FILTRATION 101 - etouches€¦ · The Real Cost Of Poor Filtration • Short Oil Drain Intervals....
Transcript of FILTRATION 101 - etouches€¦ · The Real Cost Of Poor Filtration • Short Oil Drain Intervals....
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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
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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?
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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
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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
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Oil Contamination Challenge
• Organic Contaminant – Soot due to
Exhaust gas recirculation, high lube oil
temperatures, Silicon, wear metals
• Inorganic Contaminants – Moisture
and fuel dilution
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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.
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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
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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.
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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
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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
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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
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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
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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
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Absolute Replacement Elements
3 Micron
Green
5 Micron
Blue 10 Micron
Orange
Elements are color coded for easy identification
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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
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Racor Bypass Filter Per 25 Vehicle Fleet
Annual Potential Savings
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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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Racor Crankcase Ventilation Filtration
The Solution
Flow Path for 4500, 6000, 8000 , and 12000 Closed System Series
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Racor Crankcase Ventilation Filtration
The Solution
Flow Path for 4501, 6001, and 8001 Open System Series
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Racor Crankcase Ventilation Filtration
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
Racor Crankcase Ventilation Filtration
Applications
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Racor Crankcase Ventilation Filtration
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.
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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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Air Filtration Media
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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Air Filtration Media
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!