Also read our AMSOIL Dealer training technical document on filtration

56 Pages·2010·0.89 MB·English

Dealer Training Series
Filtration Fundamentals
A Technical Introduction to Air and Fluid Filtration | Presented by AMSOIL INC.
Table of Contents
Introduc(cid:415) on to Filtra(cid:415) on
Filters & Why They are Important ............................................................................................5
Filtra(cid:415) on Performance .............................................................................................................5
Common Contaminants and Their E(cid:299) ects ...............................................................................6
Contaminant Size .....................................................................................................................7
Flow vs. E(cid:312) ciency Compromise ...............................................................................................8
Filter Media Types ....................................................................................................................8
Air Filtra(cid:415) on
The Importance of Air Filters .................................................................................................15
Stoichiometric Ra(cid:415) o ...............................................................................................................15
Air Filter Media ......................................................................................................................15
Air Filtra(cid:415) on Mechanisms ......................................................................................................15
Air Flow and Filter Performance ............................................................................................18
AMSOIL Ea Air Filters .............................................................................................................20
Signs of Air Filtra(cid:415) on Problems ..............................................................................................22
Industry-Accepted Standards for the Evalua(cid:415) on of Air Filters ...............................................22
Oil Filtra(cid:415) on
The Importance of Oil Filters .................................................................................................27
Superior Filtra(cid:415) on: Worth the Price? .....................................................................................27
Oil Circula(cid:415) on System Basics .................................................................................................28
Types of Oil Filtra(cid:415) on Systems ...............................................................................................32
AMSOIL Ea Full-Flow Oil Filters ..............................................................................................33
AMSOIL Ea Spin-on Oil Filter Construc(cid:415) on ............................................................................34
By-Pass Filtra(cid:415) on ....................................................................................................................35
AMSOIL Ea By-Pass Filters ......................................................................................................38
Oil Filtra(cid:415) on E(cid:312) ciency Terms .................................................................................................40
Beta Ra(cid:415) os & Filter E(cid:312) ciencies ..............................................................................................41
What does Ea Mean? .............................................................................................................41
Industry-Accepted Standards for the Evalua(cid:415) on of Oil Filters ...............................................42
Filter Lookup Resources .........................................................................................................43
Oil Filtra(cid:415) on Tips ....................................................................................................................44
Appendix
Major Causes of Premature Bearing Failure Chart .................................................................48
E(cid:299) ects of Wear Due to Par(cid:415) cle Size Graph ............................................................................49
Frac(cid:415) onal E(cid:312) ciency of Nano(cid:302) ber Layers Compared to Cellulose Engine Air Media .............50
Beta Ra(cid:415) o - Capture E(cid:312) ciency Chart .....................................................................................51
Sub-Micron Time-Weighted Average E(cid:312) ciency Graph ..........................................................52
AMSOIL Ea Oil Filters E(cid:312) ciency Graph ...................................................................................53

4
Filtration Fundamentals: Section 1
Introduction to Filtration
Introduction
This course has been designed as a technical introduc(cid:415) on to the basic
principles of air and (cid:327) uid (cid:302) ltra(cid:415) on and the various methods used to
control contaminants within (cid:302) ltra(cid:415) on systems. It is ideal for those who
service or maintain mechanical equipment, and those who market AMSOIL
products.
The material for this course is divided into three sec(cid:415) ons: the de(cid:302) ni(cid:415) on of
a (cid:302) lter, common contaminants and their e(cid:299) ects and types of media used in
both air and (cid:327) uid (cid:302) ltra(cid:415) on. The second and third sec(cid:415) ons discuss air and
(cid:327) uid (cid:302) ltra(cid:415) on respec(cid:415) vely, and go into greater detail on each topic.
