Diesel i202

Contamination Conundrums

Diesel contamination levels: SANS 342(IP400) vs. ISO4406 : 1999 standard for Diesel Fuel

Particle size distribution is an accurate indicator of the REAL contamination danger levels in any fuel sample. This is the standard used by most filtration companies anbed OEM’S.

Measuring particle fuel contamination purely on weight is out dated and blind to what the real contamination levels are. The inherent dangerous composition of particle size distribution in any given batch of diesel may vary drastically and therefore may alter the level of contamination present.

Large contaminants visible to the eye (60 micron) is not problematic, as it is easily filtered, possibly flexing filtration medium will contain the particle and it may lead to longer filtration medium life cycle as well as integrity as it assists in the “caking effect”  of contamination on a filter.

But that one single 60 micron particle can easily be 200 particles between 2-6 microns that simply blocks the filtration medium. This may lead to medium compromise or simply pass through of the normal flexing of the filtration medium. Now contamination is directed straight to the injectors, which would increase wear on the injectors, inevitably leading to failure.
Now this is a catastrophic difference but wouldn’t be detected on weight assessment of contamination as the outcomes are based on equal weight, but the different contaminants would lead to vastly varying results.

Filters block/ compromise easily with in a tenth of their indicated dirt holding capacity. Even if bombarded by only 1- 12 micron particles, as the filter is being plastered, instead of having a “caking effect” on the filtration medium. This sealing effect is fatal for sustainable filtration as the filters simply block and bypass. This phenomenon can accrue within hours from a filter change out.

It is imperative to monitor Fuel cleanliness levels on particle size distribution and the absolute sustainable cleanliness levels at all times. Case studies indicate that modern injector systems damage or even fail on just one contaminated tank.

In today’s world, defining how clean or dirty fuel is, may be critically important and as such, fuel cleanliness levels are now measured and reported according to the ISO Cleanliness Code 4406:1999. The International Organization for Standardization (ISO) created the cleanliness code (ISO4406:1999) to quantify particulate contamination levels per millilitre of fluid at three sizes: 4μ, 6μ, 14μ.

See below test report on the same diesel sample tested:

ISO 4406 – 21/19/16- This contamination level is fatal for a modern common rail injection engine

SANS 342 (IP400) – 4 m/g/kg this is only 16% of allowed contamination of 24 mg/kg.

The Official test result by SANS 342 is that this is clean diesel and passes SANS342, as indicated on report. However the ISO test reveals that the Diesel contamination levels are dangerously high for injector engines.

The end users of this fuel would assume it to be clean by SANS standards, however, this belief may be costly as the fuel is dangerously contaminated as seen through the ISO test results.

Particle size distribution is the aim of the tests for iSO cleanliness codes ISO4406:1999

SANS 342 – 24mg/kg uses mass as a contamination yard stick for measuring diesel fuel contamination.

OIL companies official view on above sample

” the iSO standard is not part of the national standard for diesel (SANS 342:2014) The IP 440 method is the only recognized measure of contamination for diesel sold through the retail segment. The ISO 4406 method that takes particle size distribution into account is not repeatable and the sample method plays a huge role in what readings you get. The 4mg per kg is well within spec and would not cause problems. The analysis report issued fully complies with standard.  Please call me in the morning to discuss this.”

FACTS:

• The SANS 342:2014 is  allowing  24/mg of particle contamination in fuel , this is a huge amount  of particle contamination see below explanation of ISO levels , literally millions of particles – 24 mg/kg is liquid Sandpaper
• ISO patch tests is extremely reliable  and totally repeatable  with similar repeatability as weight tests (SANS 342)
• Both ISO levels and SANS 342 is directly affected by sample methods.
• ISO standards are used in oils.
• ISO standards in Diesel  are widely used in the filtration industry and by OEM’s

OEM View on Warranty, FML or Rental on above sample:
OEM requires ISO 18/16/12 in the fuel tank of equipment, or the warranty, FML or rental is in danger and can result in a huge abuse claim invoice or repair bills.

Client is going to have a repair bill, irrelevant if on Warranty, FML or Rental.

South Africa’s official cleanliness level for fuel on a national standard for diesel is:

(SANS 342:2014)

Total permitted contamination is 24 mg/kg. This has been the official contamination standard for decades, even when we had ADE engines. “This is Liquid sandpaper “

Simple Way of Understanding ISO Cleanliness Codes

ISO Cleanliness codes are sourced from the International Standard of ISO 4406:99.

ISO Codes show 3 sets of separated numbers.

