filtration 101 - etouches€¦ · the real cost of poor filtration • short oil drain intervals....

VEHICLE MAINTENANCE MANAGEMENT

CONFERENCE MARCH 2013

Presented by Racor Division of Parker Hannifin

Speaker: Joe Jenkins, Engineering Supervisor

FILTRATION 101

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FUEL FILTRATION

Filtration

How much do you know about filtration?

• Do filters protect you or your investment?

• Do they make you angry because you had

to change them?

• Long lasting filters that never need to be

changed are good? Right?

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Did you have coffee this morning?

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Ever try making without a filter?

Pulp or no pulp?

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How many filters are in a typical

application?

• Fuel --------- Could be as many as 3

• Oil --------- At least one

• Air --------- One plus pre cleaner

• Crankcase -- All engines are moving to

closed crankcase system.

No road tubes.

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Over the next one hour, we want to provide you

with:

• Basic Fuel, Oil, Air and Crankcase

Filtration Education

• Understanding of filter design

• Application information

• Market players

• Future requirements

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Filtration efficiency is based on

fiber technology in 3 areas;

1. Size of fibers

(diameter)

2. Number of fibers

3. Closeness of fibers

Filtration Fiber Technology

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Filter Element Life

(Capacity) is based on

total fiber

Surface Area

Filtration Fiber Technology

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Water Separation Filtration Technology

Water Separation is also

based on fiber technology

1. Size (dia.) of fibers

2. Number of fibers

3. Closeness of fibers

4. A coating on the fibers to

increase the interfacial tension

between water, fuel and the

fiber surface.

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Standard Cellulose Filtration Media

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Media Manufactured with

Engineered Fibers

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Racor Bimodal Media

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Media Life Comparison

Cellulose Addition of Engineered

Fibers

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The Filtration Challenge !

• Transfer Pumps

• Injection Pumps

• Unit Injectors

• Injector Nozzles

• Filter & capture fuel contaminants

to avoid worn, clogged, corroded,

or failed fuel system components.

• Function efficiently for thousands

of miles or hundreds of hours.

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Current Technology Higher Pressures

Common Rail (H.P.C.R.)

New level of filtration and fuel

delivery requirements

Fuel Injection Designs are Changing!

Filtration technology is necessary

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Most OEM Performance Requirements:

• > 95% water removal

• High performance in 5%

Biodiesel (B5)

• Longer life

• Higher flow rates

• Material compatibility with

ULSD and Biodiesel

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• Primary (Pre-Filter) for Vacuum Applications

• Final (Secondary) for Pressure Applications

Fuel Injection System

Fuel Reservoir

Return Line

Racor Pre-Filter /

Water Separator

( 98% @ 10 to 40 microns )

Lift Pump

Racor Final Filter

( 98% @ 4 to 7 microns )

Typical Fuel Filtration System Designs

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Fuel Injection System

Fuel Reservoir

Return Line

Racor Pre-Filter /

Water Separator

( 98% @ 10 to 40 microns )

Lift Pump

Racor Final Filter

( 98% @ 4 to 7 microns )

• Two filter system increases filter life and efficiency

• Good for biodiesel use

• Secondary may collect some water

• Balance filtration optimizes performance and life.

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Racor Systems

Three Stage Filtration

• Filtration

• Coalescing

• Separation

2, 10, or 30 Micron

Element

Optional Heater and

Water Sensor Probe

Self-Venting Drain

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AquablocR

Brown 2 micron

Blue 10 micron

Red 30 micron

Engineered Fiber Technology

Racor Division

Micron Rating

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Racor Systems

Applications

Primary Filter Application

Manifold Application

Turbine

Series

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EPA07

MEDIUM DUTY

Trends:

HDEP

HEAVY DUTY

490R-DDC

• Unit/Module Construction Cartridge Filters

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It is Important to Use Original Replacement

Elements

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Racor Fuel System Options

Heaters (especially for biodiesel)

• Electric, return fuel, coolant heat

exchanger

Gauges

• Dial with set pointers

• Pop-up type

Water-in-Fuel Sensors

• Stand-alone

• Remote electronics

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Products to Filter

Any Hydrocarbon Fuel Diesel, Gasoline, CNG, LPG, LNG,

Kerosene, Aviation Gas, or Jet Fuels

Racor Systems

Fuel Filtration at any Flow Rate

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OIL FILTRATION

Challenge

• Engines are running hotter and

dirtier! ( Remember Injection

pressures?)

• Shorter Oil Drain Intervals

• Higher Soot & Sludge Levels

• Higher Operating Costs

• Engine Oils Have Changed To work

with Emissions Equipment

Oil Contamination Challenge

• Organic Contaminant – Soot due to

Exhaust gas recirculation, high lube oil

temperatures, Silicon, wear metals

• Inorganic Contaminants – Moisture

and fuel dilution

The Microscopic Wrecking Crew

• There is no single property of lube oil that

challenges the reliability of engines more than

suspended particles.

