Fleelguarí ❑° MICRON RATING

ESI Presentation a,Zl á

g
mpany
D 1 um = 1 millionth of a meter.
❑ = 1 thousandth of one millimeter.
OBJECTIVE ❑ um = micrometre
ó 40 to 90 um - human hair diameter. or micron
To give understanding to the role of lubricating
o 70 um - grain of table salt.
crankcase oil filtration. From its grass roots
40 um
concept through to a new patented filter concept.
ó 10 um - grain talcum powder.
o
o
The presentation is formatted to show how
Fleetguard's dedication to
oó below 40 um - visible only
with magnification.
♦
♦
♦
achieving fine

filtration has not been disregarded at the o

expense of achieving greater service intervals o
and filter life. WITHOUT COMPROMISE oo 10 um

5um
Designed by: Jet/ Crook, Fleetguard Australia Technical Support Manager 1997
o

o
o Largest single SAEJ726C Test Dust.
FILTER MICRON RATINGS glass bead
Chemical Analysis of Test Dust

o Chemical
o
Absolute. Single pass using glass beads.
o
o
o
0
o
o 3
o
o
oo 0-5 39+1-2
o 5 - 10 18+1-3
o 10-20 16 +1- 3
o 20 - 40 18+1-3
o 40 - 80 9 +1- 3
a 80 - 200
o
o
o

D
MICRON RATINGS Beta Ratio. Multi pass, real dust.
o
D Bx = ratio (upstream
o count divided by x = Particle sine counted
o downstream count).

o
D
«..^vc^...QQ^'
^^£,^^ir.,+y+•±^ xa^• W '.'"`^:'aé°^n:<&^ 4. ,^,0 ^: e ,. ti^a^^^yS K ^ i:.

tr

L t r ^L. .
o - Upstream
❑ count Downstream


o
MICRON RATINGS Beta Ratio. Multi pass, real dust. o
MICRON RATINGS Beta Ratio. Multi pass, real dust.
o o Efficiency
o Eg. B4o = 75
o Efficiency = 100 -100/ratio % of contaminant
X = micron size
0 o removed
0 ie 100 - 100/75 o
0 o Bx =1 0
0 % o
=100-1.3 Bx = 2 50
00
= 98.7% •o Bx = 4 75
Bx =10 90
o
• Bx = 20 95
o
o
• Bx = 50 98
o
Bx = 75 98.7 (same as absolute glass bead)
o = 100 99
o
•
o Bx=200 99.5

full flow lube

up to mid 50's

0
0
E COMBO FILTRATION
0
❑ Flow Diagram. Lubricating Oil System
❑ t. Oil Pu,
❑ 2. Ptesswe Requlal. Valva
• 1 Oil Relurn lo Pan
• 4 tlíuh Presume Rabel VaNe
S Oil . Pan
❑
6 Oil Ilierrno.al
❑ 7, Oil Cooier
❑ 8. Byoeaa Flllerad 011 Return
❑ 9. Combln.lon Oil Ilfter
❑ I0. Filler Ryoass Valva
• '
11. Accessory Orive, Alr Compzesso.
12_ Irller Ge.s
0 13. Viscos», Sensor
❑
0
❑
10 --
O
n
0
❑ 9 -
O

L_1

full flow lube

up to mid 50's

Wire Screen
• Iow capacity
• Iow filtration efficiency

❑
of

oo Traditional Cellulose Media

o
o
ó • Most common
o
ó • Wood pulp fibres
❑ - random fibre size
❑ 12 to 60 micron in dia.
ó - resin binder required
° - inexpensive
o
ó • Good for standard service
❑ - standard pressures and flow
o
o • Loses efficiency over time
o
o
o

❑
❑
Synthetic Media
° • GREATER EFFICIENCY with Synthetics
o 1986 on
o • REDUCED FLOW RESTRICTION •❑ Microqlass
❑
Consistant fibre diameter
° synthetic cellulose ❑ no loss of capacity
fibre dia.- 1 to 20 micron fibre dia.- 12 to 60 micron ó 'lmproved efficiency at 10
❑ micron & aboye. Eg. at 10
micron 100% + improvement.
❑ • lmpervious to moisture damage
•o * Requires screen backing
❑
o • Relative cost is high.
• Requires fibre resin binder
o • Short chopped fibres
u?
f: l

Winner of 1995 American

Fleetguard Nelson Leadership

o
o in Filter Technology
o

StrataPore

1955 1960 1965 1970 1975 1980 1985 1990 1995 2000
Year

Top o
or ° ANTI-DRAINBACK VALVE for inverted filters
Bottom ❑ Head of oil on top of the
❑ gasket valve forces outer
Bypass ❑ !^ rim of gasket to seal hard
0 up against nutplate. Oil
Valve...sometimes ❑ will not drain back to sump
located either in the ❑ during shut clown.
mounting head, top of
the element or bottom {.. '

of element o OPEN
Bypass valve ensures
engine is never starved of ❑ Anti-drainback valve ! + 1 +
° forced away from
oil. However oil will
sealing face of '
bypass unfiltered to the nutplate by the flow
bearings of oil
CLOSED
Hyr.., Fwyw
El _

o
Why finer filtration than full flow filtration provides?
o
1NLY PARTICLES THE SAME SIZE AS THE BARRIER OIL FILM CAUSE
o THE DAMAGE
o
o COMPONENT Oil film
thickness
D 1
❑ ° ,-+"
❑ Ring fo Cylinder .3 - 7
❑ m
o Rod Bearings .5 - 20 i
o
o Main Shaft bearings .8 - 50 c
r
o
❑
Turbocharger bearings .5 - 20 o
n
o Piston pin to bushing .5 - 15
❑ s
o Valve Train 0- 1
o
o Gearing 0- 2
o
o

o
o
5 TO 20 MICRON PARTICLES CAUSE Historical results documented in
•o
o SAE 710813 & SAE 7890089
o THE MOST ENGINE WEAR
oD SAE 790089
Stacked Disc Media
❑ 600
❑ 500 ®Full
• Flow
❑ Average Weight
400 Only

Loss in Milligrams 300 O Full

Flow
with
0 200
Bypass
100
Upper Lower Upper Lower
o Conn Conn Main Main
o Rod Rod Bearing Bearing
Piston Ring Wear Bearing Bearing Shell Shell

Q D R STALEY, GENERAL MOTORS CORP.

o
Average Weight Loss from all o "CORRELATING LUBE OIL FILTRATION
components (Mg) ó EFFICIENCIES WITH ENGINE WEAR", SAE 881825

• 900 •ó"Abras/ve engine wear can be substantially

• 800
700 o Full Flow Only o reduced with an increase in filler single pass
• 600 ó efficiency.
D
• 500 ❑Full Flow wth
400 Pleated Bypass o Compared fo a 40 micron filler, engine wear was
°

reduced by 50% with 30 micron filtration. Likewise,

300
• 200 ■ Full Flow with •CI wear was reduced by 70% with 15 micron filtration.
Stacked Disc
100 Spin-on • Controlling abrasive contaminants in the range of
0 n 2to 22 microns in the lube oil is necessary for
•
• controlling engine wear."