• The first number looks at the amount of particles larger than 4 micron
• The second number looks at the amount of particles larger than 6 micron
• The last number looks at the amount of particles larger than 14 micron

For Example if we get a reading of ISO 21/18/12:

1. In the first number being 21, which looks at particles that are bigger than 4 micron the number of particles we find are between 1,000,000 and 2,000,000 per every 100ml of fuel
2. In the second number being 18, which looks at particles that are bigger than 6 micron the number of particles we find are between 130,000 and 250,000 per every 100ml of fuel
3. In the last and third number being 12, which looks at particles that are bigger than 14 micron the number of particles we find are between 2000 and 3000 per every 100ml of fuel

The table to the right,
Shows us the number of particles you would get per 100ml of fuel which is specified against each number in the micron range. As the above text depicts when the ISO reading of 21/18/12 is explained.

The most Damaging microns are found between the 6-14 range and having a high particle count between this micron range of course causes damage to important parts of your operating machinery such as your injectors, which as we all know are a costly exercise to replace, especially on a truck engine.

Therefore monitoring your fuel and the contamination thereof by using an effective filtration system will ensure longer engine life and of course assist in decreasing your operating costs.

Please note that the human eye can only see particles 60 micron and larger, thus the contamination particles above are not visible to the naked eye.

GAS to liquid ( GTL) clear diesel

This sample shows no visible contamination, thus its clear to the eye.

• BUT see what the YELLOTECH labatory test report says!
• It’s the fuel sample of the fuel analysis report above -ISO 21/19/16
• This highlights the Conundrum faced by the consumer.
  – Fuel suppliers are within the official specification: SANS342, which is the accepted standard.
  – OEM’s can decline warranty, FML or rental on ISO level standards found within the tank, thus showing they mainly reject the SANS342 standard.
  – This leaves the Client liable for payment.

OEM warranties for diesel are mostly based on iSO 4406 Standards minimum of 18/16/13 not based on SANS342 as used by several accredited labs to only complying with fuel industry legislation specification of 24mg/kg for a PASS, but also PASS fuel test that is Crucial / FAIL to what is recommended and required by OEM standards 18/16/13.

Same fuel sample tested by two accredited labs, have two totally different results (Pass vs. Requires Urgent Attention)

Fuel industry standard specification has to comply by law to SANS 342 with a max particle contamination of 24 mg/kg, (measurement of contamination done through the total weight is ineffective as a standard). Injectors have micron clearances of single micron sizes, therefore the total of particle physical size distribution and the total physical count amount, is far more important. The index of harmful particles between 1-12 microns in the fuel is vital, as highly contaminated equates to a liquid sandpaper effect to engine injectors and are far more blinding/compromising to quality OEM on- board filtration mediums. Inherently the efficiency and capacities constraints are compromised. OEM warranties are based on iSo levels 4406 and require a minimum of 18/16/13, should this not be met it leads to “abusive invoices”.

If you want to extend the economic lifecycle of equipment without unnecessary fuel related issues, ensure testing and complying to OEM iSo-standards and do not rely on the fuel industry’s, out-dated SANS342 standard for fuel compliance.

Most fuel in the market fails the OEM requirement s, due to the bad practices of using labs that purely comply with the fuel industry’s legislation for PASS and not if the fuel is suitable for modern engines. Creating a false sense that the fuel used is suited for the required micron clearances in most engine injectors.

Fuel to the eye appears “shining clear” with no visible contamination; however, high levels of contamination are far too small to be viewed with the naked eye.

OEM warranties for diesel are mostly based on iSO 4406 Standards minimum of 18/16/13 which is not based on SANS342, as used by several accredited labs to only comply with the fuel industry standard specification of 24mg/kg for a PASS, this however, equates to a FAIL by the recommended and required by OEM standards.

Each user of fuels should have a blueprint practice of filtering fuels when transferred and stored, as well as correctly sampling fuel and testing to iSO 4406 standards, to ensure OEM compliance and simply lower the cost of equipment ownership.

Most fuel in the market place does not comply to iSO 4406 18/16/13 due to no filtration or worse filtration systems that are simply lacking in supplying sustainable cleanliness levels. The BAD practice of using spin-on filters in bulk fuel applications, even in multi housings, is simply ineffective as they lack the dirt holding capacity required and the internal construction to handle the various differential flow pressures. Test your fuel for compliance after “filtering” regularly and utilize an accredited labatory that tests fuel to iSO 4406 levels.

Standards minimum of 18/16/13 which is not based on SANS342, as used by several accredited labs to only comply with the fuel industry standard specification of 24mg/kg for a PASS, this however, equates to a FAIL by the recommended and required by OEM standards.

Each user of fuels should have a blueprint practice of filtering fuels when transferred and stored, as well as correctly sampling fuel and testing to iSO 4406 standards, to ensure OEM compliance and simply lower the cost of equipment ownership.