• Small particles ride in the oil indefinitely

because they can not be captured.

• The destruction can be continuous.

Financial Challenge

• Maintenance Costs – High cost of

maintenance – (parts and labor) and down

time for fleet vehicles

• Disposal Costs – High cost to dispose of

the engine oil and filters

The Real Cost Of Poor Filtration

• Short Oil Drain Intervals.

• The oil cleanliness is maintained in many cases by changing it. Oil does not wear out, it simply gets dirty and looses it’s additive package.

• Accelerated engine wear. The current filtration is not adequate to capture the smaller engine damaging particles.

• Solids such as soot are not controlled even though the additives keeps them suspended, they pass right through the standard lube filter. Soot is an abrasive sub micron material that causes wear and increases viscosity which prevents proper oil film that protects the moving parts from friction.

• Poor lubrication reduces engine life. Friction is caused by asperities contacting one another as the two surfaces are rubbed together.

• Oxidation caused by moisture increases viscosity. The oxidation rate of the oil is doubled for every 20 degree increase in temperature.

Engine Oil Flow Process

Typical Lube Oil Circuit

Pressurized lube oil is filtered through the standard 7-40 micron full flow filter

Wear particles under 20 micron are still

flowing through the lube system

Engine Lube Oil Circuit

Fitted With Bypass Oil Cleaner

• Pressurized lube oil is filtered through the full flow filter.

• A secondary bypass oil cleaner, is added for additional filtration

• Oil is now more than 50% cleaner

Industry Trends

• Longer oil drain intervals

• Changes in oil chemistry to meet emissions

• Increased engine temperatures generating more sludge and soot

• “Green” products to reduce waste stream of used oil and filters

• Engineered cellulose and synthetic media

Successful Oil Bypass Products

• Light duty kits include hose and fittings

• GM 6.6L Duramax, Dodge 5.9L/6.7L Cummins and Ford/Navistar Power Stroke 6.0L & 6.4L through 2010

Top Load Bypass Oil Cleaners

• Absolute ISO (Beta) ratings, 3u, 5u, 10u

• High capacity

• Top load for easy service

• Clean element change

• Multiple sizes

• Larger engine sump capacity

Absolute Replacement Elements

3 Micron

Green

5 Micron

Blue 10 Micron

Orange

Elements are color coded for easy identification

Solution – Racor Bypass Oil Cleaner System

• Optimize vehicle expenditures through

cleaner lube oil

• Improve engine reliability

• Reduce vehicle / equipment down time,

increase productive up time

• Reduce environmental impact of used

oil and filters

Racor Bypass Filter Per 25 Vehicle Fleet

Annual Potential Savings

CRANKCASE VENTILATION

FILTRATION SYSTEMS

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The Problem

Open and unfiltered engine crankcase fumes (oily

aerosols) are vented into the atmosphere causing

environmental pollution and engine component

damage.

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The Problem

Open and un-filtered (Impactor Style) engine

crankcase breather vents which allow piston blow-

by containing oily aerosols to coat intercoolers,

turbochargers, and electronics.

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The Problem

Engine Performance Problems Related to

Inefficient Crankcase Filtration • Loss of Power

• Increase Warranty Cost

• Emission Compliance Problems

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Racor Crankcase Ventilation Filtration Basic

Engine Schematic

Diesel Engine

Crankcase

Vent

Turbo

Charger

CCV

Oil pan

Air Filter

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Racor Crankcase Ventilation Filtration

Basic Engine Schematic

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Industry Trends

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Racor CCV Filtration (Closed)

The Solution

CCV8000 CCV6000 CCV4500 CCV1500 CCV3500 CCV12000

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The Solution

Flow Path for 4500, 6000, 8000 , and 12000 Closed System Series

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The Solution

Flow Path for 4501, 6001, and 8001 Open System Series

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Media

Racor current offers three types of media

• 04 Media is used in Open Systems to where the customer wants to

improve filtration of a regular draft tube.

• 08 Media is used in systems where approximate 80% efficiency is required

• 10 Media is used in system where greater than 90% efficiency is required

- 04 Low Efficiency - 08 High Efficiency - 10 Ultra Efficiency

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Racor Market Segments

Mobile

Bus Light Truck Heavy Truck

Agriculture Marine Power Generation Engine

Locomotive

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CAT 3126 & 3196

Marine Engines


Applications

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Application

Bus Installation

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Current Success Stories with Racor CCV™

Product Line

Several Parker Racor Distributors

have been successful in securing

various CCV contracts with state

grant money. The money was used

to retrofit several hundred busses in

each of the different districts. This

amounts to hundreds of thousands

of dollars for the Distributors just in

installations. The Distributor will

benefit from CCV replacement

elements for years to come.

