Eliminator Training

Cummins and Alfa Laval

Simultaneous Engineering
Cross Functional Team
Failure Mode Effects Analysis
Design Reviews
Quality Plans
Applied Mechanics Testing
Model Builds
Development and Production Testing
Field Testing
 Eliminator Background
• First introduced on KV Marine engines in early 1990’s
• Mining business turned out to be more interested at first
• Marine customers are now very interested to reduce
filter disposal
• Currently released on K38, K50, Q45, Q60 and Q78
engines.
• Most recently released on QSK19 engines (Feb 2007)
-backwards compatible with K19

• Currently working on QSK38 redsign

 Released product portfolio
QSK78 Engine QSK19 Engine
 Released product portfolio
QSK60 Engine KV50 Engine
 Integrated System

 Bolts directly to engine

– Uses existing disposable filter head attachment
points
 No external power requirements
– Filtered oil back-flushes the filter
– Filtered oil drives the hydraulic motor
– Backflushed oil drives the centrifuge
 System Design
Filter Centrifuge
 Protects the engine  Cleans the lube oil
 Full flow  Bypass flow
 Automatic self-cleaning  Disc stack centrifuge
Flow Diagram (KV and QSKV)

Filter Filter
Outlet Inlet

Return to
Sump
 Flow Diagram (QSK19 Only)

Filter
Outlet

Filter
Inlet

Return to
Sump
 Filter Element Design

 Full flow protection of the engine

 Robust, triple layer stainless steel mesh filter elements
 Fine filter mesh sandwiched bet. high strength support mesh
 300 psig burst pressure
 Constant and low oil pressure drop across filter elements
 Centrifuge Design

 Backflush flow cleaning:

– cleaner oil, longer oil life, longer engine life
– removes particles down to and below 2 
 Based on proven, Alfa Laval disc stack centrifuge tech.
 Cleaned oil drives centrifuge
 Sludge collects on liner inside the centrifuge bowl
 Typical Lube System

 Spin - on ‘paper’ filters

 Oil/filter change intervals: 250 hours

 Downtime, labor, disposal

Lube System with Eliminator

 Self cleaning full flow filtration

 Integral centrifugal bypass filtration
 Extended oil change intervals
 Dispose of only the sludge from the oil
 No filters to stock on ships
 Full Flow Filtration
 Stainless steel wire mesh disks
 35 micron absolute filter effectiveness
 20 micron nominal filtration.
 Continuous back-flushing (self-cleaning)
 Very low and continuous pressure drop
 No service until engine rebuild
Bypass Centrifuge Filtration

 Highly efficient centrifugal filter

 Filtration down to and below 2 microns
 Cleans back-flushed ‘dirty’ oil
 Driven by oil pressure at 5200 rpm
 Eliminator Specifications
Centrifuge Cleanout 2,000* Hours
Wire Mesh Cleanout 20,000 Hours
Oil Change Interval 500 Hours +
Payback period appx 2 years

Lower Downtime - Lower Labor - Higher Productivity

No Filter disposal costs - Lower Oil disposal costs

Projected Savings per year - $ 7000

*times will vary based on engine condition, horsepower and oil type
 Eliminator Specifications
Centrifuge speed 5200 RPM
Oil Pressure drop 1.5 Kpa
All Oil types CE, CF4, CG, CH or newer
Synthetic, Organic
Absolute Filtration 35 microns
Nominal Filtration 20 microns
C’fuge Filtration < 2 microns
Weight 114 kg (KV)
 Comparative Advantage

 Better engine protection

 Lower maintenance
 Lower downtime
 Extended oil change intervals
 Cost effective operation
 Added profit for engine sales vs filter
sales over life of engine.
 Separation Theory
d 2 ( p  l )
Vg  g Stokes Law
18

 Particle diameter d ( m )
 Particle density p ( kg / m )
3

 Density of the continuous phase l ( kg / m )

2

 Viscosity of the continuous phase  ( kg / m, s )

2
 Gravitational acceleration g (9.81 m / s )
Relative Particle Sizes

50 Microns (.0020) Human Hair Diameter

40 Microns (.0015) Pollen

25 Microns (.0010) White Blood Cell

8 Microns (.0003) Red Blood Cell

2 Microns (.00008) Bacteria

 More Particle Size Data
Particle Filtration Spectrum
Scanning Electron Microscope Optical Microscope Visible to Naked Eye

