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0.4 4.0
0.5 NMHC 2.5
2004 option 2 15.5 0.1 2007-2010
only NHHC+NOx 0.3 NOx 3.0
Phase-In
98% Reduction
0.2 2.0
2007 0.14 15.5 0.2 0.01
0.1 1.0
0.0 0
Urban Bus Engines 1990 1994 1998 2002 2006 2010
Model Year
Year HC CO NOx PM Source: US Environmental Protection Agency
Crankcase Pressure
Flow vs. Pressure Drop Curves Crankcase Inlet Pressure (in.H2O)
2 Blue Line - Run 1
9
1 Yellow Line - Run 2
Red Line - Run 3
Pressure Drop (in.H2O)
8
7 0
Saturated
6 Element -1
5
4 -2
3
Dry -3
2 Element 0 5 10 15 20 25
1
Turbo Inlet Restriction (-ve)
0
0 1 2 3 4 5 6 7
This procedure establishes the CCV element or breather efficiency for particles over 0.3 micron. The efficiency is
gravimetric and pertains to the particles entrained in the air stream which enter and leave the CCV device. This type
of efficiency is a good indicator of overall performance for a unit on an actual engine where the challenge aerosol
contains oil droplets and solid soot particulate. It will reflect the actual loading and of aerosol particles and release of
coalesced oil in the real world setting.
This standard contains instruction for a test that evaluates the key function of the media. It is the second test
performed on a medium. A 50 liter sample of air is taken upstream and then downstream of the filter. Both samples
pass through the laboratory papers and the weight upstream and downstream is recorded. From this data, we can
calculate the carryover of particles that remain entrained in the gas stream. The challenge rate and carryover in
grams per hour is found and gravimetric efficiency over the 50 liter sample is established. The particle distribution
analysis is performed with a laser spectrometer or a coronal cascade impactor. The sampling technique is similar. An
isokinetic sample is diluted approximately 100 times, and passed through the measurement instrument.
Particle Distribution vs Efficiency (Racor Aerosol Racor Test and Engineering
Test Bench)
The particle distribution curve below is a sample set
of data taken from the automated test stand. Both
gravimetric efficiencies and particle distribution curves
can be generated. The test stand has a heated,
temperature controlled environment in which aerosols
are generated. A laser particle spectrometer takes
upstream and downstream measurements. The stand
has capability to conduct:
Costs Service
Parasitic
Engine
Device Efficiency Cost Require-
HP
ments
Several types of closed crankcase ventilation devices Losses
exist on the market today. Many of those devices Non-Driven
Low Efficiency $ No No
are very different from the Racor product offering. Cyclone
Implementing another emissions control device to an Low - Good
Impactors $ No No
engine can be a costly exercise. When considering the Efficiency
cost implications, many factors must be decided about Simple Lowest
the technology that effect the efficiency, purchased $ No No
Breather Efficiency
price, cost of installation, cost to the end user, price in
Coalescing
power consumption and fuel. Separation
Good to
$$ Yes No
Excellent
Filtration
No
Device Effectiveness or the Efficiency of Oil Electrostatic Good, But Not
$$$ High Service/ Yes
Separation Filter Consistant
Repair Costs
Service Requirements
CCV Media, Types, Advantages and
W
hat are the acceptable change intervals for servicing
the CCV device?
Disadvantages
Air Filters vs. CCV Filters: The Differences
Will the unit have a high efficiency changeable filter to
protect the turbo? Filtering the aerosols from the blow-by gas is only half of
the requirements for media. Once the oil has collected
Does the customer want a fit for life unit at the in the media, it must be released. For any given flow
expense of the turbo? rate and upstream pressure on the media, a specific
saturation level is achieved. Media saturated with oil
Parasitic Power Consumption is very different than media plugged with dust or dirt.
Here is where the CCV filter departs from any similarity
Extended service intervals may require a device that with air filters. The two are often confused by customers
is driven mechanically or by a separate electric motor. and our competitors alike. Although the fluid that flows
What is the overall fuel consumption required to do through a CCV media is gaseous and mostly air, the
this? Running a device equivalent to a 70 watt light CCV filter is primarily a coalescing filter, not a particle
bulb on an engine costs more in fuel than the cost of a trap like an air filter. Air filters rely on the impaction of
service element in the time the service element would particles to separate the solids from the air stream. Air
be changed. filters also use the dirt itself to create a surface cake
of particles to sieve more particles from the air passing
through the pleated walls of the medium.
The chart to the right shows many CCV devices
available on the market today and the relative choices The life expected in a CCV filter has to do with its ability
in selecting a unit. to drain oil. Engine air filters typically provide ample
surface area to collect numerous amounts of particles. dary
Point A Oil release boun
Point A
CCV filters must coalesce aerosols to collect an amount Efficiency
Pressure
of liquid downstream. Oil is a liquid. When oil is in
ion
t
Drop
aerosol form, it is still a liquid. As aerosol particles join
ura
sa t
together in the media, they pool together. The pools are
Oil
formed into droplets, and the droplets eventually are Time
pushed to the downstream side of the media. As the Time
droplets grow, they are shed out of the media and trickle
off of the outer surface. This process of growing small
particles into droplets and shedding them is the act of Depth Loading Media: Saturation & Oil Release in Elements
coalescing. Thick-walled medium are uniquely suited to coalesce
aerosols. Depth loading media is meant to operate at a
permanently saturated state over the life of the element.