Section Objectives
A(cid:332) er studying Sec(cid:415) on 1, you should understand and be able to explain the
following terms and concepts:
1. The func(cid:415) on of a (cid:302) lter
2. E(cid:299) ects of unchecked contaminants in air and (cid:327) uid systems
3. Three main (cid:302) lter characteris(cid:415) cs
4. Three main contaminants and how they a(cid:299) ect lubrica(cid:415) on systems
5. Range of contaminant sizes and the contaminant size of greatest
concern
6. Flow vs. E(cid:312) ciency Compromise and methods to minimize it
7. Seven (cid:302) lter medias and their applica(cid:415) ons (air, oil or both)
Section Keywords
The following keywords are de(cid:302) ned in this sec(cid:415) on. Pay par(cid:415) cular a(cid:425) en(cid:415) on
to their explana(cid:415) ons as these concepts will serve as building blocks for
future lessons.
Absolute E(cid:312) ciency
Beta Ra(cid:415) o
Capacity
Cellulose Media
E(cid:312) ciency
Filter
Flow
Foam Filtra(cid:415) on Media
Full-Synthe(cid:415) c Media
Flow vs. E(cid:312) ciency Compromise
Large Par(cid:415) cles
Medium Par(cid:415) cles
Micron
Nano(cid:302) ber
Small Par(cid:415) cles
Synthe(cid:415) c Nano(cid:302) ber Media
Typical Full-Flow Filter E(cid:312) ciency
We(cid:425) ed-Gauze Media
Wire-Screen Filter Media
Filtration Fundamentals: Introduction to Filtration
5
Filters & Why They are Important Filters & Why
They are
Important
A (cid:302)(cid:3)(cid:367)(cid:410)(cid:286)(cid:396) is a porous membrane
that gas or liquid is passed Filtration
through in order to separate out Performance
1
ma(cid:425) er in suspension. In vehicular
n
applica(cid:415) ons, this ma(cid:425) er is dirt, dust,
o
contaminants or par(cid:415) culates, all i
t
the same and all detrimental to air c
e
and (cid:327) uid systems if le(cid:332) unchecked.
S
Proper (cid:302) ltra(cid:415) on results in two
overall bene(cid:302) ts: it ensures the
equipment has a sa(cid:415) sfactory service
life and maintains the equipment’s
performance.
Filters are crucial in automo(cid:415) ve applica(cid:415) ons because they remove
contaminants that enter mechanical and lubrica(cid:415) on systems. Without
proper (cid:302) ltra(cid:415) on, these contaminants would create signi(cid:302) cant damage to
mechanical components. Contaminants, such as dirt and silicon par(cid:415) cles,
can be introduced from the environment or can be by-products of
equipment opera(cid:415) on. If le(cid:332) uncontrolled, these contaminants can cause
accelerated wear on engine components and reduce equipment e(cid:312) ciency.
From a systems standpoint, (cid:302) ltra(cid:415) on can be divided into two major types:
air and (cid:327) uid. Both are important and serve speci(cid:302) c func(cid:415) ons necessary to
maintain vehicle cleanliness and e(cid:312) ciency.
Filtration Performance
A good (cid:302) lter is designed to perform well in a number of areas. When
choosing an air or oil (cid:302) lter, three main (cid:302) lter characteris(cid:415) cs should be
considered.
The (cid:302) rst of these is (cid:327)(cid:3)(cid:381)(cid:449). The (cid:302) lter must have the ability to (cid:327) ow an
adequate amount of air or liquid for normal applica(cid:415) on opera(cid:415) on.
The second considera(cid:415) on is the usable (cid:272)(cid:258)(cid:393)(cid:258)(cid:272)(cid:349)(cid:410)(cid:455) of the (cid:302) lter. The (cid:302) lter must
have adequate contaminant-holding capacity to remain in service for an
acceptable period of (cid:415) me.
Finally, a (cid:302) lter’s (cid:286)(cid:312)(cid:3)(cid:3)(cid:272)(cid:349)(cid:286)(cid:374)(cid:272)(cid:455) refers to its ability to adequately remove
contaminants of a size cri(cid:415) cal for the applica(cid:415) on.