0.001 0.01 0.10 1.00 10.0 100 1000

micrometer
Human
Virus Bacteria Hair

Tobacco Smoke Coal Dust Beach Sand

Pin
Red Point
Blood Pollen
Cell

SAE Fine Test Dust

Fuel Soot

Lube Additives Engine Wear Debris

Full Flow Lube Filter

Full Flow and Bypass Filter

Full Flow and Centrifugal Filter

 Oil Cleanliness & Engine Wear

 Engine wear and oil life is

directly related to lube oil
cleanliness.
 Contamination particles
should be less than the oil film to
prevent wear on moving parts.
 Normal KV Engine Wear
Component Wear Rates
Particle Main Rod Piston
Size Bearings Bearings Rings
(microns) (mg/hr) (mg/hr) (mg/hr)
0- 5 11.9 14.4 28.4
5 - 10 16.1 20.0 23.6
10 - 20 7.4 4.6 4.4
0 - 80 8.2 5.1 14.5
 Eliminator Data; KV
DIFFERENTIAL COUNTS
NEW USED
PARTICLE DIAMETER PARTICLE
IN MICROMETERSIZE ANALYSIS - CENTRIFUGE
600000 2.25 5000 530000
2.75 2000 285000
3.50 2000 290000
500000
DIFFERENTIAL COUNTS

4.50 1500 90000

5.50 1000 42000
400000 NEW
 6.50 500 22000
7.50 0 14000 USED
300000 9.00 0 18000
12.50 0 16000
200000 17.50 0 9000
22.50 0 2500
27.50 0 1000
100000
40.00 0 1000
75.00 0 500
0 150.00 0 500
2.25 3.50 5.50 7.50 12.50
300.00 0 0 22.50 40.00 150.00

PARTICLE DIAMETER IN MICROMETERS

 INSOLUABLES [% wt]

0
1

0.2
0.4
0.6
0.8
1.2
1.4
1.6
1.8
0

100

200

300

400

500

TIME [Hours]
600

650

700

750

VISCOSITY 100C [cST]

11
11.5
12
12.5
13
13.5
14
14.5

100

200

300

400
Eliminator Data; KV

500
TIME [Hours]

600

650

700

750
 Eliminator Data; KV

10 18
9 16
8 14
7
12
6
TAN

10

TBN
5
4 8
3 6
2 4
1 2
0 0
0 100 200 300 400 500 600 650 700 750 0 100 200 300 400 500 600 650 700 750

TIME [Hours] TIME [Hours]

 Eliminator Data; KV

90
3.5
80
3
70
IRON [PPM]

60 2.5

COPPER [PPM]
50
2
40
1.5
30
20 1

10 0.5
0
0
0 100 200 300 400 500 600 650 700 750
0 100 200 300 400 500 600 650 700 750
TIME [Hours] TIME [Hours]
 Standard vs. Eliminator
• Oil samples from the sump were taken for two
configurations:

With the “standard” cartridge filters configuration.

With the add-on of the CCU in the system.

•Oil particle counts were carried out by Alfa Laval.

 Test Results
“standard” configuration

1200000

1000000
Number of particles
(per gram of oil)

800000

600000
1 hour
400000 6 hours
200000 11 hours
16 hours
0

9
3.5

4.5

5.5

6.5

7.5
2.25

2.75

12.5

17.5

22.5

27.5
Size (µm)
 Test Results
adding the CCU in the system

1200000

1000000
Number of particles
(per gram of oil)

800000

600000
9 hours
400000 21,5 hours
34 hours
200000

9
3.5

4.5

5.5

6.5

7.5
2.25

2.75

12.5

17.5

22.5

27.5
Size (µm)
 Conclusions
• After the 34 hours of testing with the CCU, the number of
particles per gram of oil decreased by more than 50% for
particle sizes under 4 µm when compared to the “standard”
configuration.

• With the standard configuration, the system seems to have

reached its equilibrium.

• With the add-on of the CCU, the equilibrium is still not

reached.
 Conclusions Continued

• Such a reduction in the number of “small” particles from

the system would have the following benefits:
Less engine component wear for longer life of your
engine.
Prolonged oil life resulting in extended oil change
intervals.
 Conclusions Continued

• Such a reduction in the number of “small” particles from

the system would have the following benefits:
Less engine component wear for longer life of your
engine.
Prolonged oil life resulting in extended oil change
intervals.
 Alfa Laval Contacts

• Greg Schmelz, Key Account Manager. +1 317-889-3032

greg.schmelz@alfalaval.com

• Ted Esplin, Director OEM business, +1 215-443-4195

theodore.esplin@alfalaval.com

• Guillaume Estachy, R&D Engineering, +33-1-30-81-82-11

guillaume.estachy@alfalaval.com