Testing by Cummins shows sludge is abrasive to engine

components.
The small inorganic materials (dirt and wear metals) contained
in the sludge increase its abrasive nature.
Additionally, the presence of sludge actually creates more
u sludge
600

500

400
o
300
Q
200

100

o
New oil Sludge

o
❑
o EFFECTS of SLUDGE ❑ ' • If soot dropout
o o occurs and it
❑ II o
ó l • Oils fail because the o plugs the full flow
o ° 8° dispersant package is no element, bypass
❑ e° longer capable of keeping
❑
° the soot in suspension
oo valve cracks open
o allowing unfiltered
o oil through to the
• As soot agglomerates and falls out, it forms o
engines moving
sludge and interferes with the desired functioning o parts.
ó of the oil. It also becomes somewhat abrasive in o
❑ the system. ó • Unfiltered contaminated
o • Removing sludge from the system allows oil to oil increases engine wear
❑ perform effectively for longer periods. ó and reduces life to
overhaul.
o ❑

80 to 90% of
o contaminant is
o
o ORGANIC
o
o
o Je'
o
Grams

t'. wa ry rp
❑ REAL WORLD
❑ CONTAMINATION F --^^
o Stacked discs excel
o
o Fleetguard's extensive field tests have shown when compared to
less than 20% of total matter trapped by a lube pleated cellulose for
filter is inorganic (dirt) capturing contaminant

0 MEDIA DURABILITY
❑
❑

•o Test data from over 44 cellulose filters from

❑ several companies
ó • In service 50 to 80 thousand KLMS.
o
o • Between 30 & 50% failed bubble point test. Filters failing
ó the test can either hole or weaken the media and allow
o unfiltered oil to pass to the engine. Field experience
o demonstrates that this wear will typically be noticed as
premature top end wear.
o
o
❑

o 0
MEDIA DURABILITY o
0 o
o StrataPore melt blown synthetic media
ó Cellulose media has resin binder to hold the wood O • More consistent performance than
o pulp fibres together. This resin binder breaks ❑
• microglass
❑ down over time losing tensile strength.
❑
• • Cost comparable to microglass
ó • Additionally, the cycling from repeated start-ups ❑ •Strong continuous fibres - welded
o causes the pleats to move. At the point where the joints
ó media is fixed in the adhesive, the repeated •
o
o • No binder
ó movement stresses the media causing failure.
o ❑ • Gradient density applications
o CONCLUSION: Cellulose ❑
Uf, deben is c a>f swa.41.1 is (hl» d

o filters are not durable

o
o
enough for applications
beyond 40 thousand ❑
0 111
Mi« wad. debele k ch.. by IAe rne
klms. or 500 hrs.
ó❑ o
❑

o
ayer. TMese ere set." Me »Males tlsd
CAe1! Ice hect.»; ts ee eeyl•e.

• Superior strength
General Performance Comparison

• Multi-Iayered with o
o
progressively more o

efficient media o
o `
x x x x x
• Individually optimized ❑ T x
x ir.

sheets for desired partirle o

•
❑
size provides the ability to
—^-Siseen
increase media filtration ❑
❑ —ú—• Cellubse
without sacrificing o
x Cellulose Synihetic
contaminate removal. o Synlh& s (.O raed SP)
`'
W Winner of 1995 American Time
Filtration & Separations ❑

Society Award
❑ glass o StrataPore provides consistent high efficiency
C] stratapore

Mullen test. First media fracture PSID (FS1000 media)

n
I__l

SAE 790089
shows some
"COMBO" Full flow 1 bypass
engine FROM
component wear
reduced 50% 2 x filters for
when using Full fine filtration
Flow and Bypass
filtration together TO
1 x filter filter
for fine
filtration 10% of the full flow
oil passes through
the stacked disk
bypass element
and travels directly
back to the sump.

o
o
o Old compared with New
o
o StrataPore Combo
o
• LF3000: CECO
o ,
77-
MEDIA STRENGTH
❑ Enhanced media utilisati
40
o maximise capacity.
35
❑ ^^^ Coarse, Medium & Fine Iayere
^I
o 30
o
o 25
Louvered Centre 20 Std. Glass
o
o Tube, 150% more • 15 StrataPore
o open area. á 10
o Decreased 5
o
o resistance to flow at 0
o all rated conditions
o Media Only - no backing material
(hot & coid)

o
o o
Old compared with New StrataPore Combo Old compared with New StrataPore Combo
D
ó COLD OIL FLOW o HOT OIL FLOW
o 6 GPM SAE 15W40 at -10C 40 GPM SAE 30 at 120C
o
D 3
❑ 2.95-'
❑ 2.9 /
o 2.85
— D Ñ 2.8'
D
• 60' Cl Formar LF3000
❑ u New Lfsuuu ❑ t1 2.75
— O New LF3000
❑ 40¡ ❑ 2.7'
D —__
❑ 2.65
❑ 20 ' Engine testing proves that
❑ 2.6
❑ o reaching oil pressurisation 2.55 ,!)::_ .,..
o
❑ as much as 3 seconds faster
D
❑ can triple camshaft life. ❑
o F]
o L

Stra.taPor-e
LF3000seres wlth

' Better media stabilisation ie. 4 hot

melt beads
' 50% improvement in lowering coid
oil flow restriction.
• 25% quicker pressurisation. This
can equate to seconds in below zero fibres, NO RESIN BINDERS
temperatures.
• Stronger media to withstand
Stacked Disc bypass filter media not only
industry's movement towards removes the fine damage causing
increasingly abusive operating particulate, it provides the attraction
conditions & ESI. medium (cellulose) for sludge holding.

Engine Life Not Predicted by Lab Dust Tests

Relative Life in M l 1 FP Test
0 Compared to SAE J1858 Dust Capacity
° 200 200
RLife
❑ m
❑ Á150 ■ Grama 150
❑ a

❑ 100 1001
0 á
❑ U
11 tY
50
❑

❑ 0
❑ ASTM Filter D Filler B Filler L LF3000 LF9009 Venturi L
❑ Ref

Consumer Price Index

ESI Presentation 1980
UP ó0% 1997

-----------------
1997
Conventional
Oil and Filter
System
° top 150 Fleets in
Service Interval , NA in 1980
....only 18 still opera ring
LI


o
o o
• Improvements to the oil and filter efficiency
o increase the expected engine life. o M§uard
o o EXTENDED SERVICE INTERVAL (ESI)
o • Provides also the opportunity to extend service o
o
intervals without reducing the engine life. Lube System Filtration
o o
o o
o
o incr Engine Life
o RULE NO 1
❑ Engine
incr. service ó FILTERS ALONE CANNOT MAXIMISE SERVICE LIFE
ó Life o
o Advanced Oil o
o Conventional (min. CG-4) and o • Fleetguard recommends you work closely with your oil
Oil and Filter Filter System ❑ supplier when developing any ESI program
o System
o o
o
• Use oil analysis to establish and verify change intervals
o
Service Interval o
o o
o o
o o

o
o
LUBE OIL
Advanced Oil Technolgy means the o
FILTER MEDIA'S ROLE HAS CHANGED o
o • Premium oils typically contain higher concentrations
o of additives to allow them to perform longer before
o
o failure.
o
Ÿ ' Synthetic or semi-synthetic oils resist breakdown
❑ better than conventional oils because of a more stable
base stock.
o
ó ' Hydrocracked isodewaxed base stocks have better
ó oxidation and soot dispersency characteristics than
❑ conventional solvent base stocks and rival synthetic
o and semi-synthetic base oils in some characteristics.
o
1,1 o
o
o
o