Most fuel in the market place does not comply to iSO 4406 18/16/13 due to no filtration or worse filtration systems that are simply lacking in supplying sustainable cleanliness levels. The BAD practice of using spin-on filters in bulk fuel applications, even in multi housings, is simply ineffective as they lack the dirt holding capacity required and the internal construction to handle the various differential flow pressures. Test your fuel for compliance after “filtering” regularly and utilize an accredited labatory that tests fuel to iSO 4406 levels.

Why do quality original OEM on-board filters block prematurely or worse fail? This results in down time and costly repairs!

The Answer is simply that the designed dirt holding capacity of the filters is exceeded! The onus is on the owner of the equipment to ensure that fuel is clean and within the OEM warranty specification inside the Fuel Tank of the equipment. Cleanliness standards being iSO 4406 levels 18/16/13 not the Fuel industry standard compliance specification of SANS 342 of 24 mg/kg – equitable to liquid sandpaper. It is no wonder that the filters FAIL or lose efficiency during the allotted time based service intervals. Because of common rail engine impoverished requirements of a cleanliness level of 12/9/6 at the injector, bulk fuel management has become more important than ever. Ensure your fuels are sustainably filtered, through the fuel supply chain and test regularly for compliance to iSO 4406 18/16/13 levels. iCerMax™ iSo-Specsure™ filters for bulk tanks, mobile bowsers and tank cleaning equipment (bulk and on-Board Tanks) ensures OEM warranties are sustainably met, as our filters BLOCK and will not compromise on the filtration medium.

7 ton of Engine Muscle, 60 ltr, V16, 2013 kw – constant power = fuel consumption at 417LPH

Operating this for 500 hours to service intervals in a mining application and one may be playing Russian roulette if the mine does not have proper bulk tank/ mobile bowser sustainable filtration systems, as well as an on-board equipment fuel tank cleaning program. The injector pressures are 1600 bar, this requires permanent clean fuels and relying on the on-board filters to have the dirt holding capacity to supply the required clean fuel could prove to be a very costly risk. OEM high quality spin-on filters compromise or at best block, if confronted with fuel contamination levels in excess of iSo 18/16/13 in the on-board tank. This is why OEM warranties on fuel require 18/16/13, as a minimum fuel cleanliness level. Test fuel regularly for compliance to the OEM warranties and don’t rely on Fuel Analysis Reports, which base fuel test results for Pass or Failure against the fuel industry standard of SANS 342 of 24mg/kg, as this level of fuel quality is equated to liquid sand paper for injectors.

Benefits of Filtration

Lack of sustainable filtration and its direct negative impact on revenue.

Filtration is all about the reduction of wear in Fuel systems and the optimisation of their economical lifecycles. Sustainable filtration in fuels and oils at correct cleanliness levels easily extends the economical lifecycles of machinery by 20% and lowers their direct operational costs.

Combustion efficiency and lowering component wear is the prime objectives .We don’t understand or realize the material impact contamination has on our equipment, as the focus or budget has historically been lacking. The advancement in equipment technology requires improved cleanliness levels. Actual case studies have proven that sustainable cleanliness levels are becoming a necessity and that filtration pays with multiple returns in various direct and indirect benefits .The lack thereof impacts on various budgeted costs or has dire consequences.

To demonstrate this, consider the negative impact of current inadequate filtration systems on the fuel systems and economical lifecycles of your equipment.

Direct impact in fuel system on all of the following crucial elements:

Note: Contamination wear affects the entire fuel system and all internal combustion parts directly. Replacing the injectors doesn’t reverse the impact of contamination damage. The sleeves, piston, piston rings, bearings are all affected directly by contamination abrasion, heat disbursement and increased soot ,as the contamination passes through to the exhaust system.

Injector life > There is a direct correlation in wear and the sustainable cleanliness levels of fuels. Injectors are vital for optimal performance, as they are directly responsible for the continuous optimal diesel spray pattens and the maximum possible oxidation of the fuel. Both are directly negatively impacted on by wear on the injectors.

Spray pattens > injectors today have up to 12 + spray holes in one nozzle and inject up to 6 to 9 times per single piston burn cycle-CAT. i.a.w very advanced. If this is directly adversely affected this leads to poor fuel oxidisation.

