CleanDiesel Overview

Hydraulic and Fuel Filtration Division

TM

CleanDiesel Overview Training

1. What is the history of CleanDiesel program?

2. Why would a customer need CleanDiesel?

3. What types of products are available through

CleanDiesel?

4. Where would I find customers for the

CleanDiesel Products?

A Brief History About CleanDiesel/Velcon

1953 Founded by Lu Taylor to address rocket

fuels’ cleanliness. Velcon is recognized as

the global aviation fuel technology company

May 2009 Velcon is acquired by The Sterling Group

Nov. 2009 Velcon acquires Chemflo adding process

filtration

2011 Velcon acquires Twin Filter in the

Netherlands

May 2012 Velcon Acquires Warner Lewis GmbH

Nov. 2012 Parker Hannifin Acquires Velcon Filters,

LLC

July 2015 Parker Merges Velcon Division with

Hydraulic Filter Division to form Hydraulic

and Fuel Filter Division (HFFD)

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Diesel Market Trajectory

• Global demand for diesel engines forecast to rise by 7% through 2017. • Diesel fuel demand is increasing as a result

• Tier 4 HPCR Injection technology demands substantially cleaner fluid to levels of ISO12/9/6 at the injector

• 90% of engine issues are the result of dirt and/or water contamination

• The cost of downtime in diesel applications is significant

• Removal of abrasive particles smaller than 4μm (micron) is common

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Value

Property UnitASTM

D975Caterpillar Cummins

Detroit

Diesel

Ash content %wt. < 0.01 < 0.02 < 0.02 < 0.01 D482

Carbon residue %wt. < 0.35 < 0.35 < 0.30 D524

Water ppm < 500 < 100 < 200 D1796

Sediment - 18/16/13 18/16/13 ISO 4406

API gravity °API 34 to 40 30 to 45 33 to 43 D1298

Flash point °F > 125 legal limit > 125 legal limit D93

Cloud point °Flowest

ambient

10 below

lowest

ambient

10 below

lowest

ambient

D93

Sulfur* %wt. D2622

Copper Strip

Corrosion- < No. 3 < No. 3 < No. 3 < No. 3 D130

Cetane Number - > 40 > 40 > 40 D613

Kinematic viscosity cSt 1.9 to 4.5 1.4 to 4.5 1.3 to 4.5 D445

Lubricity mm @ 60 °C < 0.52 < 0.45 < 0.46 D6079

Gums and resins mg/100 ml < 10 D381

Asphaltenes %wt. n/a n/a < 6.5 n/a D6560

Test

Standard

* Sulfur limit requirements depend on grade (S15: 15 ppm; S500: 500ppm; S5000: 5000 ppm)

OEM Standards TM

HPCR Systems

• Injector operation is more susceptible to deposits and particles between moving parts

• Wear causes clearances to increase, and the creation of “channels” between hard sealing seats

• Leakage

• Poor emissions

• Increased fuel consumption

• Loss of injection pressure, and

• Dilution of crankcase oil

• Water molecules erode metal surfaces, reduce fuel lubricity, causing significantly reduced injector life

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Off-Highway Tier 4

Engines Requirements

• Fuel injectors operate at super high pressures to achieve emissions

standards (30,000 psi+)

• Injector nozzles openings as small as 2um wide (40 um is visibility

limit with human eye)

• Requirements for diesel fuel based on ISO code cleanliness levels

(18/16/13 for storage, 12/9/6 at the injector)

• Requirement for water removal from fuel (levels down to 200ppm)

• Fuel for Tier 3 engines, does not meet needs of Tier 4 engines

• Manufacturers advise: No warranty coverage due to improper fuel

filtration

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• Diesel is regulated differently in different parts of the world

• Many different types of diesel in the global market: • ULSD

• EN590

• Off-road

• Marine

• Biodiesel (many)

• Winter blends

• etc

• Diesel is enormously variable and regulation from the supply side is limited in terms of cleanliness.

• Regulation and requirements are now being driven from the manufacturers.

• The World Wide Fuel Charter was put in place to help address this regulatory shortfall.

Global Variability TM

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• Non-binding Agreement among Industry Groups

World Wide Fuel Charter TM

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• Established Global Definition for Diesel Fuel Cleanliness

• Per WWFC, Fuel is expected to be 18/16/13 or cleaner.

WWFC TM

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• Because the WWFC is not enforced, engine manufacturers are using warranty validation as a means of enforcement.

• Examples: • Caterpillar

• MTU

• Cummins

Manufacturer Specs TM

Source: Cummins Bulletin 4087297 - 2013

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• Engine warranties are now tied to fuel quality

• Evidence of warranty denial based on high particle counts from fuel samples taken by the Engine OEM.