OIL FAILURE o Why OIL ANALYSIS

0
• Shows how much engine wear has taken place by
0 measuring how much of each metal is suspended in
• Loss of dispersant control additives results in
increased oil consumption and engine wear due to
o the oil
deposits
o • Measures viscosity, the fuel soot in the oil, and its
' Loss of acid control additives results in corrosive ❑ TBN or its " total base number" ie. how well it
bearing wear neutralizes acid.
o
' Loss of anti- wear control additives results in
ring and valve train wear. • TMC recommends oil analysis as a vital tool for
o
extending drain intervals.
o
❑

10


o
❑
Oil analysis should include: o ONLY USE FILTERS
❑ DESIGNED FOR ESI APPLICATIONS
•
•
• VISCOSITY measurement
'TBN "total base number" or how well it
o
❑
• Fleetguard has done extensive engine and field testing to
determine the key requirements for lube filters for use at
• neutralizes acid. extended service intervals
• • TAN 'total acid number'' both evaluate o
o • We have found there are 4 key criteria to evaluate
• oxidation, nitration and show thermal
ó a filters ability to perform in ESI applications.
degradation, an early warning of wear additive o
condition.
• MEDIA and general construction DURABILITY
• COOLANT contamination test is also o
recommended (not just water). Small coolant
ó • FILTRATION EFFICIENCY
leaks over extended drain intervals can become ó • FILTRATION CAPACITY
a major concern.
o • SLUDGE REMOVAL

•o
o
o
Venturi Combo Filter Design
o Venturi Combo design
o
o
with alI flow going to
top end of engine
o * fits existing heads
o
o
o
* simplifies piping

o
o
o
• Conventional LF3000
°° design with separate
o full flow and by-pass
❑
• circuits
o
o

o
o
Venturi Combo Circuit o
o
Venturi Combo
What does it do?
o
❑ Generates flow through the highly
o restrictive bypass media.
oo
o
o
❑ Technically it
❑
o should be termed
❑ a "shunt Filter".
❑ However, for
o E>

r >Q
clarity, it is referred
E> ¡--^ to as a`venturi
combo" full flow
conventional combo venturi combo ❑ ¡^.^ bypass filter.
o
cI
I:I


Venturi Combo
How does it do it ? Venturi Combo
• Flow through the highly restrictive
bypass section is generated by the ' The expansion section of the nozzle
venturi nozzle placed in the outlet of the then recovers the added flow restriction
fluid flow. due to the increase in fluid velocity as
it exits the throat of the venturi.
' Flow from the full flow section creates
a Iow pressure zone at the bypass
section generating increased flow p
through the bypass stacked disc media.
Approximately 20% of the fluid leaving the
filter passes through this high sludge
pop
holding fine filtration medium and joins up
with the full flow.

• VENTURI COMBO vs LF3000

❑
CA Definite Must for ESI

Field test Contaminant Captured ❑ CUMMINS SOOT TEST

Medium
Duty Cycle
ó Latest specification for oil
performance and engine filter
plugging
Light Duty 1 Venturi Developed by API (American
Cycle
Combo ❑ Petrolium Institute) and the EMA
LF9009 (Engine Manufacturers Association)
ó Filter plugging engine test measures
LF3000 ability of an oil to perform in a heavy
Combo ó duty diesel engine in a severe duty
❑ cycle.
❑
ó Oil failure is measured by the
❑ time required to plug a highly
efficient reference filter.

o CUMMINS SOOT TEST Non Bias ó CUMMINS SOOT TEST Non Bias
° Independent laboratory results ó0 Independent laboratory results
Relative Contaminate Removed ' Synthetic FF ❑
• * Synthetic FF no
❑ (no Bypass filter) Relative Life
❑
•❑ BP

❑ 5
Cellulose FF w
Pleated cellulose
•❑ 5 * Cellulose FF w
Pleated cellulose

A00 o❑ 4
BP BP

❑
❑•❑ 4
❑ Synthetic FF w ' Synthetic FF w

!I1
3 Pleated cellulose ó 3 Pleated cellulose
BP •❑ BP
❑
• 2 StrataPore FF ó2 StrataPore FF
❑
❑
I w Stacked Disc
(LF9009 Venturi
❑
• 1
w Stacked Disc
BP (LF9009
D O Combo) ❑ Venturi Combo)
Ll • o
Li Venturi removed 4 X More Contaminate than Synthetic Full Flow only filter. •❑ Venturi allows same oil to perform 4X longer than FF synthetic
L' fI

12


o
0
Total Filter Contanin. Total Filtoí Conteninant

Average ot 5 9ftwa

LF3000 LF9009 Average of 5 lillers ach

0
LF9009
._ __
0 LF3000 44
50 – -------
0 -
lag
ME.
___ _ LF9009 0 40

35 -- -- ---
r LF3000 0
LF9009 hcr.ot
26 Cr G.(
e LF3000

$liJI. 0 25 -

O 20 -
0
MYNYYYNY
RYYNRYYNR lo – - 7 -
O :::::
3 3
1,3000 L,301075 1F3000 L.01076 :::
25,456 miles
Mounl TrudJnp
25,767 miles
■Axiol Tiudung
30.615 miles
AwnO E*pr•s5
31.904 miles
Avenó Exprese 0 O
LFIOOO
25458 rrees
I.F90 ■ 078
25 767roe.
LF3000
30 615 n4w
LF.1D76
319.94 n.
0
Mural Tiwldng Mural Trucwig Avee.erts. Avwdl Barias
E4 Full F.« Organtc ByPass Organic 0 Full Flow lnorgatwc ByPess Inorgarwc
0
O

o o

o o

o o

o Venturi Combo o

o o Venturi Combo
o What are the advantages ? o
o What are the advantages ?
o
Stacked disc media with a unique o
o 1 Superior strength StrataPore media
o
o blend of cellulose fibres that have a
o o for stability over extended use.

o natural attraction for sludge.

o o
This ensures the full-flow section of the Maximum dirt holding from multi
o

o filter remains cleaner and open to flow. o layered StrataPore media.

o o
Also designed for superior holding
o
o Improved internal
o capacity as well as fine filtration.
o
and externa! gasket
o o

o StrataPore's low attraction material for better

• • No need for extra plumbing adaptors.
o o
❑ to sludge (organics) allows it longer service stability.
o Simply replaces the existing full-flow filter providing the
o to remain operable longer for HNBA "hydrogenated
advantages of two types of filtration in one screw-on unit.
•
❑ the purpose of trapping only nitrile"
o