Fuel oxidisation> It is vital to optimise and maintain fuel oxidisation as it impacts on all of the following:

• Temperature disbursement Delayed or heat build up due to droplets, or worse, streams of diesel, leads to combustion chamber failure. The combustion heat does not timely disburse, resulting in the piston and sleave deforming, due to excessive heat.
• Fuel consumption the wear of injectors and the internal combustion chamber directly impacts on fuel efficiency. In actual case studies this were conservatively 5 -12% over a timeline. This cost alone justifies attention and an active focus on filtration. Fuel saving alone pays for filtration costs, if not budgeted. Unburnt fuel simply increases heat, dilutes oil and exits thought the exhaust system.
• Soot formation Soot is a highly abrasive substance and naturally occurs during diesel combustion, however improperly burnt fuel drastically increases soot. Soot also affects the spray pattens directly, as it deposits on the spray nozzle and increases internal abrasion wear, everywhere.
• Oil dilutions Fuel and soot dilution, through poor combustion, negatively affects the functional service intervals and effectiveness of oils. This increases internal wear and leads to premature failures.
• Toxic emissions Direct result of bad combustion. The excessive soot exiting and depositing on the exhaust is a clear indication of poor combustion.
• Engine Lifecycles are directly economically extendable by a minimum of 20%, if fuels and oil are sustainably filtered to the required cleanliness levels. Fuels should be a minimum of
  3-4 mg/kg at bulk tank levels, this is the current European specification.
• Engine failures have a direct correlation to both particle and water contamination. Contamination failures are totally preventable by the implementation of a contamination blueprint. Even small improvements assist with filter capacity constraints.
• Running costs are materially affected but are mostly budgeted for. We are used to treating the symptoms, not the cause, due to lack of sustainable cleanliness levels.
  Running, maintenance, fuel, down-time and financial replacement costs are all directly materially impacted.

What is normal wear and how do we bench mark it? Firstly benchmarking is complicated due to a multiple of variances. However through case studies and multiple fuels sampling it is clear that contamination levels are simply above adequate. Minimum 20% increase in economical lifecycle on all equipment is achievable, especially on the current contamination blueprint low base levels, which are totally achievable.

Test on filtration:

1. What are your current cleanliness levels on fuel and oils? IN ISO Levels
2. Were correct test procedures followed for representative sample extraction?
3. What does the OEM suggest in terms of cleanliness levels? 18/16/13 about 3-4 mg/kg
4. Who actively monitors the cleanliness levels?
5. Whose responsibility is it to maintain tank farms?
6. Who is monitoring the changing of filtration filters and air breathers?
7. Were these filters in bypass or filtration medium compromised?
8. What is your contamination blueprint?

Currently most bulk filtration is totally inadequate or non-existent, placing severe capacity constraints on downstream filters. The filters simply can’t handle the sheer volume of particles, particle size and water contamination it has to contain. Downstream filters have capacity and filtration efficiency constraints. When compromised on capacity, they simply go to bypass mode or medium compromise occurs. iCerMax™ filters mediums is sustainable, as the medium offers depth filtration with multi support addressing channel formation or medium compromise – i. That is why dirt restrained by iSo-SpecSure™, stay in filters. Vast dirt holding capacity, flow rates, service intervals, surges and sustainable cleanliness levels are all benefits of iCerMax™ .

The sole intent of this is to bring awareness to contamination and the impact on equipment.
We’ve read about contamination for years, in various publications, but seldom take correcting action.

This is one of the easiest projects to implement – a contamination blueprint, with a high return, as the current market base is substandard or neglected. It is the market’s view that it is the responsibility of third parties to combat contamination. The bad news is they won’t, if they are not reimbursed for implementing and maintaining these cleanliness levels.

Facts on filtration

It is interesting to note according to OEM’s that over 75% of all engine failures is directly contributed to the fuel system or heat.

Mining houses are starting to understand the value of sustainable filtration, taking ownership of their bulk tanks and investing into cleanliness levels on oils and fuels.
This is due to a learning curve based on actual case studies and the realization of the technical advancement of equipment. Kumba –Sishen site is a model example.

Lack of sustainable filtration and inadequate design on main bulk tanks and mobile tanks leads to capacity constraints and compromises on the equipment’s water and particle filters. Contamination levels must decline, not increase during handling. A few spin-on filters or single bulk filters are inadequate to sustain the required cleanliness levels.

Filters today have efficiency – micron rating, if matched correctly BUT capacity is the “Achilles heel”, mainly due to capacity constraints and surges.

“The fuel systems of most diesel engines are equipped with water separators and two-stage fuel filters. Machine manufacturers add these or other fuel filtering systems to their equipment. Such devices will handle small amounts of contamination, but continued or excessive contamination of the fuel system will result in accelerated wear of the engine and the fuel system components “ – Source: DEEP: intense multi million dollar study on: Diesel Emissions evaluation Program – www.deep.org

A 420 hp truck is fitted with a world leading brand filter with a maximum dirt holding capacity of 50g (premium to market standard). The SABS contamination specification is 24mg /kg, which translates (0.835) to 24mg/ltr. This means that every 50 ltr of fuel ads 1 gram of dirt to the fuel system.