• This has been observed in: • Mining

• Power Generation

• Forestry

• Marine

Manufacturer Specs TM

Particle

Size

(µm)

Fluid

Tested

per mL

ISO

Code

> 4 1845 18

> 6 572 16

> 14 53 13

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ISO 4406 Counts

More Than Up to

24 80000 160000

23 40000 80000

22 20000 40000

21 10000 20000

20 5000 10000

19 2500 5000

18 1300 2500

17 640 1300

16 320 640

15 160 320

14 80 160

13 40 80

12 20 40

11 10 20

10 5 10

9 2.5 5

8 1.3 2.5

7 0.64 1.3

6 0.32 0.64

ISO 4406: 1999 Code Chart

Particle per milliliterRange

Code

Reported out as: 18/16/13

• The number of particles counted per millilitre

of fluid is then sorted into 3 BINS and

converted into a broad classification code

• The codes are expressed in a 3 part rating,

such as 18/16/13

• Extrapolated from the ISO 4406 chart would

equate as

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Fuel Contaminants per

ISO Cleanliness Levels

• Bulk Fuel Treatment

Annual Fuel Contamination Mass kg (lbs)

Annual fuel

consumption

106 Litres ( Gal)

Delivered Fuel ISO Cleanliness Level

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

25 ( 6.6 ) 400 (882) 100 (220) 25 (55) 6.3 (14)

75 (19.8) 1,200 (2,646) 300 (661) 75 (165) 19 (41)

100 (26.4) 1,600 (3,572) 400 (882) 100 (220) 25 (55)

200 (52.8) 3,200 (7,055) 800 (1,764) 200 (441) 50 (110)

300 (79.3) 4,800 (10,582) 1,200 (2,646) 300 (661) 75 (165)

Example: Site receiving 200 ML per year with at a Cleanliness level of 20/18/15

would also receive approx 800 Kilos of solids.

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ISO18/16/13 ISO21/19/16 ISO12/9/6

The flow of fuel TM

• Tests have shown that the cleanliness level

can rise by 1-2 ISO codes each time the fuel

is moved or handled

• Specifying fuel cleanliness as shipped from

the refiner does NOT guarantee that the fuel

will be at the desired level when entering the

asset, vehicle or machine

• ISO4406 is a logarithmic scale meaning that

ISO12/9/6 is 256 x cleaner than ISO21/19/16

256x drop in cleanliness

Common Contaminants

• Solid particulates • Dust, dirt, rust, metallics

• They cause of over +80% of fuel system failures

• They damage the surfaces of injectors and fuel pump, altering clearances, which affects the delivery of the fuel to the combustion chamber

• Liquids • Water, Air, Engine Coolants, Oils, chemicals

• Cause of lubrication breakdown, oxidation and compatibility issues

• Microbial activity

• Soft Resinous • Asphaltenes, heavy chain polymers, waxes/gums, poorly

blended additives & other deposits. 16

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Types of Water in Fuel

• Two major classes of water within hydrocarbons

• Dissolved :

• water molecules closely associated with the hydrocarbon

molecular framework

• Not free to move within hydrocarbon and associate with

surfaces.

• Lower concern for lubricity loss or corrosion

• Free :

• Water molecules emulsified within hydrocarbon but

associated with other water molecules, and bulk water.

• Free to associated with surfaces

• Negative impacts to lubricity and corrosion

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Sources of water contamination in

diesel fuel:

• Delivery of contaminated diesel from

supplier

• Condensation with storage tanks or

vessels

• Rain water through tank hatches or

enclosures

• Wash down water through breathers or

vents

• Temperature change of diesel fuel

resulting in dissolved water turning into

free water

Water Contamination TM

FILTER VESSELS

AND SKIDS

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How do we control & maintain

fuel cleanliness levels?

• It starts with a consistently clean fuel supply.

• Fuel is NOT sterile & free of contamination as it leaves the refinery process.

• Increases in contamination levels occur during subsequent transport, storage and transfer. Fuels delivered to a site are rarely at a cleanliness level that meets modern & future engine & fuel system OEM requirements, and thus fuel contamination control on a mine site is a critical issue.

• Again, there are 3 main types of contamination that need to be controlled & monitored; • Solid particulates

• Moisture (water)

• Microbial activity – occurs in the boundary region between water & diesel

• Modern ULSD’s and bio-diesels may not have an extended storage life, and may have an effective “use by date” unless managed. There is still much to learn on the longer term stability of these modern diesel fuels.