❑ the dirt (inorganics).

o o
o

Venturi Combo
r,
Os'f- - Setter Engine Protection Venturi Combo
Specially suited for Long Life Oi!s
0'1 Dt!'
Specially suited for Long Life Oi!s Setter Engine Protection
l! •Grea t er optime Lower Operating Costs Reduced Wear

• Greater optime Lower Operating Costs • Reduced Wear

c Cummins Cummins Cummins
Cummins
Signature, ISM &
n LF67013363/3325 LF 3000 Short version
ISX engines
H. LF9000 0
0
0
LF 9325 LF 9009 LF 9001 o V01V0 LF3321/3379
• o
LLF 9000 1
Komatsu
❑ Mack, Cat LF667
0
❑ LF 747/3453
o Detroit pre '93 Detroit post
Caterpillar
0
o Series 60 '92 Series 60 Caterpillar HD Normal Duty
o John Deere

• LF 3333 / 3380 LF 3620/3671 L F691N3566 LF691/LF3374 o LF 9667 RE58935

o LF 9747

0 0 ^-
0 ó
LF 9333 LF 9691A L F 9691 LF 9010
Y

Recommended filter service intervals no longer than 72,000 klms or

• 1,000 hrs or OEM recommendation.

1-1
1:1

13


Cummins EnGine Comsan Source A ?roval Method

What is Fleetguard's Warranty on p for Venturi Cummins Applied Filters
0
ó ES System producís? CECo SAM 10765
oq
7MED1A MIGRATION FLOW CHARACTERISTICS
ó
a A slight change has been malle under the
"Duration" section in the Warranty coverage.
Ó MULTIPASS TWA EFFICIENCY (min 60% @ 10 micron)
ó This further strengthens what is currently the 9BUBBLE TEST
❑
ó strongest filtration warranty in the industry. ó CUMMINS SOOT TEST
E ELEMENT COLLAPSE
extract:
HHYDROSTATIC BURST
o
Duration: This Warranty extends from the date of
❑ installation of the Fleetguard product through the E. IMPULSE PRESSURE

duration of the OEM recommended or Fleetguard HVIBRATION FATIGUE

D published service life for the application. COLD FLOW RESTRICTION

o ó Ó SEAL COMPATABILITY AND DUABILITY

❑
MI Conclusion
o
Conclusion
Use lube filters designed for ESI applications with:
The keys to extending lube ó.
service intervais are: ó Improved durability media and gaskets for reliable
❑ performance.
❑
ó 1. Use oil designed for ESI applications. (Min. CG-4) ❑ . High efficiency for reduced engine wear

❑2. Use oil analysis designed for ESI to establish and ❑ • Low restriction, especially during coid starts, for reduced
ó verify change intervals. ó wear
u3. Consult your engine supplier for recommendations ó • High capacity for "Real World" contaminant for extended
on oil change intervais. ❑ life.
634. Use lube filters designed for ESI applications o • Performance on CUMMINS SOOT Filter Plugging Engine
❑ ' T es t for proven results

14


0 CENTRIFUGE RATIONALE
°Industry Trends:k Centrifuge Benefits:
0 °^ ■Extended Service ll Filtration ■ Cenlrífuges base
0 ■ Mínimum life-cycle cost ❑ rv s ES ) lj re t y super i or
❑ ♦ Long service interval Q ■ Environmental Translation: sludge capacity,
❑ ❑ Regulation compared to (ilters
0 ; ♦ Low r lacement arí cosí
♦ EPA NOx limits
❑ '( }: ♦ Low labor cosí to servíce toward
❑ driving ConeStaC eflíciency
❑ "' -- "`"^ ■ Maximum Life & Reliability of Engine ❑ retarded timing =
meets or exceeds
❑ ♦ Low wear rases ❑ increasing oil soot
even stacked-disk
♦ Low oil consumption ❑ loading
bypass filters
❑ ♦ Filler/Oil disposal
❑ ',; ■ Minimize environmental impact ❑ issucs

■ Capability to use lower quality oils 0 ■ lncreasing engine ■ Encapsulated design

1 0 reliability and durability minimizes disposal
❑■ lncreasing engine quantity and cosí
power density ♦ Incinerable
capsule especially
0 ❑■ Easierlcleaner suited loe EL'
o ❑ maintenance demand market

gressure-Driven Bypass Centrifuge: Fluent V4.25 CFD Analysis of a

❑ ■ A "B}pass" centrifuge offers high capacity
1-tenis Turbina
Conventional Centrifuge Inlet Zona Close-Up
■ Pressurized engine lube oil is supplied to a vessel 150 B.C.
Velocity Vector Plot

❑ with tangential outlet jets (Hero Turbine)

■ Conclusions:
ó' Centrifuge turbine rotates due to reaction force
♦ Flow clings to
D ■ Centrifuga) force causes separation of particles
❑ ■ Flow returns to the engine sump by gravity hub where "g"
0 force is low
0
■ Remedy:
♦ 1. Force tlow
0 further out
❑ ♦ Full-Flow
Filler ♦ 2. Reduce
sedimentation
D distance with Note sirange
reverse now
Cone Stack
phenomenon
which is typical
in high speed
rotating axial
tlow fields.
❑

Evolution of the "Cone Stack" Increase Residence Time by

Increasing Tank Surface Area
■ Consider a simple settling tank Flow In
°0
❑ ■ Particle "Free-fall" selocity is gis en by
❑ Stoke's laos:
❑ o
❑ v= dia l* (Dp—Df) 9
Flow
❑ 18 * vise o
D
❑ ■ To increase efficiency, w e could
Out
• ■ Problem:
o
o ♦ Increase particle sine
❑
❑ ♦ Increase density dillérential
♦ Tank size grows too large
❑
❑❑
♦ Reduce (luid eiscosity
•
♦ Fine/Coarse sediment accumulates unevenly
♦ Increase the residence time lincrease tan):
❑ sal hice crea ot reduce the Ilouratel ó
♦
❑ Decrease the distance par 'kit must Irar el lo
D
❑ be separated ❑
❑ ♦ Increase the "e" lince ❑
L_l
❑

17

15


o Use Angled Divider Plates so Material

o
o Reduce Settling Distance by o Slides off Plates
Sub-dividing Flow Channels Flow in

Flow in

1Flow out
--1' Flow 0
0
---Lj 0

o
.Problem - Channels plug up o0o
with separated material and
• Finally, to increase "g".
blockflow Mar parida enlers
%id boundary laye,
Vflow goes to zero
O0 only Vg rernains
❑

Make the Tank Round, Use Cones instead

of Plates, and Spin to increase "g"

Cone stacks have

been used for over
100 years in
o
centrifuges
.-But not in
pressure-driven
centrifuges
Three Fleetguard
acceleration = c0 2 r
U.S. patents to date