Which translated means that in every 2500 ltr of diesel there is 50g of dirt, as is allowed per the contamination specification, thus the filter can possibly be compromised on capacity. This directly indicates that the filtration systems on trucks are periodically compromised, which leads to internal wear and which is responsible for premature failure. Especially if service intervals are taken into consideration based on distance and not volume of dirt retained in the medium. There are case studies where one BAD forecourt refueling has led to engine failure.

The cost benefit ratio 1:10, which is fractional as to what contamination is costing in parts, fuel consumption, down-time, the logistics around breakdown, production losses, failures, back-up equipment and the life cycles of equipment. The worst is that we delegate this
important function to third parties without accountability or reimbursement for implementation and maintaining proper sustainable cleanliness levels in our fuels and oils. Take ownership of your contamination, the rewards are more than merely financial.

We know from history that older trucks use more fuel than when they were new. One major contributor to this is the internal wear inside the engine. The contamination that has over time impacted negatively on the components, the injectors, sleeves, piston rings etc.,
By introducing sustainable filtration, the wear patterns are materially reduced, therefore the fuel saving of 4-6% pays for the filtration costs over and over again.

Contamination is liquid sandpaper – water & particle – which directly affects inefficiencies, warranties and life cycles

Material balance equation of contamination

Ctn = Cto + Ca-Cs

Total contamination = Start contamination + added contamination – removed contamination
The more you remove contamination at bulk tanks, mobile tanks and on equipment, the lower your total contamination at any specific point.

“Knowing the cleanliness level of a fluid is the basis for contamination control measures” Manufacturers specify optimum cleanliness levels for fuels, oils (engine, hydraulic & gear etc.)

Useful in warranty, FML claims if one adheres to and implements these cleanliness levels on a sustainable level.

Filtration Media Integrity

TOO MANY LARGE and especially small PARTICLES CAUSE THE FILTERS TO PLUG.

This results in large numbers of particles being forced through. This gets progressively worse as the differential pressure across the filter increases. Vibration, medium flexing & surges accentuate the problem. – iCerMax™ doesn’t have this problem as the iSo-SpecSure™ medium simply can’t be compromised, even at the filter’s saturation point.

Filtration impact The cost of bulk filtration or additional pre-filter filtration, is a fraction of the downstream negative impact on equipment, if there is inadequate, non-sustainable or even no bulk filtration. MOST quality filters today have excellent efficiency, but have capacity constraints / limitations that are exacerbated by surges and vibration. These capacity constraints in high quality filters are typically from 50g in trucks (440 hp) spin-on to 2kg in high quality bulk tank filters. This is concerning if it is taken into consideration that every 50 liters of diesel is allowed 1g of dirt, on a 24mg / kg official fuel specification at oil company point of sale.

Filters are more compromised on capacity than we realize in normal day to day service intervals. This is frequently discussed in the press (read articles on our website) The actual cost is neither unknown nor quantifiable, but filtration companies estimate that for every R1 spent on filtration, R10 is saved. The lack of adequate or sustainable filtration has a direct proven impact on:

• Economical life cycle of equipment (minimum 20%)
• Maintenance cycles
• Engine failure – 70 % of engine failure is due to the Fuel system or heat
• Breakdown direct and indirect costs – Utilisation of equipment
• Fuel usage/ efficiency, especially later on in lifecycles 5-15%
• Soot / carbon build up, fuel dilution in oils
• Emission carbon footprint

The above impact on operational and capital costs are material, but we don’t comprehend the full impact as it is budgeted on the way we are used to operating. The current development into more advanced technology is going to be more of a culture shock, than the first advancement from ADE engines. Some of the large mining groups are starting to materially invest in filtration, as they have realised the direct impact on their operational costs through case studies. Our medium does not compromise, even at filter saturation point.

Our Competitive Advantage is that our Brand of Products are unique and utilise patented concepts that provide both cost and functional benefits. They also complement one another to provide a total solution to contamination, both particle and water in Diesel. Materially lowering operational costs and extending the economical lifecycle of equipment.

What is the impact of stop start and surges on media?

An operating system is at risk whenever the critical contamination level is exceeded

Contamination levels determine the individual components wear rate (useful life) and ability to perform as intended (functionality).

System design, filter performance and maintenance practices largely determine the contamination level in a system.

Filters are expected to maintain contamination below critical tolerance levels. Filter performance in a dynamic operating system is variable based upon flow rate and flow density, changes in flow rate (duty cycle), viscosity, fluid and structure borne vibration (Hz), contamination levels, ingression rate and several other conditions. All filters are subjected to some form of system dynamics.

