CL2000 - The Future of Cylinder Plating
Cameron's Compression Systems now offers the service of electrolytic hard iron plating (trade name CL2000) for the protection and restoration of power cylinders for large industrial engines. Cameron's Compression Systems will utilize CL2000 hard iron plating as the engineering standard on our new unit and aftermarket product lines including Cooper Bessemer, Ajax and CSI (IR/Clark/Worthington parts).The CL2000 process supersedes the use of porous chrome plating in its entirety within Cameron's Compression Systems. Concern for environment, health and safety is rendering the process of hexavalent chrome (chrome six) plating a less attractive option within our industry, and electrolytic hard iron plating has been used for many years and has a successful track record as an alternative to porous chrome plating.
New Facility and Process
The new Cameron's Compression Systems center of excellence for the CL2000 process is the Ponca City, Oklahoma Compression Specialties facility that specializes in the manufacture and repair of large bore power parts for reciprocating engines. Construction of the new CL2000 cell began in May 2006 and started to produce CL2000 cylinders in early September 2006. The new, state-of-the-art 12,000 square foot CL2000 manufacturing cell contains fourteen brand new tanks for cleaning, rinsing, waxing, wax removal, and plating. Other new equipment installed includes rectifiers, circulating pumps, and heaters and coolers to maintain proper bath temperature. The cell can accommodate most major lines of power cylinders including the industry’s largest such as the 29” bore Nordberg’s found mostly in municipal light plants and the 82” / 26” DLA FM31. Brand new cranes and hoists have been added to accommodate the industry’s largest and heaviest cylinders. Also, a new ventilation system has been added to comply with E.P.A. air quality standards.
The new Cameron's Compression Systems center of excellence for the CL2000 process is the Ponca City, Oklahoma Compression Specialties facility that specializes in the manufacture and repair of large bore power parts for reciprocating engines. Construction of the new CL2000 cell began in May 2006 and started to produce CL2000 cylinders in early September 2006. The new, state-of-the-art 12,000 square foot CL2000 manufacturing cell contains fourteen brand new tanks for cleaning, rinsing, waxing, wax removal, and plating. Other new equipment installed includes rectifiers, circulating pumps, and heaters and coolers to maintain proper bath temperature. The cell can accommodate most major lines of power cylinders including the industry’s largest such as the 29” bore Nordberg’s found mostly in municipal light plants and the 82” / 26” DLA FM31. Brand new cranes and hoists have been added to accommodate the industry’s largest and heaviest cylinders. Also, a new ventilation system has been added to comply with E.P.A. air quality standards.History and General Background
The CL2000 hard iron plating process was developed by Van der Horst U.S.A. as an alternative to chrome plating for cylinder reclamation with a low environmental impact. The hard iron plating process project was initiated in 1993. The process was perfected over time and a patent was subsequently granted in 2002. CL2000 is 99.9% pure electrodeposited iron with excellent adhesion properties and can be molecularly bonded to a wide range of base metals. Both chrome and CL2000 are applied in the same manner and can be inspected under identical technical guidelines for adhesion and porosity variation.
CL2000 has an average tensile strength of 235,000 psi and the sheer strength exceeds 50,000 psi. CL2000 hard iron plating has an average hardness of 45-50 HRc (421 Brinell). The hardest portion of the deposit is typically an average of .008 inch thick nearest the outer surface. By comparison, industrial chrome typically has a range of hardness between 68-70 HRc.
CL2000 hard iron plating on a new cylinder will have an average thickness of between .008”-.015”. This is consistent with hard chrome, since on a new cylinder the average thickness would also be specified as .008”-.015”. However, up to .500” of hard iron plating may be uniformly deposited if necessary or required in the event of reclaiming a severely worn cylinder bore. This is achieved by depositing an underlay of iron of a lesser hardness that will not create stress and a weakening of the parent material.
The CL2000 hard iron plating process was developed by Van der Horst U.S.A. as an alternative to chrome plating for cylinder reclamation with a low environmental impact. The hard iron plating process project was initiated in 1993. The process was perfected over time and a patent was subsequently granted in 2002. CL2000 is 99.9% pure electrodeposited iron with excellent adhesion properties and can be molecularly bonded to a wide range of base metals. Both chrome and CL2000 are applied in the same manner and can be inspected under identical technical guidelines for adhesion and porosity variation.
CL2000 has an average tensile strength of 235,000 psi and the sheer strength exceeds 50,000 psi. CL2000 hard iron plating has an average hardness of 45-50 HRc (421 Brinell). The hardest portion of the deposit is typically an average of .008 inch thick nearest the outer surface. By comparison, industrial chrome typically has a range of hardness between 68-70 HRc.
