Diesel Fuel Filtration

Particulate and water removal

solutions for diesel fuel applications
Diesel Fuel Filtration

Introduction Defining Acceptable Fuel Cleanliness Levels

With increasing operating costs (e.g., fuel usage cost, While Diesel fuel cleanliness can vary significantly along the
equipment downtime cost) and strict environmental legislation fuel supply chain, one engine manufacturer defines typical
(e.g., GHG emissions), the mining industry faces difficult incoming fuel cleanliness at a cleanliness level of 22/20/17
challenges when running fleets of large diesel powered per ISO 4406.
engines. To ensure optimum engine performance and reliability, For EUI fuel injection systems, equipment OEMs typically
particulate and water contamination in diesel fuel must be require a fuel cleanliness level of 18/16/13 per ISO 4406.
controlled to acceptable (specification) limits. Standard New HPCR engines require diesel fuel cleanliness levels
on-board fuel filters are not designed to handle high levels as low as 12/9/6 per ISO 4406.
of contamination. Therefore, to prevent premature plugging
and frequent change-outs of on-board filters, fuel cleanliness
should be controlled throughout the entire fuel supply chain.
The Impact of Particulate Contamination
on Diesel Powered Engines
There are three types of engine fuel injection system
failures that can be attributed to the presence of hard,
particulate contamination: ISO 22/20/17 ISO 18/16/13 ISO 12/9/6
• Mechanical failures from component wear and blocking How Dirty is it Really?
component movement
To put this into a more practical perspective, the table below
• Electrical failures (typically as injector solenoid shows the equivalent contaminant mass and water volume that
burnout) from silting around the poppet valve stem, would be pumped in one year for a large mine site using 137,000
restricting movement liters of diesel fuel/day, for various fuel contamination levels.
• Performance failures from blocking of injector nozzles ISO 4406
and altering injector spray patterns 22/20/17 20/18/15 18/16/13 12/9/6
Cleanliness Code
Kilograms of
Diesel Engine Fuel Injector Systems particulate contaminant 800 200 50 0.4
As engine fuel injection technology has progressed, pumped per year
so has its sensitivity to contamination.
Water Content (ppm) 5000 1000 500 100
Electronically Controlled Unit Injectors (EUIs)
Liters of water equivalent
The injector nozzle openings of EUIs are 6-7 µm in diameter. 250,000 50,000 25,000 5,000
pumped per year
These openings can become blocked or suffer erosion from
particulate contamination as diesel fuel is passed through Thus, if 0.5 % (5000 ppm) of the fuel was water, the mine
them at high pressures. Nozzle shape can be changed would pump approximately 250,000 liters of water, equivalent
or spray patterns altered, adversely impacting engine to $200K* worth of fuel.
*based on 80 cents per liter
performance in the form of reduced power output and
poor fuel economy. Diesel Cleanliness – a Site-Wide Investment
High Pressure Common Rail System (HPCR) Diesel fuel cleanliness control must be a site-wide investment
HPCR system technology offers improved power and fuel and managed with advanced particulate and water filtration
efficiency and lower exhaust emissions. To achieve these technologies, from the point of delivery, through storage,
results, HPCR systems operate at pressures in excess of 2000 right up to the dispensing nozzle.
bar and have injector nozzle openings in the 2-3 µm diameter
range. This requires diesel fuel 30 times cleaner than what Supplying equipment with diesel fuel at required
is acceptable for standard EUIs and over 100 times cleaner cleanliness levels will result in a number of
than what is typically dispensed at the pump. This level of significant benefits, including:
cleanliness cannot be attained with on-board filtration alone; • Improved diesel engine performance and reliability
supplementary bulk and point of filling filtration is required. • Improved diesel engine operating costs
• Reduced diesel engine maintenance costs
• Reduced vehicle downtime
• Reduced fuel consumption
• Reduced air pollution