Filters encounter frequent and rapid changes in flow rate accompanied by frequency changes. Bulk tank filters typically experience dynamic conditions during start up and shut down.

Two key characteristics of filter performance are capture efficiency and retention efficiency.

Capture efficiency can be thought of simply as how effectively a filter captures particles while Retention efficiency is a measure of how effectively that filter retains the particles it has captured. A filter is not a black hole, and its performance must not be based solely on how efficiently it captures particles. If not properly designed and applied, a filter can become one of the most damaging sources of contamination in a system.

• The phenomenon of releasing captured contaminant is called unloading, and can result in temporary contamination levels, that are well above the critical contamination tolerance level of a system.
• This phenomenon can best be described as “contaminant unloading”. As the Filter element captures more dirt, greater amounts may be released back into the system that it is installed to protect when the element is subjected to a dynamic flow condition and change in differential pressure across the element. Unloading may also occur when the flow rate changes from high flow to low flow, represented by the alternating smaller peaks. The filter element typically recovers shortly after the dynamic condition, but highly contaminated clouds of fluid from contaminant unloading can cause severe component damage and unreliable system performance.
• Excessive unloading in the early stage of element life may be symptomatic of an element that will eventually fail and lose its efficiency all together (media breakdown).

During the restart-Cold start test there is no contaminant being injected so any particles measured were already in the system or were released by the element (unloading). The result is a temporary state of highly contaminated fluid that has resulted because the filter element did not properly retain the dirt.

Filter element performance is at its worst during flow changes isolating those sequences can help predict performance in dynamic flow systems

The advantages of using iSo-SpecSure™ filters:

• There is surety of sustainable cleanliness levels, compared to other market filtration mediums, as iCerMax™ iSo -SpecSure™ don’t form channels, don’t have medium migration and there is no severe unloading or element collapse.
• Structural integrity, iCerMax™ iSo-SpecSure™ eliminates filtration medium breakdowns or compromise caused by multiple surges , hammering effects, operating pressures ( high or low ), severe pressure variances,
• Excellent sustainable Capture efficiency –unsurpassed Micron ratings even under severe pressures and surges.
• Holding capacity and dirt retention (the main “Achilles heel” of various filtration mediums) are exceeded, as dirt remains in the filter due to the unsurpassed structural integrity of the filter medium i.a.w there is no costly dirt surges or any seepage that negatively affect or compromise the cleanliness levels.
• Reliable filtration monitoring sensors/ pressure gauges. As the medium does not compromise the filtration monitoring sensors reflect the actual real time status of the filtration process thus eliminating estimated change intervals based on shifts, volume, or on hourly or distance monitoring.
• Process applications efficiencies: the inherent characteristics of iCerMax™ allow for a functional optimisation design of processes, which requiring a superior multi-functional filtration solution.
• With higher pressures/ flow rates and their vast dirt holding capacity iCerMax™ iSo-SpecSure™ & iAquaMax™ set new standards in bulk filtration sustainable cleanliness levels and totally in a league of their own.

Depth filtration is closer to the perfect filter as it conforms closer to filter performance criteria.
The effective repeatedly micron beta rating is substantially higher than surface filtration and the ultra-important beta stability (see ref) uncompromised with our filter media. Therefore capable of continually removing micron contaminant at higher efficiency with vast increase in contaminant holding capacity

Both hard and soft contaminants penetrate into the depth media. Captures contaminants within its structure, as opposed to on the surface. Allowing for long life with minimal increase in pressure drop

Depth filtration – the General preferred technology – uses a relatively large volume of porous filtering media to capture contaminants at various depths deep within the filter element as the fuel and oil passes through. Depth filters featuring this type of construction provide maximum contaminant loading and long service life with a greater filter efficiency over a variety of particle sizes.

Semi-solid contaminants will penetrate the media and not glaze-over the surface as per surface filtration.

”if it flows through iCerMax™, the cleanliness levels are improved and sustainable, with depth filtration cleanliness levels”. The iSo-SpecSure™ medium simply can’t be compromise and thus it provides surety on sustainable filtration

• Depth Filtration not surface filtration
• Sustainable cleanliness levels with a single pass
• High flow rates even with surges
• No channel formation or medium collapse
• Structural integrity – handles surges and contamination
  caking with ease
• High or low pressures, no element collapse
• Ultra low resistance to flow and differential pressure
• High efficiency – 100% sustainable
• Multi medium layers & multi medium supports –
  improves filtration efficiency
• Vast dirt holding capacity -Long filter life
• Excels in all of the eight main filtration criteria

Benchmarking sustainable cleanliness levels in filtration of:

• Fuel (diesel, petrol & biodiesel)
• OIL (hydraulic, gearbox & engine)
• Air intake filtration

It is structurally sound and can’t do the following:

Filter Performance Monitoring –Cellulose & synthetic medium will “break” due to excess contamination and dirt -holding capacity limitations, surges, pressure variances, water, bio diesels,etc. – iCerMax™ iSo-SpecSure™ simply is a superior design , not subject to these limitations. iCerMax™ ensures sustainable filtration even on a single pass.

