed Automobile Manufacturer usingReputed Automobile Manufacturer usingHIQUENCH MT 650HIQUENCH MT 650 satisfactorily since ’94. satisfactorily since ’94.

ProcessProcessProcessProcess•• Carburised in SQF and CGC FurnacesCarburised in SQF and CGC Furnaces

Q hi iQ hi i HIQUENCH MT 650HIQUENCH MT 650•• Quenching in Quenching in HIQUENCH MT 650HIQUENCH MT 650•• Oil Temp. 120 Oil Temp. 120 ℃ ℃ in CGC, 120 in CGC, 120 -- 140 140 ℃℃ in SQFin SQF

Problem FacedProblem FacedProblem FacedProblem FacedDark appearance of quenched components Dark appearance of quenched components pp q ppp q p

High dirt count of the componentsHigh dirt count of the components

Manual cleaning / buffing requiredManual cleaning / buffing required

The problem was more severe in The problem was more severe in

CGC furnace.CGC furnace.

AnalysisAnalysis –– Process ApproachProcess ApproachAnalysis Analysis –– Process ApproachProcess Approach

Study of the process Study of the process

Study of system parametersStudy of system parameters

Discussions with Discussions with

customercustomer

Factors Identified

System RelatedSystem Related

Quenchant RelatedQuenchant Related

System ImprovementsSystem ImprovementsSystem ImprovementsSystem Improvements

OnOn line 20 Micron filter installedline 20 Micron filter installedOnOn--line 20 Micron filter installedline 20 Micron filter installed

PrePre--cleaning started with our cleaning started with our HICLEAN L2HICLEAN L2

Post Quench Cleaner changed to Post Quench Cleaner changed to HICLEAN L2HICLEAN L2

Furnace soot blowing frequency and procedure Furnace soot blowing frequency and procedure

improvedimprovedimprovedimproved

Furnace Controls improvedFurnace Controls improved

Shifted to better quality LPG Shifted to better quality LPG

Product UpgradationProduct Upgradation

Additive package Additive package

d i dd i ddesigneddesigned

SSSimulated lab trials takenSimulated lab trials taken

Additive added in quench tankAdditive added in quench tank

ResultResultResultResult

Significant improvement in theSignificant improvement in theSignificant improvement in the Significant improvement in the surface appearance achievedsurface appearance achieved

Millipore value improved from Millipore value improved from 88 10 mg to 410 mg to 4 6 mg6 mg88--10 mg to 410 mg to 4--6 mg 6 mg

Satisfied CustomerSatisfied CustomerSatisfied Customer Satisfied Customer

New product developedNew product developedNew product developed New product developed –– HIQUENCH MT 640 BQHIQUENCH MT 640 BQ

ConclusionConclusionConclusionConclusion

It is possible to It is possible to EnhanceEnhance

Quenchant PerformanceQuenchant Performance

With Systematic Approach With Systematic Approach y ppy pp&&

UserUser –– Supplier CollaborationSupplier CollaborationUser User –– Supplier CollaborationSupplier Collaboration

QUERIES ARE WELCOME

Thank Thank You !