Saturation is dependent on the flow rate of the system.
What makes CCV applications unique?
A new element absorbs aerosol until a level of saturation
Coalescing a liquid from a gas stream is done in many is reached. Point A below shows the point where the
industrial settings. The uniqueness of CCV filtration element stops absorbing the coalesced droplets and
verses industrial coalescing applications is the begins to shed oil. After the initial release of oil from the
intolerance for internal pressures. It is not uncommon newly saturated element, the efficiency may fall by as
to achieve 99.9% efficiency coalescing oil out of much as 10%. The fall uncovers the masked performance
industrial compressed air systems. This is achievable of the element while the new element is busy absorbing
due to excellent media with high differential pressures oil droplets. The initial rise in pressure drop is very low
(approximately 5 PSI). CCV systems cannot handle the during the absorption phase. As the element is used,
same differential pressures. Oil pans, head gaskets, assuming a constant flow rate, a steady saturation level
rocker cover gaskets, and engine shaft seals are is maintained as oil droplets are coalesced and shed.
all susceptible to crankcase pressures that pale in Continued use of the element will produce a slightly
comparison to compressed air systems. A human can elevated efficiency from Point A. As dirt clogs the
produce enough lung pressure through a soda straw element, pressure drop begins to build until the element
to exceed many engine manufacturers’ allowable pressure drop exceeds the system limit.
crankcase pressures (8 in.H2O). More modern engine
designs allow for higher crankcase pressures, but O
bo il sa Efficiency
almost none exceed 1 PSI (27.8 in.H2O). The pressure un tu
Operating da r a t
ry ion Point A
loss across the filter element is directly tied to the ability Saturation
of the media to shed oil. All filter medium rely on the level
(CFM)
Cooler exhaust gas results in incomplete combustion,
and higher soot content in the exhaust gases. Min
• Rich combustion.
Idle
Engine
• Poor piston ring sealing.
Rated
Load
• High piston temperatures on the bottom surface. Oil
flashes and boils on these surfaces.
As the engine runs, blow-by is being created. The blow-
• Burning of multi-viscosity oils and organic additives. by never stops entering the crankcase from the piston
chamber. As the load on the engine increases, so will
the flow rate of the blow-by.
Racor media formulations include glass micro-fiber.
New research is being done with a nano-fiber medium.
The placement of the pressure regulator in the system
As a depth loading material, nano-fibers are not very
will affect the life of the CCV filter. Racor places the
successful at meeting the low pressure drop
pressure regulation valve in a location that is ideal
requirements for CCV applications. Further
for optimizing element life and closely monitoring
advancements in blended micro-fiber and nano-fiber
crankcase pressure. The ideal Racor system and a less
mixtures yield more promising results. One of the more
advantageous system are described below.
attractive qualities of nano-fibers is that they are formed
with nylon polymers. Nylon fibers can be disposed of
more easily than glass fibers.
P1 P2 P3
(Pressure at (Turbo
crankcase) Restriction)
Filter
Turbo Restriction
25-
30”
Vacuum Regulating/
(in.H2O)
Air Filter
Clean
Dirty
Load Drain
Condition Line
15.00
Filter -0.12
Vacuum Regulating/
-5.16
Sump Pressure Relief Valve
-10.20
-40 -30 -20 -10 0
Check
Valve CCV3500 Pressure Regulation with Blocked Media
Crankcase Pressure (hPa) 30.00
21.86
CCV Heaters
Racor CCV heater kits are an optional accessory for
engine applications operating in severe weather. In cold
weather applications, the gases and vapors processed
Impaction Plate
by the CCV systems are affected by ambient conditions.
The freezing air that has passed through the engine
compartment, by the radiator fans, force the canister
to function as a heat sink for the crankcase gases.
The canister is cooled to ambient temperature and oil
Idealized, all oil aerosol particles that are separated mist and water vapor particles traveling through the
from the streamlines coalesce from a film that is able CCV system will then coalesce against the cold interior
to drain from the collection surface. Real life results surfaces of the CCV canister. This process introduces
generate two other possibilities. microscopic particles of oil and water to each other.
1. Particles with significant inertia may bounce off the When they mix, an emulsification of the two liquids
collection plate and re-entrain themselves in the occurs. This emulsification turns the two particles into a
exiting streamline. creamy jelly-like substance. The mixture slowly builds
up as cold air continually cools the canister and the
2. Particles too small to be fully effected by the abrupt process repeats itself. The emulsified oil-water mixture
change in direction proceed past the collection plate collect to a point where element life is compromised and
without being separated. crankcase pressure will rise.