CL2000 hard iron plating on a new cylinder will have an average thickness of between .008”-.015”. This is consistent with hard chrome, since on a new cylinder the average thickness would also be specified as .008”-.015”. However, up to .500” of hard iron plating may be uniformly deposited if necessary or required in the event of reclaiming a severely worn cylinder bore. This is achieved by depositing an underlay of iron of a lesser hardness that will not create stress and a weakening of the parent material.
Key Advantages over Chrome Plating
Environmentally friendly. CL2000 is 99.9% pure electrodeposited iron with physical properties comparable to low carbon steel. Chemicals used include: Sodium Metasilicate, Sodium Hydroxide, Mineral Spirits, Microcrystalline Petroleum Wax, Activated Carbon, Ammonium Chloride, Sodium Laural Sulfate, Epsom Salt, Fluoboric acid, DS 800 solvent, Ferrous Sulfate and Sulfuric Acid. A comprehensive review of the MSDS sheets for these chemicals indicates there are no environmental problems evident, provided that they are disposed of in the proper manor. If the chemicals are neutralized and packaged correctly, they can be disposed of as a class III non hazardous waste.
Outstanding porosity. One of the most important and beneficial features of electrolytic hard iron plating is the porosity of the surface. Here, the term porosity refers to “pores” in the surface of the cylinder that act as lubricating oil reservoirs. The porosity is electrically etched, mechanically induced or a combination of both.
The average depth of the porosity in chrome is .001-.003 inch, however in the case of hard iron the porosity channel depth can be any desired depth (limited by the base metal), but the most optimum depth range is from .0005-.010inch. The surface of CL2000 is characterized by a network of channel-type porosity which greatly enhances its lubricant retaining characteristic.
Aside from the nature of the porosity, the main difference in the appearance of the hard iron and chrome is that chrome tends to have a satin finish whereas CL2000 does not.
Sour gas fit. An additional benefit of CL2000 over chrome plating is its suitability for sour gas applications. Chrome plating does not hold up well when the H2S levels exceed 1% in the fuel. Following successful field tests with hard iron plated cylinders in Ajax engines and Cooper Bessemer engines in the early to mid ‘90’s, CL2000 became the standard coating for cylinders in all engines using fuels with more than 1% H2S.
Parts commonality. For the end user, the transition from chrome plating to electrolytic hard iron plating is transparent. The same power ring sets are used for both hard chrome and CL2000 hard iron plated cylinders.
Put CL2000 to work for you. Years of field experience with favorable results combined with the environmental friendliness of it makes CL2000 a desirable replacement for porous industrial chrome plating. Want to know more about CL2000? Ready to place an order? Call our Ponca City facility at 1-800-654-6419 or consult with your local Cameron's Compression Systems sales office today.
Environmentally friendly. CL2000 is 99.9% pure electrodeposited iron with physical properties comparable to low carbon steel. Chemicals used include: Sodium Metasilicate, Sodium Hydroxide, Mineral Spirits, Microcrystalline Petroleum Wax, Activated Carbon, Ammonium Chloride, Sodium Laural Sulfate, Epsom Salt, Fluoboric acid, DS 800 solvent, Ferrous Sulfate and Sulfuric Acid. A comprehensive review of the MSDS sheets for these chemicals indicates there are no environmental problems evident, provided that they are disposed of in the proper manor. If the chemicals are neutralized and packaged correctly, they can be disposed of as a class III non hazardous waste.Outstanding porosity. One of the most important and beneficial features of electrolytic hard iron plating is the porosity of the surface. Here, the term porosity refers to “pores” in the surface of the cylinder that act as lubricating oil reservoirs. The porosity is electrically etched, mechanically induced or a combination of both.
The average depth of the porosity in chrome is .001-.003 inch, however in the case of hard iron the porosity channel depth can be any desired depth (limited by the base metal), but the most optimum depth range is from .0005-.010inch. The surface of CL2000 is characterized by a network of channel-type porosity which greatly enhances its lubricant retaining characteristic.
Aside from the nature of the porosity, the main difference in the appearance of the hard iron and chrome is that chrome tends to have a satin finish whereas CL2000 does not.
Sour gas fit. An additional benefit of CL2000 over chrome plating is its suitability for sour gas applications. Chrome plating does not hold up well when the H2S levels exceed 1% in the fuel. Following successful field tests with hard iron plated cylinders in Ajax engines and Cooper Bessemer engines in the early to mid ‘90’s, CL2000 became the standard coating for cylinders in all engines using fuels with more than 1% H2S.
Parts commonality. For the end user, the transition from chrome plating to electrolytic hard iron plating is transparent. The same power ring sets are used for both hard chrome and CL2000 hard iron plated cylinders.
Put CL2000 to work for you. Years of field experience with favorable results combined with the environmental friendliness of it makes CL2000 a desirable replacement for porous industrial chrome plating. Want to know more about CL2000? Ready to place an order? Call our Ponca City facility at 1-800-654-6419 or consult with your local Cameron's Compression Systems sales office today.
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