Covered by 3 US peto.
C)utstrmJing separa' inn perfonnts.e.
impro.cd ?IMP t con% cena.,

le.er quicker ser, ice - no sludge se.ping

Disíxisublc incinerable ConeS.C I cap.&
I:xtenda lile ol' !ES SY.I.A' full-ilutr lilters
(--111(,0 bolos)
110 ha Inng se', ice iffier,ul
Pendí., ,pro, al and MI:ases t. Quantum
tif engines

16


u
High Efficiency & Capacity = Longer FuII-tlow Life
u Field Test: Natural Gas Engine
u❑ ■ Two centrifuges installed Centrifuge Effect on Full Flow Filter Plugging
10% Overspeed/Overfuel test
0
❑
• 700 Foil Flow + ConeStaC Centrifuge (two tests)
❑ 600 • Full Flow + Conventional Bypass Filler
500
❑❑
❑ g 400
0 0300
❑ zoo

0
1 °

aump
Hp1 IR•KVS 4 cyd° Nel. Gu
gslirl SAEIO
1 f4 APesigi i olNprasa .un
330 RPM rsiing apaM
o 71L 1160FJ
0 50 100 150
Elapsed Test Time (hours)
200 250

High-Performance Soot Centrifuge PPT

BCurren t Product Summary lel13'nCuIfWW
o ■ Centrifuge provides inherently o ^r 01 Ilddw ^
■ Objective: a.^
FgwrN . ITllrrl.a. / Me1°X
le nl xrl
high capacity ♦ Determine the inertial separability of soot fdC7rN1
,Y, LI• lLMIM
i° MM
ó
o
❑ ■ ConeStaCT ttechnology greatly
p improves separation efficiency
❑
❑
❑
in lube-oil
♦ Demonstratefeasibílityof renrovalvia
❑ high-speed ConeStaC centrilitge design
❑
u " "
♦ Reaches performance of stacked-
disk media bypass filter
o • why9
❑
❑
♦ NOx lintits and recen' EPA actions cause
increased lube oil soot loading
0 ■ Encapsulation provides quicker
• xosvr?
❑ and cleaner centrifuge service ❑ ♦ Soot control is achieved with ConeStaC +
0 ♦ A11-plastic design provides ❑ doubled rotor speed
❑ incinerability ❑ ♦ High speeds require new impulse-turbine
0 ❑ drive and low friction design
❑ ■ Increased efficiency and high
0
❑
0
capacity extends lile of
foil f lo>v filters
CoheStae- fftri4t
0
0
0
g ES SYo7r 0

Disposable ConeStaC Rotor: Industrial ^trifu e PPT

ó❑ Comparative Advantage ■ Objective:
❑
0
100, - Performance Comparison: Efficiency ve_ Particle Size ❑
❑
❑
♦ Develop an air-driven
centrifuge suitab(e for
industrial separator AOA-fOAt Aff $f 40[0
- lool[r IfAnA9s
It0/ Ax010i TOKI
❑ applications such as
^ ❑ Ceramic grinding
❑
❑
Predicted CS41
❑ apptication - mlchining
❑
70° ° - Disposable Rotor with
❑

❑
ConeSlsC

~ Cenlrimax
^ ^-
•
❑
Iluid clean up
Hydraulic systems
- "Filler" can
❑
0
40°° —- ^^^ F le etgua rd L F34 I6
(Cenlrimax cross
❑■ 1Vhy' ,
0
❑ ♦ Deliser cero high !p ONOf t 9n`gIH
❑
° purchaxd from
❑
JO°
Baldwin( efliciencv and capacite in a ="=i,
L7 nnlch lose er cosí product
❑ 'han motor-dril en rigs
In°c r^
LJ r^ ❑ • Flow?
♦ Air pressure dricen turbine r ^a
♦ 1IPSC ConeStaC rotor
❑ !' 5 1^' 15 2ii 25
0 Par-tic le irnicroni 1.7 i,:„,;.,:, .,
LI design 1111 INU^ ^ .,,
U [-1

17


❑ Technology Summary:
2]

• ■ Cun-ent technology efforts focus on:

❑ ♦ Reducing initial cost ofproduct (Disposable rotor)
❑ ♦ lncreasing rotor speed (High Performance Soot
❑ Centrifuge)
❑
• ♦ Developing a unique low-cost industrial centrifuge
❑ product
p ■ Future technology possibilities:
• ♦ Integrated filter/centrifuge housing designs
0
❑ ♦ Electrically driven rotor (fuel, industrial, etc.)
❑ ♦ Liquid/óquid separation (fuel/water, hydraulic
❑ fluid/water, etc.) Coí,eSta.0
❑
• ♦ Solidlliquid separation with continuous solid phase
?????
p bleed-off (self cleaning)

0
o

18


Worn rings
Scuffed pistons
Burnt valves
Corroded bearings
All may appear to have nothing in
common with the cooling system, when in
fact, these problems are often the
symptoms of improper cooling system
maintenance.

Program

• System Function & Problems

• TEC 50 with DCA4
•Chemicals used and function
• Why coolant filters
• Chemical Depletion
• Testing SCA,s & Adjusting
• XL Coolant & maintenance

❑ LD Compared with HD truck

• Combustion LD
o HD
temperatures are o
greater 2,200 deg C 0
Usage per year 15 to 25K klms 200 to 300 klms
• Cooling system o
Load Factor < 30% around 70%
removes the bulk of o
heat First Overhaul 250,000 klms 1.25M klms
❑ Total vehicle life
° 320K klms 3.2M klms
• Coolant circulates o
45K to 60K litres per ❑ System volume 5 to 15 ltrs 15 to 60 ltrs
o
hour. Wet Sleeve Liners NO YES
n
❑
U
0


HD Diesel System

PROBLEMS
Deposits & Scaling
General Corrosion
Aluminium Corrosion
Cavitation Corrosion
Foaming

LIMT

O k; 4.r n o? : a (: 3
line<s, M.

S' :xetuT,

Engine Manufacturers limits on make-up water

LINER PITTING or cavitation

corrosion caused by
imploding vapour bubbles
will eat clean through the
liner wall.
Shock wave impact Nitrite & Molybdate forms a hard surface with the
measured at 15 to 20,000 metal, thereby shielding the metal from the effects
PSI of bubble implosion and subsequent pitting.

a
á Major HD Engine OEM 's now insist on 50%
oGLYCOL.
0 Also must meet HD standards.
o
ó ASTM D 6210-98 (HD fully formulated glycol based)
TMC RP 329 (HD fully formulated glycol based)
o
❑ TMC RP 338 (extended service)
ó CECo 3666132 (HD fully formulated glycol based)
ó CECo 3666286 (extended service)
o
o
o
o

TEC 50 THE COMPONENTS in DCA4 (SCA)