When considering (cid:302) lter performance, remember the (cid:327)(cid:3)(cid:381)(cid:449)(cid:3)(cid:448)(cid:400)(cid:856)(cid:3)(cid:286)(cid:312)(cid:3)(cid:3)(cid:272)(cid:349)(cid:286)(cid:374)(cid:272)(cid:455)(cid:3)
(cid:272)(cid:381)(cid:373)(cid:393)(cid:396)(cid:381)(cid:373)(cid:349)(cid:400)(cid:286). A (cid:302) lter that is very open and free-(cid:327) owing will generally have
poor par(cid:415) cle removal e(cid:312) ciency. Conversely, if a (cid:302) lter has excellent small-
par(cid:415) cle removal e(cid:312) ciency it will generally be more resistant to (cid:327) ow and
have a rela(cid:415) vely short life expectancy.
AMSOIL Ea Filters employ a number of mechanisms to mi(cid:415) gate the (cid:327) ow
vs. e(cid:312) ciency compromise, including specialized design techniques and
sophis(cid:415) cated materials and (cid:302) lter media. These specialized techniques and
media types are discussed further in Sec(cid:415) ons 2 and 3.
Filtration Fundamentals: Introduction to Filtration
6
Common Common Contaminants and Their Eff ects
Contaminants and
Their Effects
Solid Matter (air & oil)
According to a study published by the Society of Automo(cid:415) ve Engineers
(SAE), approximately 400 tons of solid material is suspended in every
cubic mile of air over a city. Even more solid ma(cid:425) er is suspended over
agricultural areas during certain (cid:415) mes of the year. Of this solid ma(cid:425) er,
a signi(cid:302) cant por(cid:415) on is airborne dirt and dust. The dirt and dust found
naturally within the
environment is of greatest
concern due to its abrasive
nature.
Uncontrolled inges(cid:415) on and
circula(cid:415) on of air-bound
abrasive material can
reduce the life expectancy
of an internal combus(cid:415) on
engine by as much as 60 to
80 percent, which is why
(cid:302) ltra(cid:415) on is so crucial to
Figure 1.1
Solid matter from the environment can reduce the life engine and component life.
expectancy of an internal combustion engine by 60 to 80
The minute par(cid:415) cles found
percent.
naturally in the environment
can signi(cid:302) cantly increase wear to engine components, ul(cid:415) mately limi(cid:415) ng
the engine’s opera(cid:415) ng life.
In four-cycle engines, dirt and dust contamina(cid:415) on can result in valve-guide
wear. Dirt and dust that reaches the combus(cid:415) on chamber can increase
piston and ring wear and damage the cylinder liner. These par(cid:415) cles are
eventually carried by the oil to other engine components such as bearings,
cranksha(cid:332) s and camsha(cid:332) s.
Figure 1.2
Almost half of all bearing failures can be attributed to dirt.
Water (air & oil)
Water accounts for up to 4 percent of the air. When condi(cid:415) ons are right,
that water condenses into liquid form and enters lubrica(cid:415) on systems. The
e(cid:299) ects can be catastrophic. Water reduces oil’s ability to lubricate and
can combine with other molecules to cause chemical reac(cid:415) ons that form
corrosive compounds and acids. Most recognizably, water promotes the
forma(cid:415) on of rust, increasing the poten(cid:415) al for harmful rust contamina(cid:415) on
to develop within the system.
Filtration Fundamentals: Introduction to Filtration
7
Soot (air & oil) Contaminant Size
Soot is a (cid:302) ne, dark powder that results from incomplete combus(cid:415) on.
Modern engines are designed to capture soot in the oil; while electronic
controls and high injec(cid:415) on pressures have signi(cid:302) cantly reduced the levels
of soot produced during combus(cid:415) on, it remains an impurity that must be
1
managed within the lubrica(cid:415) on system.

n
o
As soot levels increase within the crankcase, the e(cid:299) ec(cid:415) veness of the
i
t
lubricant’s dispersant addi(cid:415) ve is reduced, causing the soot to cluster into c
larger par(cid:415) cles that increase wear to cri(cid:415) cal components. e
S
Contaminant Size
Contaminants suspended in air or (cid:327) uid can be very small. To grasp just how
small these par(cid:415) cles are, an understanding of the measurements involved
in their classi(cid:302) ca(cid:415) on is necessary.