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Water Removal

• There are 3 primary methods for removal of

water from diesel fuels • Coalescing Filter - elements designed to coalesce or bring

together smaller droplets to form larger

• Absorption - elements with absorption media (like a

disposable baby diaper) to soak up free water

• Drainage - drain tanks and sumps with settled water

• Be aware of secondary methods dealing with

water removal • Chemicals - Some chemicals are used to make the fuel

hydroscopic (absorb water) so that water is taken to the

combustion chamber.

• Magic Solutions - Adding absorption materials, snakes,

magnets, UV lights etc

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Coalescing

• Coalescing filters are filters which are

designed to bring together (coalesce) small

water droplets into larger droplets thus

allowing the water to fall away into the filter

sump.

• Water coalescing initiates by water droplets

impacting with a hydrophilic fiber matrix

within the Coalescer. Ref picture

• Coalescer filters will remove particles so

they require pre-filtration protection at or

below the micron rating of the Coalescer to

prevent the Coalescer from blockage by

particles

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Coalescing

• Coalescer elements are

manufactured in reverse to

normal particle filters

• Initial fibers are initially finer and

become larger through the

element

• The finer the initial fibers, the

greater an effect on

destabilizing the emulsion and

initiating coalescing, therefore

higher coalescing efficiency

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Vessel Design & Construction

• What considerations are used for specifying the correct vessel? • Fluid

• Fluid Flow rate

• System Temperature

• System Pressure

• Micronic, Separator, Clay

• Material Cost

• Corrosion Allowance

• Contaminates

• All of the above

Housings

• Housing for AD-6 & DFO-6

• DVX • Configurations: Filter, F/S,

Aquacon®

• Flow Rates up to 176 usgpm

• 2” NPT Inlet/outlet

• Small Housings – Aquacon® Focused • VF61 / VF62

• 5” dia

• 12/24” lengths

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DVF Series Housings

• Vertical filter housing for

Micronics Filtration

• Typically Fixed Installation

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* Use threaded bases (TB) where ever

possible

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DV Series Housings

• Vertical Filter-

Coalescer/Separator

Housings

• Up to 2,100 usgpm

• Typically Fixed

Installation

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* Use threaded bases (TB) where

ever possible

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Coalescer

Separator

Operation

Most widely used

form of bulk fuels

filtration in the world

DP

Gauge

Pressure

Relief

Automatic Air

Eliminator

Coaelscer

Elements

Separator

Elements

Manual

Drain

TM

Diesel Filtration Skid

• Optimized Complete Bulk Filtration Solution for Removing Solid and Water Contaminants

• ASME code

• Swing bolt closures

• Independent DP gauges

• Air eliminators

• Walkway

• I/O Sample Ports

• Isolation Valves

• Press Relief Valve

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Rela

tive In

jecto

r L

ife %

Water in ppmv in fuel

Water Contamination TM

Reference Cummins inc

Particle Analyzers

• Integrated Particle Monitor (IPM)

• icountACM20

• icountBSplus

• icountFS

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IPM® Integrated Particle

Monitor

• Independent monitoring of system

contamination trends

• LCD display screen or no display for

OEM applications

• Continuous measurement or

programmed sampling periods

• Full PC/PLC integration technology

• Communication options: CANBUS,

ModBus, RS-232, Cellular

Telemetry

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TM

icountPD

• Independent monitoring of system contamination trends

• Warning LED or digital display indicators for various contamination levels

• Visual indicators with power and alarm output warnings

• Cost effective solution to prolong fluid life and reduce machine downtime

• Continuous performance for prolonged analysis

• Full PC/PLC integration technology

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icountFS

• Fluid viscosity as high as 300cSt

• Sampling period from 5 seconds to 999 seconds

• Storage up to 250,000 samples

• ISO4406:1999, NAS1638 and RH%

• Reducing adaptor

• Completely self contained

• Download onto any PC Via RJ45 or via Wi-Fi

• Sample directly from a reservoir or tank

• Low or high pressure testing

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Flow Differential Pressure

Module (FDPM® MK II)

• Data Storage

• 2 GB via MicroSD

• >3 years of data storage

• Electrical Certifications

• Ratings: IP-65 & NEMA 4X

• ATEX - Class 1 Zone 2 Group D

• Options

• Pressure Inputs

• Two individual pressure transducers

• One differential pressure transducer

• Data Networking

• Ethernet and RS-232

• Wireless and GSM Cellular in development

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Sizing Particle Filters

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VF-2456 4.5 gpm/in 9 changes/yr $152K over 7 yrs VF-3656 1.5 gpm/in 0.7 change/yr $55K over 7 yrs

Sizing Particle Filters