It is for these two cases that Racor supplements the
inertial separation with a media in the full flow path of
the exit gases, bridging the entire volume of the exit flow The preceding information was provided by Tom Tomchak, Racor
path. The presence of the depth loading media provides CCV Engineering Manager, and the Racor Engineering Team.
coalescing for particles that would not otherwise be
To learn more about Parker Racor’s complete line of Crankcase
separated. Design parameters such as gas and aerosol Ventilation Filtration Systems and the specific CCV™ product for
particle Reynolds number, temperature, orifice size, and your application, please contact racortech@parker.com
many secondary parameters are examined to optimize
the performance of the separator. Parker Racor has a global network of engineering, manufacturing
and service locations that are listed on the outside back cover of
The operation of inertial separators are largely this publication.
dependent on velocity, and therefore flow rate. The
disparity in performance between coalescers and
impactors show itself when sizing a unit to an engine
Worldwide Filtration Manufacturing Locations
North America Europe Asia Pacific
Compressed Air Treatment Compressed Air Treatment Australia
Filtration & Separation/Balston domnick hunter Filtration & Separation Castle Hill, Australia
Haverhill, MA Gateshead, England +61 2 9634 7777
978 858 0505 +44 (0) 191 402 9000 www.parker.com/australia
www.parker.com/balston www.parker.com/dhfns
China
Finite Airtek Filtration Parker Gas Separations Shanghai, China
Airtek/domnick hunter/Zander Etten-Leur, Netherlands +86 21 5031 2525
Lancaster, NY +31 76 508 5300 www.parker.com/china
716 686 6400 www.parker.com/dhfns
www.parker.com/faf India
Hiross Zander Navi Mumbai, India
Finite Airtek Filtration/Finite Padova Business Unit +91 22 651 370 8185
Oxford, MI Padova, Italy www.parker.com/india
248 628 6400 +39 049 9712 111
www.parker.com/finitefilter www.parker.com/hzd Parker Fowler
Bangalore, India
Engine Filtration & Hiross Zander +91 80 2783 6794
Essen Business Unit www.johnfowlerindia.com
Water Purification Essen, Germany
Racor Japan
+49 2054 9340
Modesto, CA Tokyo, Japan
www.parker.com/hzd
209 521 7860 +81 45 870 1522
www.parker.com/racor www.parker.com/japan
Engine Filtration &
Holly Springs, MS Water Purification Parker Techno
662 252 2656 Racor Osaka, Japan
www.parker.com/racor Dewsbury, England +81 66 340 1600
+44 (0) 1924 487 000 www.techno.taiyo-ltd.co.jp
Racor – Village Marine Tec. www.parker.com/rfde
Gardena, CA Korea
310 516 9911 Racor Research & Development Hwaseon-City
desalination.parker.com Stuttgart, Germany +82 31 359 0852
+49 (0)711 7071 290-10 www.parker.com/korea
Parker Sea Recovery www.parker.com/rfde
Carson, CA Singapore
310 637 3400 Hydraulic Filtration Jurong Town, Singapore
www.searecovery.com Hydraulic Filter +65 6887 6300
Arnhem, Holland www.parker.com/singapore
Hydraulic Filtration +31 26 3760376
Hydraulic Filter Thailand
www.parker.com/hfde
Metamora, OH Bangkok, Thailand
419 644 4311 Urjala Operation +66 2186 7000
www.parker.com/hydraulicfilter Urjala, Finland www.parker.com/thailand
+358 20 753 2500
Laval, QC Canada www.parker.com/hfde
450 629 9594
www.parkerfarr.com Condition Monitoring Centre Latin America
Parker Comercio Ltda.
Norfolk, England
Filtration Division
Process Filtration +44 (0) 1842 763 299
Sao Paulo, Brazil
domnick hunter Process Filtration www.parker.com/hfde
+55 12 4009 3500
Oxnard, CA www.parker.com/br
805 604 3400 Parker Kittiwake
West Sussex, England
www.parker.com/processfiltration Pan American Division
+44 (0) 1903 731 470
Miami, FL
Madison, WI www.kittiwake.com
305 470 8800
608 824 0500 www.parker.com/panam
www.scilog.com Parker Procal
Peterborough, England
Phoenixville, PA +44 (0) 1733 232 495
610 933 1600 www.kittiwake.com Africa
www.parker.com/processfiltration Aeroport Kempton Park, South Africa
Process Filtration +27 11 9610700
Aerospace Filtration domnick hunter Process Filtration www.parker.com/africa
Velcon Filtration Birtley, England
Colorado Springs, CO +44 (0) 191 410 5121
719 531 5855 www.parker.com/processfiltration
www.velcon.com
Parker Twin Filter BV
Zaandam, Netherlands
+31(0)75 655 50 00
www.twinfilter.com
© 2015 Parker Hannifin Corporation. Product names are trademarks or registered trademarks of their respective companies. Bulletin RCR017678/US
1M 03/2006 © All rights reserved.