This is a sample from new tanks with a high turnover volume – with the assumption that the diesel must be clean. Bottom sample – sediment at bottom – large amount of metal particles, – Free water clearly visible with traces of fungal presence.

Middle sample – Clean and clear to the eye BUT it is over four times the SABS cleanliness spec, at over 80 mg /kg. The particles you can’t see cause the most damage to your equipment and the smaller the particles sizes, the more the shear volume of dirt particles exponentially.

Result of contamination

Levels of contamination

Sample of a patch magnified to 100X showing a fluid at a cleanliness of approximately ISO 22/20/18, fairly typical of fuel at the filling pump

Sample of a patch magnified 100X showing a fluid cleanliness of approximately ISO 14/13/11, the target level for clean diesel fuel.

Current cleanliness recommendations by some manufacturers of high pressure fuel injection systems have already indicated they need significantly cleaner fuels. They already require fuel in an ISO 4406 cleanliness range of 12/9/6 or better for on-vehicle filtration.

Several studies have been conducted on fuel cleanliness coming out of the pump, and it’s not uncommon to find a newly-delivered batch of diesel fuel with an ISO cleanliness level of 22/21/18. Cleaning fuel from an ISO 4406 cleanliness level of 22/21/18 to approximately 12/9/6 or better requires approximately a one thousand times reduction in the particulate contamination.

Amber diesel -Orange juice – silent failure- “Water added to diesel during deliveries”

• Not detected by water finding paste
• Not removed by absorption medium nor “normal market “filters
• However our Water separator efficiency does show its presence
• This amber diesel that would directly go to the combustion chamber with damaging consequences
• A large percentage of failure is not particle contamination but actually water related failures
• Usually detected during OEM warranty claims investigations

Free & Suspended water in diesel

System remains optimal – no efficiency loss- due to no capacity problems as it operates on a coalesce pressure system and therefore does not suffer from the same capacity constraints associated with normal filters, Normal filters have capacity constraints and get blocked by sheer water volumes or particles effecting their water separation abilities.

iCerMax™ is a leader in filtering free and suspended water with our proprietary iAquaMax™ and Duo-AquaTrap™ water filter range

Gauge Filtration Monitoring – How Accurate is it?

This is not an uncommon site, filtration both water and particle severely compromised. The filtration system filters installed, working indefinite. This cannot happen with iCerMax™ iSo-SpecSure™ as the medium do not compromise, and the seals are designed not to compromise. Therefore the pressure gauges are a TRUE indication and sustainable filtration not compromised at any time.

Particle contamination is “liquid sandpaper” and dirt larger than 0.7 micron and smaller than 5 micron is “crusher stones” in a modern engine.

Lower contamination levels upstream at bouser and downstream on the fiscal vehicle, improve physical wear patterns and directly extend economical lifecycles and improve fuel consumption due to longer optimal fuel spray patens inside combustion chamber, due to less internal wear of injectors and critical engine parts.

Direct correlation between ISO cleanliness levels and economic lifecycles of equipment – E.C. Fitch

Test done by E.C. Fitch on oil contamination levels. This illustrates the direct correlation between cleanliness levels and efficiency lifecycles. By changing ISO level standards, we increased pump life from 2 > 14 years.

Education on filtration and contamination control fundamentals is just as important as the type of component or system to buy. This leaves us to ask the main question: What does the end user want his filtration systems to accomplish at the end of the day? Cost vs. benefits?

Why is filtering so critical? Why are fuel systems the number one contributor to engine failures? Contamination in diesel is nothing more than “liquid sandpaper “. It has a direct negative impact on lubricity and increases wear patterns exponentially or directly cause component failure. Some of the clearances in engines can be as tight as 2 Micron in injectors at pressures of 1800 – 3500 bar; in the combustion chambers there is a ring gap clearance of 0.09-0.12 mm or 90-120 micron at pressures up to 230-280 bars. Contamination in the fuel can adversely affect the performance and reliability of the combustion components and this will affect the overall efficiencies (carbon generation, heat, oil, emissions and fuel), lifecycles and failures.