Figure 1.3
The size of nano(cid:191) bers is equal to one millionth of a meter -
smaller than the diameter of a human hair.
A (cid:373)(cid:349)(cid:272)(cid:396)(cid:381)(cid:374)(cid:3)((cid:1106)), or micrometer, is a very small unit of linear measurement
equal to one millionth of a meter, or .00000039 inches. To get an idea
of the sizes that micron measurements relate to, consider the following
examples:
• The diameter of a human hair is 50 to 100 (cid:1106)
• The smallest par(cid:415) cle visible without magni(cid:302) ca(cid:415) on is 40 (cid:1106)
(cid:62)(cid:258)(cid:396)(cid:336)(cid:286)(cid:3)(cid:393)(cid:258)(cid:396)(cid:415)(cid:3)(cid:272)(cid:367)(cid:286)(cid:400), which measure 0.5” or larger, pose only a small threat to
lubrica(cid:415) on systems because they are easily (cid:302) ltered out from the intake air
stream.
(cid:68)(cid:286)(cid:282)(cid:349)(cid:437)(cid:373)(cid:3)(cid:393)(cid:258)(cid:396)(cid:415)(cid:3)(cid:272)(cid:367)(cid:286)(cid:400), which measure 25 (cid:1106) to 0.5,” are more di(cid:312) cult to (cid:302) lter
from the air stream and are of greater concern. However, the threat of
medium par(cid:415) cles is diminished because they are larger than many of the
Filtration Fundamentals: Introduction to Filtration
8
Flow vs. clearances within an engine. Their size prevents them from entering the
Effi ciency
contact areas between many components and limits their ability to cause
Compromise
accelerated wear.
Filter Media Types
(cid:94)(cid:373)(cid:258)(cid:367)(cid:367)(cid:3)(cid:393)(cid:258)(cid:396)(cid:415)(cid:3)(cid:272)(cid:367)(cid:286)(cid:400), those in the 5 - 25 (cid:1106) range, are the cause for greatest
concern because their size allows them penetrate the clearances between
wear-sensi(cid:415) ve components. Once these small par(cid:415) cles become lodged
in the gaps between components, contact occurs and results in increased
fric(cid:415) on and wear. The size of these par(cid:415) cles makes them par(cid:415) cularly
di(cid:312) cult to remove from the lubrica(cid:415) ng system.
Par(cid:415) cles smaller than 5 (cid:1106), in general, can be suspended safely within the
oil (cid:302) lm and pose li(cid:425) le threat.
Figure 1.4
Particle size effects on wear. (Courtesy of MANN+HUMMEL)
Flow vs. Effi ciency Compromise
The(cid:3)(cid:327)(cid:3)(cid:381)(cid:449)(cid:3)(cid:448)(cid:400)(cid:856)(cid:3)(cid:286)(cid:312)(cid:3)(cid:3)(cid:272)(cid:349)(cid:286)(cid:374)(cid:272)(cid:455)(cid:3)(cid:272)(cid:381)(cid:373)(cid:393)(cid:396)(cid:381)(cid:373)(cid:349)(cid:400)(cid:286) refers to the converse rela(cid:415) onship of
(cid:327) ow and e(cid:312) ciency and how it e(cid:299) ects (cid:302) lter media density. As the density of
(cid:302) lter media increases to improve e(cid:312) ciency, the ability of air or (cid:327) uid to (cid:327) ow
through the media is diminished.
The (cid:327) ow vs. e(cid:312) ciency compromise presents a challenge for (cid:302) lter
engineers. Filter e(cid:312) ciency can be improved by increasing media density;
however, media that is too dense restricts (cid:327) ow and does not provide
adequate amounts of air or liquid for op(cid:415) mum performance.
One common method of mi(cid:415) ga(cid:415) ng the e(cid:299) ects of the (cid:327) ow vs. e(cid:312) ciency
compromise is increasing the (cid:302) ltra(cid:415) on surface area by folding or plea(cid:415) ng
the media.