Diesel fuel cleanliness control -

from delivery, to storage, to pump, to injector...
Diesel Fuel Filtration

Filtration Applications and Product Positioning

Fuel Delivery

Main
Storage
Tank
Mobile Surface Fleet
Secondary
Storage Tank

Mobile Fuel Trucks

Shovels and Loaders

Underground
Storage
Underground Fleet Tank

Contamination Control Recommendations

Bulk Fuel Liquid/Liquid Point of Use Mobile Support On-Board Air Breather
Treatment Coalescer Fuel Treatment Fuel Treatment Fuel Treatment Filter
Particulate Free Water Particulate Particulate Particulate Particulate
Filtration Removal Filtration Filtration Filtration Filtration/Water
Basket strainer PhaseSep® Ultipleat Diesel Ultipleat Nylon Depth Ingression
or coarse metal Liquid/Liquid Fuel Filters SRT filters Media Fuel • Filter rating:
mesh strainer coalescer >300 L/min • AP grade Filters 1-3 µm in Air
pre-filtration • JS grade (>80 USgpm) filter medium • Heavy duty • Desiccant
Ultipleat® Diesel or finer • JZ grade or severe duty available in
Fuel filters pre-filtration filter medium grade filter PFD series
• JN or JS grade required Ultipleat medium
filter medium SRT filters
<300 L/min
(<80 USgpm)1
• AP grade
Filter Medium Performance filter medium
Filter Medium Target Downstream
Grade ISO Cleanliness Level2
JS 17/14/11
JN 15/13/08
JZ 14/12/09
AP 14/12/10

Based on typical fluid cleanliness levels; if fuel is adequately pre-filtered, max flow can be increased up to 835 L/min (220 USgpm)
1

Dependent on upstream bulk/point of use/mobile support fuel cleanliness levels

2
Pall Diesel Fuel Filtration Products

Ultipleat Diesel Nylon Depth Media Ultipleat SRT PhaseSep Liquid/Liquid

Fuel Filters Fuel Filters Filters Coalescers
Housing Features Features Housing Features Features
• Designed to ASME Section • Proprietary polymeric • Auto-pull element removal • Unique stacked element
VIII Div. 1 requirements, media with optimized mechanism for easy and design - separator and
with code stamping removal efficiency and fast element removal coalescer in one unit
as an available option dirt capacity for ‘heavy • Cap or head service • Large diameter
• 10 barg (150 psi) pressure duty’ and ‘severe duty’ configurations flouropolymer media;
rated vessels applications performance not impaired
Element Features
• Carbon Steel and 316 • Compatible with • 3" and 6" diameter by the presence of
Stainless Steel options biodiesel fuels Ultipleat (wave-shaped surfactants or fuel additives

• Horizontal and vertical • For fuel flow rates up pleat) filter medium pack • In-to-out flow direction
configurations to 650 litres per hour • Stress Resistant • Wide fluid compatibility
(170 gallons per hour) Technology (SRT) media
Element Features
• Can be configured for for enhanced performance
• 6" diameter Ultipleat
particulate and water under cyclic flow and dirt
(wave-shaped pleat)
control in a single stage loading conditions
filter medium pack
• Available accessories: • Anti-static filtration medium
• In-to-out filter element
- Priming pump • In-to-out filter element
flow path
(manual or electrical) flow path Air Breather Filters
• Coreless element - Diesel fuel heater
configuration for • Coreless element Features
- Water in fuel sensor
environmentally - Pressure sensor/switch configuration for • Optimum protection
friendly disposal - Temperature sensor environmentally against airborne
friendly disposal contamination ingression
into vented fluid systems
• Suitable for flow rates up to
1500 L/min (400 USgpm)

Pall Aeropower Further documentation is available at pall.com/mining

Pall Corporation has offices and plants throughout the world. For Pall representatives
25 Harbor Park Drive in your area, please go to www.pall.com/contact
Port Washington, NY 11050
+1 516 484 3600 telephone Because of technological developments related to the products, systems, and/or
+1 888 333 7255 toll free US services described herein, the data and procedures are subject to change without
notice. Please consult your Pall representative or visit www.pall.com to verify that
this information remains valid. Products in this document may be covered by one
Melbourne - Australia or more of the following patent numbers: EP 0 930 926; US 5,480,547; US 6,332,987;
+61 (0)3 9584 8100 telephone EP 0 667 800; EP 0 982 061; EP 1 380 331; US 5,543,047; US 5,690,765; US 5,725,784;
+61 (0)3 9584 6647 fax US 6,113,784; US 7,083,564; US 7,318,800; EP 0 667 800; EP 0 982 061;
EP 1 380 331; US 5,543,047; US 5,690,765; US 5,725,784; US 6,113,784;
[email protected] US7,083,564; US 7,318,800; EP 1 656 193.
© Copyright 2011, Pall Corporation. Pall, , Phasep and Ultipleat are trademarks of Pall Corporation.
® indicates a trademark registered in the USA.
ENABLING A GREENER FUTURE.SM and Filtration. Separation. Solution.SM are service
marks of Pall Corporation.

IMDFFENb Produced in the UK January 2011