A FULLY FORMULATED ENGINEERED NITRITE Protects cast iron & steel (liners).
FLUID Test chemicals
MOLYBDATE — Combines with nitrite for liner pitting
WATER (deionised protection. Good multi-metal protector.
Potassium PHOSPHATE Buffer maintains pH @ 9.5 -10.5 & protects
alum.
50%
NITRATE Aluminium & solder protection.
GLYCOL
SILICATE Aluminium & solder protection. Low concentration
MBT Copper, brass & solder protection.
ADDITIVE 50% s TT (Tolytriazole) Stable support for MBT, copper, brass, solder.
DCA4 Organic inhibitors Forros a film to protect copper , solder, aluminium
0.4 units per litre
Scale inhibitors Mineral depositing prevention.
ao @UE11 Mona Antifoulants l Surfactants Oil, grease & solids depositing prevention
Anticavitation Polymer Cavitation protection, inferferes with bubbles.
,^ ^I?X!I!N & L:.N_D_I_NG Antifoaming agent Foam build-up prevention.
 GLYCOL GLYCOL
LOWERS THE FREEZE POINT minus 37C
v LOWER Surface Tension Than Water
n RAISES THE BOIL POINT
122 C @ 1 atmosphere cap pressure.
8% at 50% by volume or • Makes the coolant wetter.
• Allows better penetration of additíves into the
Safeguards against head cracking and pores of the metal.
corrosion by reducing possible localised
vaporisation.
Slightly HEAVIER Than Water
Also note unleaded petrol engines at idle run 25%
hotter at the hect rejection surfaces than leaded • Cushions the shock wave of cavitation
fuelled engines. corrosion

GLYCOL
Why Use Coolant Filters?
BENEFITS at 50%
Published data from multiple sources
50% to 100% better show direct benefit from filtering
aluminium protection contaminate from coolant
REDUCED :
Wear
20% to 50% extra
liner pitting Corrosion
protection oven that Pitting
of water/SCA . Plugging
Scale formation

COOLANT FILTERS
Why FiItratíon?
• Reduces water
Repairs per 100 trucks
pump seal leakage.
- Survey over 11,600
engines operating with
and without water filters.
—3 to 1 reduction in
water pump seal leakage
between fleets using filters
and those not. Hui
-W hen sized correctly provides a simple fool m wfWater Filters
SAE Technical Paper Series, 881270 wlo Water Filters

proof method for replacing spent SCA's. quoting multiple sources

Coolant Filter Flow Path

radialor

High angina
pressure

1
Low
pressure

o
❑
o
2' 1-_oMY' 000000

RESTORE ..best for silicate gel removal

o
ó RESTORE PLUS ... best for scale,oil and grease
ó removal.
o
° • Mix Restore cleaners 10% in clean water or 20% for
❑ extreme contamination.
o
o
•
Open all coolant heater circuits
0 • Run in engine 1.5 hours to 4 hours maximum.
❑ • Dump and fill with clean water.
° Run minimum 15 minutes then dump.

óo • FUI with fresh coolant.

REPLACE DEPLETED ADDITIVE (DCA4)

as per Service Chart (approx. 0.1 units per litre)
SCA's (DCA4) DEPLETE WITH USE
0.8 max. 0.8 0 max.
u
n

t
s s
0.4 ideal 0.4 ideal
0.3 111111. 0.3 min.
o_ 0.2
oi o.

20,000 klms (250 hrs) oil change intercals - max lile zSi,llllll IJ. ms. 16,000 In_s) 20,0001Jms (250 hrs) oil change intervals- ma.x Vire 385,(101) kilos. _(h,OilU hrs)


o
DCA4 (SCA)
oo NITRITE -
Test chemicais
Protects casi iron & steel (liners).
ó CHECK DCA4 ADDITIVE LEVEL AT
ó LEAST TWICE A YEAR MOLYBDATE Combines with nitrite for liner pitting
o protection. Good multi-metal protector.
o
❑
o Potassium PHOSPHATE Buffer maintains pH @ 9.5 - 10.5 & protects
o alum.
❑ Based on results, follow the directive NITRATE Aluminium & solder protection.
ó given on the test kit, either; SILICATE Aluminium & solder protection. Low concentration
o
MBT Copper, brass & solder protection.
ó 1. Pre-charge with DCA4
TT (Tolytriazole) Stable support for MBT, copper, brass, solder.
2. SERVICE dose with DCA4 or.. Organic inhibitors Forms a film to protect copper , solder, aluminium.
o Scale inhibitors Mineral depositing prevention.
0 3. Do not add at this time. Antifoulants 1 Surfactants Oil, grease & solids depositing prevention.
Anticavitation Polymer Cavitation protection, interferes with bubbles.

DCA4 Service Requirements

STOP.E AT TEMPERA Tl1t.5

N CA YC.;N./FRiE7FPCANT re, (E. P.:0 Below 0.3 Replace service filter and add 1 litre of DCA4
25% 33% 40% 50+x, 60% per 32 litres of coolant. (kit inst.)
111 Note: Alternatively, if coolant approaching Maximum Service
4 strip pack Lite, dump the system and refill with new Compleat 50 Premixed.
CC2602AM

50 strip pack 0.3 to 0.8 Continue to replace service coolant filter or

CC2602M add liquid DCA4 service dose at each oil drain
interval.

Aboye 0.8 Do not replace service filter or add DCA4 liquid

until the concentration falls below 0.8 units per
litre. Test at every subsequent oil drain interval.
level fans below 0.8 units per litre.

Maintenance Intervals for Coolínq Systems up to 76 litres. Maintenance Intervals for Cooling Systems aboye 76 litres.
Instan service filter(s) and lor liquid containing number of SCA Instan service filter(s) and lor liquid containing number of SCA
units below units below

Service System Size in Litres System Size in Litres

Kilometirtterva I Hours 4 - 19 19 - 38 42 - 57 60 - 76
Interval 76 -144 117 - 189 193 - 284 288 -378 382 - 568
Hours
16001 - 24000 251 - 375 2 4 6 8 751-1000 25 50 80 100 150
0- 16000 Hours 0- 250 2 2 4 6 Hour;
501 - 750 20 35 60 75 110
251 - 500 15 25 40 50 75
0 - 250 10 15 20 25 40

Starting out on the high side GREATER SAFETY MARGIN

Example: Hose breaks, coolant Ioss, top-up with

water only ADDITIVE PACKAGE DILUTED

DCA4 Service Filters: DCA4 LIQUID

Litres SCA units
max.
Part No. SCA Units Part No.
WF2070 2
WF2071 4 DCA60L 0.47 L 5

WF2072 6 DCA65L 1.89 L 20

ideal
WF2073 8 DCA70L 3.78 L 40

WF2074 12 DCA75L 18.9 L 200 min.