Filter Media Types
This sec(cid:415) on covers the various types of (cid:302) lter media; some of which are
used in both air and oil applica(cid:415) ons, while others are best-suited to one
applica(cid:415) on or the other.
Common types of air (cid:302) ltra(cid:415) on media include cellulose, we(cid:425) ed-gauze,
Filtration Fundamentals: Introduction to Filtration
9
nano(cid:302) ber, open-celled foam and synthe(cid:415) c (cid:302) bers.
Common types of oil (cid:302) ltra(cid:415) on media include cellulose, cellulose/synthe(cid:415) c
blend, wire screen and full synthe(cid:415) c.
1
Cellulose Media (air & fl uid)

n
(cid:18)(cid:286)(cid:367)(cid:367)(cid:437)(cid:367)(cid:381)(cid:400)(cid:286)(cid:3)(cid:373)(cid:286)(cid:282)(cid:349)(cid:258) is a natural media derived from plant (cid:302) bers. The (cid:302) bers
o
are rough in texture and vary in size and shape. Cellulose (cid:302) bers are
i
t
typically heat-cured and mixed c
with resins to increase s(cid:415) (cid:299) ness. e
S
Cellulose media has been used
for many years and is employed
in the majority of (cid:302) lters in the
market. Its performance varies
depending on processing and
the type and amount of resin
used to bind the (cid:302) bers. Filters
produced with cellulose media
are usually designed to meet
Figure 1.5 original equipment manufacturer’s
Cellulose (cid:191) bers made from plant materials
(OEM) requirements and provide
adequate performance.
Cellulose/Synthetic Blend Media (fl uid)
Cellulose/synthe(cid:415) c blend media typically consists of cellulose (cid:302) bers
combined with high amounts of bonding resins and various amounts of
glass or polymeric (cid:302) bers. Cellulose/synthe(cid:415) c media (cid:302) lters normally provide
be(cid:425) er e(cid:312) ciency and capacity than cellulose media (cid:302) lters.
Wetted-Gauze Media (air)
(cid:116)(cid:286)(cid:425)(cid:3)(cid:286)(cid:282)(cid:882)(cid:336)(cid:258)(cid:437)(cid:460)(cid:286)(cid:3)(cid:373)(cid:286)(cid:282)(cid:349)(cid:258) is a naturally occurring material o(cid:332) en used in air
(cid:302) lters. We(cid:425) ed-gauze (cid:302) lters are composed of layered co(cid:425) on (cid:302) bers we(cid:425) ed
with a tacking oil to trap contaminants. This media is usually employed in
high-performance (cid:302) lters where high air(cid:327) ow is required; however, (cid:302) ltering
e(cid:312) ciency is generally compromised. We(cid:425) ed-gauze (cid:302) lters require repeated
cycles of washing and re-oiling, which can reduce their e(cid:299) ec(cid:415) veness.
Synthetic Nanofi ber Media (air)
Polymeric refers to a chemical process that creates a structure of repea(cid:415) ng
molecular elements. (cid:69)(cid:258)(cid:374)(cid:381)(cid:302)(cid:3)(cid:271)(cid:286)(cid:396)
is a term used to describe (cid:302) bers
with a diameter less than 1 (cid:1106).
The consistent structure and
small size of polymeric nano(cid:302) bers
enable high e(cid:312) ciencies. Recently,
(cid:400)(cid:455)(cid:374)(cid:410)(cid:346)(cid:286)(cid:415)(cid:3)(cid:272)(cid:3)(cid:374)(cid:258)(cid:374)(cid:381)(cid:302)(cid:3)(cid:271)(cid:286)(cid:396)(cid:3)(cid:373)(cid:286)(cid:282)(cid:349)(cid:258)
has been used in conjunc(cid:415) on
with cellulose media to create
a composite, high-e(cid:312) ciency
Figure 1.6 (cid:302) lter. The combina(cid:415) on features
Synthetic nano(cid:191) bers on cellulose media
cellulose media covered by a thin
layer of polymeric nano(cid:302) bers to
increase e(cid:312) ciency with minimal impact to air(cid:327) ow. Filters produced with
synthe(cid:415) c nano(cid:302) bers on cellulose ‘composite’ media can be cleaned using
compressed air or a vacuum.