March 26, 2013

Air Filtration Systems

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The Challenge

1. Dust

2. Water

3. Salt

4. Silica

5. Burning Embers

Goals:

1. Remove dust and debris from incoming air

2. Protect engine from dust contamination

Contamination Will Cause:

• Worn piston rings

• Scored cylinder liners

• Excessively worn or failed turbo chargers

• Fouled charge air coolers

• Sludge buildup

Excessive blow-by

High oil consumption

Loss of power

Excessive Smoke

=

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How Much Dust?

10 lbs of dust drawn into the air cleaner inlet:

Efficiency Dust Into Engine

99.99% .001 lbs (.016 oz, 0.45g)

99.95% .005 lbs (.08 oz, 2.27 g)

99.0% 0.10 lbs (1.60 oz, 45.4 g)

95% 0.50 lbs (8.00 oz, 226 g)

90% 1.00 lbs (16.0 oz, 454 g)

Media is rated a minimum 99.9% efficient per the

ISO 5011 Test Standard (Formerly SAE J726C).

Where’s Racor?

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Air Filtration Media

Synthetic Felt

Safety Media Oiled Cotton

Washable

Media

Galvanized Wire

Ember Separator

Heavy Duty

Primary Media

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Proprietary Design

• Heavy Duty Design • Designed for Diesel Air

Filtration Applications

• Water Resistant • Prevents Salt And Calcium

Migration

• Graded Porosity • “Depth Loading”

• Improved Dust Loading

• Maximizes Life

Inlet Side of Media

Outlet Side of Media

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Packaging

• Pleat Separation Technology • Pleat Support On Inside And

Outside Of Paper Pack

• Offset Cone Design • Provides More Uniform Flow

And Dust Loading

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Industry Trends

• Higher efficiency/capacity

• Higher intake air flow rates

• Less room for components, air cleaner

• Smarter packaging

• Better air flow

• Lower hood lines

• Larger cooling packages – ’07- ’10

emissions

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The Solution

• Provide Clean Air for the Engine:

• Remove airborne particulate

• Remove liquid water

• Package Must Provide:

• Low pressure drop

• High efficiency

• Long life (high dust holding capacity)

• Durability

• Ease of service

• All in Diminishing Space!

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Air Intake System

Dirty Air

(dust, bugs,

leaves,

H2O, etc.) Clean Air

Charge Air

Cooler

Hot compressed air

Turbo

cooled compressed air

Air Cleaner

Engine

Oil Sump

• Snorkel

• Pre-Cleaner

• Ember Separator

Air Inlet

• Rain Cap

• Hood Ducting

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Air Inlet - Spinaire Pre-Cleaners

• High efficiency

• Durable Aluminum and

Stainless Steel Construction

• Rust and Corrosion resistant

• UV Resistant

• Sealed bearings

• No maintenance

• ECONOMICAL

• 5 Sizes

• 4” to 9” diameter outlet

• Flow from 210 – 1850 cfm

• For high dust environments

• Extends air cleaner life by 5 to over

12 times

• Includes Clamp

• Lifetime warranty

• PN’s:

• 123583(440,550,660-990)

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Pre-Cleaner Benefits

0

5

10

15

20

25

30

0 20 40 60 80

Re

str

icti

on

(in

H2

0)

Time (Hours)

w/o Pre-Cleaner w/ Pre-Cleaner

Longer Life Shorter life

Initial Air Cleaner Restriction

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Applications

• Large Off Highway Equipment • Agriculture

• Construction

• Mining

• Large On Highway

• Customers with short Air Cleaner life

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ECO Applications

• ECO SE – FCCC, Ottawa Bus, Capacity of Texas, Bluebird, Thomas

• Yard Tractors, Delivery Trucks, School Bus, Motorhomes

• ECO SM – FCCC, Bluebird

• Motorhomes

• ECO LL - Peterbilt 33(0,5), NABI, Bluebird Wanderlodge

• Local Delivery, Dump Trucks, Etc.

Cintas (ECO LL PN: 400820014)

Detroit Diesel

Bulletin 7896

Baldor Generators

Peterbilt

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Air Cleaners – ECO BC & CM Series

Reverse Flow (Inside-Out)

• ECO BC – 720-1750 cfm

• PN’s: 094973(001-007)

• ECO Cowl Mount – 980-1750 cfm

• PN’s: 400460(001,002), 400462(001,002), 400458(001,002)

• Peterbilt & Kenworth Replacement Element PN: 78897001

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ECO BC & CM Applications

• ECO BC – Daimler (FCCC), Bluebird, Tiffin

• Motorhomes, Fire Trucks, Transit Trucks

• ECO CM – Peterbilt & Kenworth

• On-Highway Class 8 Trucks

Bluebird

Kenworth

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Market Segments

Mobile

Bus Light Truck Heavy Truck

Agriculture Marine Power Generation Engine

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Racor Air Filtration

Review

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Racor Air Filtration

ECO Series 1 Stage

EAVLR Series 4 Stage

ECO XL Series 3 Stage

Good - Better - Best

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Thank you!

filtration 101 - etouches€¦ · the real cost of poor filtration • short oil drain intervals....

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