WF2075 15 DCA80L 208 L 2200

WF2076 23
WF2077 wlo SCA's 20,000 klms (250 hrs) oil change intervals - max life 385,000 klms. (6,000 hrs1

To adjust system at any time to maximum 0.8

DCA4 additive level
Pro Itfb, Ma Ieesm T17 i8 rharf will Mentlrr rhe aewwnt or D4A4^ . rtgwrrerl tn
Iba tu ,star DCA4T be 8.erl ta xfik»e 0.0 1, elther relertlne t^e arre« R7
c réon L^ l t'.\ AN+. llgwlA DI 14r er mnrWutlen et MM
0.6 0.7
+$3
~nao

0.1 0.3
Pre mis
gusta at
0.4 0.7
- tal
tAlnimom
»
Leeel
«XILM OrAS'e;;e 04
STMM ADDITIOICAL DCA4'" 1'0 BE ADDED TO SYSTFM.
CAII~
100 Litem 6,0 Litro 5.0 Litro 4.0 Litros 2.0 l.ite ' 1.0 Litro No A,tion.
ADDI'TIO.L »C.A4+'»TO B[A01..18YO blS E.M.
90 LLitro. Litrrh 4.5 Litro 3.6 Litrt-s 1.0 Llrrc3 U.) rres 1n 3t'tirin IO@11lseii 6.0 l.iue» 5.0 liuv, 4.0 1.1,7. 2.01.i, 1.01.0.4 N+ SsAon 111 Sr")ll,.Itl t><n`f
5.3
4B Itlttar. t.SIIll!A 3,111urx 1.8 1I{rr.. 0.91.Ihry \'o,ktloe x;s l '
Ulib
so ita; 4.8 4.0 Litrr. 3.2Litro 1.6 Litros 0,K litro W) A titfn
i.h I. hrt+! 0.0 lllrr8 2 lltrrs 1.1lllrrs 0. Miro. NoAoli. w szu7e .qe»I t. l0.40.áUx^
1rr3011 1 1
i
1. ,1 7itrc:^ 07 Litros 1r+,1ctiun 11T»7 84
`0 Lít>, I.,1,irrr 1.51 Inri, 2.8 Litrr. r0 Liba 1.2 lllrrs 1.51,ilta 2.0 Miss 1:i litro. 0.7 Giro. Nn..18 ■o »T1078 ee
íbIllrts 3.0 ltlrry '_i II, 1,21 Ore. n' Ylo4 e .4
í."21,ioT,: 0.6 Litro No . 684~ V.6 Mir s tin Artkn OTI075 I.f
60 Litro i.tl.lilrr 3,0 Litro 1. Litrrs wrio7e
1S
1IUnes 2.51.lncs I.S iA
,Litros ?.01hrcs 1.0 Duo; 0.5iLn1 No.ulli. ll' rin1T +.»tale. »u IH:Ai' r
50 lbxo, 3.0 Litro L5 i ',-. 2.0. litro 1.0llitro 0.5-Litro No .kcli*:oi
01~;: 1.1LOrcs 2.0 tices t.6 litrcs 0A1itrc1 0,11.ilre» ha U . 1,n
No.. Actioti al•.'• IKOI , ^
40 Li~ 2.11.itrt 2.0 Gires 1.6 Litro OS Litro . 0.4 litro . . 1Ca 1.8 tito, 1.5 Lato, i I.ilit^I O.iíIitn•. 11.3 litrts No T.kxta t'^1$
f I^rot, I.1. J.hrrA I. Gin, A.MOtros 0.411ms O..ir, \n,Nthln IN:.Láít 1.0 30
30 mores 1.0 Litro 1.5 Litro 1.' Litro 0.6 t.iire4 -0 3 Vitro Ariíor1 DLl Tet (.0 a0
'O.b l.íires 0.5 Un, 0.4itv1. A.tIlvcs 0.iUnn \0áoioo M..7st 1).0 l0A
U.? Litro No.Attil)11 UC.1081 lnn,n 111M
20 Ubres 1.Z Litro 1.11 Litrüs 0.8 Litro 0.4 Litro
t,^a °CiY Y 1 ';tF'
10 O.(' Litro 0.5 lilas 0,4 Litrrs 0,2 l.it,s 41,1 Litro No A.etíttiy

o Consumer Price Index

1980
o UP ó0% 1997
❑
o
o
❑
❑
o 1997
U

❑
1980
Freight rate DOWN 20%
o
L1 top 150 Fleets in
NA in 1980 ....only 18 still
operating

0 o --- -
o CRITICAL TO GAINING MAXIMUM LIFE
❑
•• 7th July 1999
o FROM ANY COOLANT IS:
❑❑
Nth Arnerica o
o
o ó • Use Coolant Analysis Strips or Lab Testing to
❑ evaluate maintenance practices and determine
ó
0
Con-way Transport (part of Consolidated Freightways)
o coolant life.
ó 8,000 class 7 & 8 trucks
o aó • Long Life and Extended Service Interval Coolants
o Ruan Leasing
o
are available for increased engine protection.
ó *Life of TEC 50 in normal circumstances is 380K klms.
ó 12,000 class 7 & 8 trucks o
ó ó * Life of XL Coolant is 750K klms and beyond
• ó
❑ American Freightways depending on condemnation test results ie. chlorides,
sulfate, pH. ( kit CC2608 25's CC2607B singles )
ó 5,000 class 8 trucks. o❑

o
o
o CRITICAL TO GAINING MAXIMUM LIFE XL COOLANT is 0.7
o
o FROM ANY COOLANT STOFE AT TEMPERAR.» S... F 132 ' C¡,

o C..YCOL.,íREP.P0,1T (^G:? (E. PA.

o 5% 33% 40% 50'4 60%

■■
o
• • Control of system top-off is KEY.
4 strip pack
CC2602AM

o 50 strip pack
o CC2602M
o
ó • As minimum use Fully Formulated Coolant to
❑ TMC and ASTM standards.
o • Replace depleted chemicals through slow
oo release additives filter or liquid additive.
o
o
o

g XL COOLANT XL 000LANT extended service coolant

o Liner pitting protection units/litre
H. FILTER ADDITIVE SERVICE:
o 0.8 max.
ó •Each 250,000 klms or 4,000 hrs or 1 year, install u 0.7
■ XL COOLANT
s XLF4242 slow release chemical filter for up to 60 n 0.6

❑Itrs cooling system capacity. 0.5

t
s 0.4
❑ OR
0.3
0.2
• add XL Booster -750 mis per 60 ltrs. 0.1
o 125 mis. per 10 ltrs.
o 12.5mis. per 1 ltr 250,000 klms, 4K hrs or 1 year
I.J

x L COOLANT extended service coolant XL COOLANT extended service coolant

Liner pitting protection units/litre Liner pitting protection units/Iítre

max. 0.8
u 0.7

0.6

0.5
Replace XWF 4242 0.5 2nd option ^ XL Boo ter 1x
750ml bo tle for
XL Coolant + XWF4242 • 0.4 XL COOLANT ONLY every 60 rs of
slow release filter system c pacity
0.3 min. 0.3
0.2 0.2