Filtration Fundamentals: Introduction to Filtration
10
Foam Filter Media (air)
Foam (cid:302) lter media has been available for many years, mainly for use in
smaller engines; however, it has also been successfully used in automobile,
powersports and large-truck
applica(cid:415) ons. (cid:38)(cid:381)(cid:258)(cid:373)(cid:3)(cid:302)(cid:3)(cid:367)(cid:410)(cid:396)(cid:258)(cid:415)(cid:3)(cid:381)(cid:374)(cid:3)
(cid:373)(cid:286)(cid:282)(cid:349)(cid:258) is generally re(cid:415) culated
(open cell) foam made of polyester
or polyether/polyurethane
material. Pore size is controlled
and ranges from 10 pores per
inch (PPI) to 80 PPI depending on
intended applica(cid:415) on.
Foam media is heat resistant
Figure 1.7
to 455°F (235°C), and with void
Open-celled foam media
space making up 97 percent of the
media, air(cid:327) ow is increased. As with we(cid:425) ed-gauze (cid:302) lters, tack oil applied
to the foam helps capture and retain contaminant par(cid:415) cles. Foam (cid:302) lters
are advantageous in high-dust condi(cid:415) ons because they can be cleaned and
reused.
Full-Synthetic Media (air & fl uid)
(cid:38)(cid:437)(cid:367)(cid:367)(cid:882)(cid:400)(cid:455)(cid:374)(cid:410)(cid:346)(cid:286)(cid:415)(cid:3)(cid:272)(cid:3)(cid:373)(cid:286)(cid:282)(cid:349)(cid:258) is synthesized from polymeric nano(cid:302) ber materials
such as non-woven polyester (cid:302) bers and melt-blown glass (cid:302) bers. It has
high lo(cid:332) , or (cid:327) u(cid:299) , which improves
media thickness and increases
contaminant-holding capacity.
Synthe(cid:415) c (cid:302) bers of di(cid:299) ering
sizes, density and layers can be
engineered with speci(cid:302) c air(cid:327) ow
rates and e(cid:312) ciencies. Many
foreign automobile manufacturers
specify full-synthe(cid:415) c air (cid:302) lters, and
the vast majority of cabin air (cid:302) lters
are constructed with this media
Figure 1.8 type.
Full-synthetic media
In (cid:327) uid applica(cid:415) ons, synthe(cid:415) c (cid:302) bers of various sizes and densi(cid:415) es can be
engineered to control e(cid:312) ciency and oil (cid:327) ow rates. Synthe(cid:415) c media works
well in oil applica(cid:415) ons because it is more resistant to hot oil over a longer
period of (cid:415) me as compared to cellulose and cellulose-blend (cid:302) lters.
Wire-Screen Media (fl uid)
(cid:116)(cid:349)(cid:396)(cid:286)(cid:882)(cid:400)(cid:272)(cid:396)(cid:286)(cid:286)(cid:374)(cid:3)(cid:302)(cid:3)(cid:367)(cid:410)(cid:286)(cid:396)(cid:3)(cid:373)(cid:286)(cid:282)(cid:349)(cid:258)(cid:3)technology has been used for many years in (cid:327) uid
applica(cid:415) ons. It is composed of wire strands that are woven together to
form a resilient, heat-resistant (cid:302) lter that can withstand rou(cid:415) ne cleaning.
Wire screen media can be constructed of aluminum, stainless steel, carbon
steel, brass or copper. Wire (cid:302) lters that depend on the sieving (cid:302) ltra(cid:415) on
mechanism provide capaci(cid:415) es less than those of cellulose, cellulose-blend
and synthe(cid:415) c (cid:302) lter media, and are mainly found in industrial or racing
applica(cid:415) ons.
Filtration Fundamentals: Introduction to Filtration