If should also be noted that filtration systems must offer total sustainable filtration , Paper or synthetic filtration medium are prone to periodic cleanliness levels or particle unloading leading to component wear or failure . iCerMax™ iSo-SpecSure™ filtration medium is a total sustainable cleanliness level achievable , due to the superior inherent characteristics of filtration , as illustrated ……

The Role of the Filter
To appreciate the importance of the filter in the management of the system, consider the primary function of the filter: It has to protect the components from the damaging, critical clearance-sized particles (particles that can penetrate and interfere with the working clearances of components). The filter should control the fluid cleanliness to a level that is equal to the performance, life and reliability of the system required by the user. It should allow fluid to pass through at the given flow with the minimum pressure drop (DP) to minimize stress and energy losses.

A filter must control the levels of all contaminant particles at and above the size critical to its operating system. If the filter fails to provide the necessary control of damaging-sized particles, then their presence in the system will lead to a substantial increase in the number of particles generated within the system through a chain reaction of wear. Particles entering component working clearances will become work hardened and produce more wear particles. This makes the capture of these particles, by the filter, essential to sustain the good health of the system.

Filter performance Criteria
Reliable Performance: Absolute removal of solids from fluid streams to any micron size specified.

High Integrity: iSo-SpecSure™ prevents seized particles from being released back into the liquid stream during flow or pressure surges.

Resistance to flow or differential pressures: shows how pressure drops across the filter or how much resistance to flow the filter imparts to the system. This resistance has a direct bearing on filter life

Collapse Strength: is the minimum acceptable differential pressure at which structural failure of the filter element. This is serious because unfiltered fluid can be routed back into the system.

Structural integrity: This ensure that the filter media does not leak due to holes or channelling (where the media simply form channels or collapse) This is serious because unfiltered fluid can simple flow thru the media.

Structural integrity: This ensure that the filter media does not leak due to holes or channelling (where the media simply form channels or collapse) This is serious because unfiltered fluid can simple flow thru the media.

Capacity /Efficiency: How much contaminant the filter will retain and the efficiency of the filter is removing the contaminant.

Longer Life and Lower Costs: High surface area results in high dirt holding capacity and long element life for lower net operating costs

Conclusion
The perfect filter would have no pressure drop, hold an unlimited amount of dirt, be small enough to fit anywhere in a system, give great ISO cleanliness codes, have high capture efficiency and cost nothing. Obviously this combination cannot exist, and the pursuit of the perfect compromise has always been the challenge for filter manufacturers. For many years, filtration companies have been trying to educate end users on why filtration is important and how it helps the end user protect his equipment, save him money in the long run, or both. Many end users understand that there are often trade-offs to lower micron rating and higher capture efficiencies of filters.

iCerMax™ iSo-SpecSure™ & iAquaMax™ filtration medium excels is the above filter performance criteria.

Fuel cleanliness levels in SA – WearCheck Tests

65% of 6985 WearCheck fuel samples failed. Free water and particle contamination contributed to the majority of the test sample failures – over 70% or 5000+ samples. This is a clear indication that diesel is being contaminated in the supply chain and at bulk tanks. It is a costly myth that diesel fuel in South Africa is clean when it reaches the combustion chamber of a modern engine. The shear volume of contamination is leading to failures, as OEM filtration systems are under severe pressure or failure. iCerMax ™ offer various filtration solutions to address free water and partial contamination.

Protect Diesel from theft – iP, adding water and physical diesel theft. (Protect diesel from theft)

(iP) illuminating Paraffin in Diesel – STIP lab presence Test -Accurate
Reliable test kit to verify if illuminating Paraffin (IP) was added to the diesel, exceeding the refinery percentage. Easy and extremely reliable, similar to Pregnancy stick test. Available form iCerMax™

Water finding paste
The above levels of free water is alarming. As over a third of samples failed on free water and moisture. Fact – Water is being added to diesel to increase volume. Water finding paste detects free water and is available from iCerMax™. A proven real time solution is to install the iCerMax™ iAquaMax™ filter, iCerMax ™Duo-AquaTrap™ on equipment, or inbound / outbound filtration on the bulk tanks. These filters guard permanently against human nature to add water into fuel, as a volume replacement

Solution 1 -Proprietary iCerMax™ iAquaMax ™ & Coalescer Water Separator Design –Bulk Tanks
Solution 2 – iCerMax™ Duo – AquaTrap™ System- on-board equipment
Solution 3 – All-in-one iCerMax™ “Plug and Go” Combo Skid System

Diesel theft – iCustodian™ – anti- siphon device – prevents diesel theft – this is simply the most effective device in the market place. Diesel theft – iCustodian™

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