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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TM
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