0.1 o. i

250,000 kims, 4K hrs or 1 year 250,000 kims, 4K hrs or 1 year

XL fltters Slow Ralease Chemicals

Variable thickness non-soluble permeable
StrataPore Media coatings provide graduated slow chemical Coolant Chemical
-Increased Efficiency & Capacity release. Goes In , Comes Out
-Oil Removal Properties
Clumping of pellets further siows full release. Coating
-Increased Durability Remains
CD
Slow Chemical Release THE PELLETS IN THE CENTRE
-Through diffusion and coating technology
OF BUNCH ARE LAST TO
•Optimum performance during the interval
RELEASE.
Robust filter design
- for long lile Coolant flow does not pass through or over
the pellets.
• Non-chemical Filters are available: Diffusion (tendency of chemicais to move from ateas
• For use with XL BOOSTER or other coolant products. XL Filters are available for a of high concentration to orea oflower concentration) drives
hroad range of engine applications. chemical release through small orifice finto coolant and
not coolant flow.

o
XL Filters 5 to 10 times longer service XL COOLANT
improved
Program Start Up
GASKET, more Thicker gasket o
RETAINER
chemical and ó • Fill system with XL COOLANT
heat resistant. ❑
Hydrogenated
nitrile (HNBA)
Thicker NUTPLATE
ó • Install XWF4242 slow release filter
❑
double screen
rl
polypropylene
o
StataPore MEDIA • Top-off any lost coolant with XL COOLANT only.
❑
❑
thicker SHELL
• Replace XWF4242 filter every 250,000 kims, 4,000 hrs or
zinc rñ each year.
dichromate
plaslic spring
plated
PROTECTOR CI
SPRING Where no filter fitted, add XL BOOSTER for each 60
litres of system capacity at this time.


o
o
o
o CUMMINS understanding of COOLANT Long Life only becomes relevantin
o LIFE ó systems with little coolant loss.
o o ie. Zero to 20% loss of system volume each year.
o
o Not a real issue with most
o ❑
o CUMMIN'S coolant product life at low coolant loss
o customers because of •
o
o
COOLANT LOSS. * TEC 50...380,000 klms or 6,000 hrs.
❑
❑ * Typically the total system is turned over XL Coolant....750,000 kims or 12,000 hrs.
❑ about once every 12 months. o
o
u o
o
o

Q
❑ XL CUSTOMER QUALIFICATION o Southwest Research
•❑ o
o Institute
Good Candidate for ESI Program.... o
o o October 1997
* Control of cooling system top-up. ASTM D 4985 test
u u procedure D2809
* Low coolant loss o
o aluminium water
o • Poor Candidate for ESI Program pump cavitation test
u
* Little control of top-up
o poolant : Texaco HD OAT Long life with Nitrite
o * High coolant loss
lating: Scale of 1 to 10
o Best method here is to stay with the ❑ Minimum acceptable is 8 after 100 hrs running.
a TEC 50 with the addition of DCA4 filter
❑ each oil drain. lesult: Score 1. Pump failed at 39.5 hrs.
o
o o

10
 3 FUNCTIONS of DIESEL FUEL
DIESEL FUEL SYSTEM
D Fuel Tank/s .ECTOR

O Fuel Unes PUMP

0 Fuel Filter/s
El Fuel Pump
El Supplies energy to the engine
FILTER
L TANh

Cools
El Injectors
80-90% of fuel on some systems is scavenged through
injectors to remove heat from injector tips.
O Lubricates precision parts
Closer tolerances around 10 microns and less needed
to achieve injection pressures now approaching 30,000
psi (Cummins Signature 28,000 psi)

WHY FILTRATION
OBJECTIVE

V Remove dirt and other

contaminants reducing
FILTER
L TALAN

component wear and allow

optimum fuel atomization.

NEW NOZZLE TIP SPRAY HOLES

0 Filter located between tank and Note: background shot is cross section through holes.
pump
0 Typically 6-8 thousandths inch in diameter.
Note partial vacuum on dirty side
O Note sharp edges
of media and solid fuel column in
centretube results in partially filled Ii Maintaining diameter and length is critica) for proper fuel
fiter when removed. injection.

DIRT&WATER
FUEL SYSTEM
ENEMIES

POOR MAINTENANCE 3500 Hrs.

NOZZLE TIP AT 5000 Hrs. L Note wear on spray holes from abrasive erosion
causing a change in the effective orifice size.
C Properly maintained with good filtration
El' Can result in over-fueling of the cylinder causing fuel
(Z Note, sharp edges are still intact. deposits, increased wear, and reduced fuel economy.


Finer Filtration Reduces Wear NOZZLE DAMAGE FROM

WATER IN FUEL
Significantly 0 Tip exposed to water in
fuel.
SLA Evaluation: Filtration Effects on Injector 0 Water "flashes" when
Degradation
exposed to high temperature
causing rapid increase in
ó pressure - thus blowing off the
0.4
1á0.3E --I
injector tip.

a0.2—-
.
0
15
o EL
untilered 25 rricron 10 nicron
0 Lubricity qualities of the fuel can be reduced sufficiently
to cause wear. One tea spoon of water to each litre of fuel
is all it takes.

Rust on filter components is evidence of water present.

MICRO-ORGANISM CONTAMINATION
BEST PLACE TO
D Water and diesel fuel can START CONTAMINANT
breed "bugs" and plug filters
REMOVAL
1 They can only live at fuel
water interface - living in the iMtUSTIBLE UQ0111 l
water and feeding off the
fuel.
Detection is also made via
strong, unpleasant., sulfuric
odour which masks normal
diesel fuel odour.

O Cure is to use FS (filter water separators, keep storage

tanks regularly drained, and treat with biocide.

% ASPHALTINES
Black tarry, hard, brittle
chains of long molecules

0 20 to 30 grams will plug FS1000 filter

0 8" to 10" Hg is considered plugged on
hydromechanical fuel system. (1 Hg =1/2 psi)
[51 16" to 18" Hg plugged on electronic fuel system
Tar like material forms with temperature increase,
compounded further with increasing fuel flow to tank.
M11/N14 Cummins 340 LPH
Signature 600 Cummins 586 LPH

2
 Injector Protector
Dual pleat pack
Coalescer plus filter
pleated media in one
cartridge element
FS 1201.

Wax Plugging
O As temperature approaches
zero, paraffin wax in diesel fuel
begins to solidify (cloud point)
and can plug filters.
O Fuel warmers can be installed as shown here on the Fibrecoat 3 mono element filters plus
FS1242, Also fuel can be warmed by warm coolant or return strips the water. Composite glass/cellulose
to tank fuel "thermoblend". media silicone treated.

OPUGUarIITM
D Top load no drain or prime
Three elements 10 um with
housing, also avail 25 um and 2—'-
um for Caterpillar.
El Meets Cummins,Detroit and
Caterpillar micron ratings INJECTOR

0
L TANK

FH23000 Light weight

tough construction
Up to 3 times the filter life of
conventional filters
ELEMENTS
FS19557 (10um) supplied with housing
90 GPH system (M11/N14) up to 120K klm
155 GPH systems (ISX/Sig600) up to 80K klm
FS19559 (25um) Longer life for poor fuel.
FS1020 Cat (2um) up to 48K klms
FS1011 (10um) 90 GPH systems only 80K klms
FS1021 (10um) 90 GPH systems only 80K klms
Metal ball valve

FS1010

Obsolete
drain
valve
Metal
drain
valve
Non return
valve
Throat in body
Thank you

FH23000