Why

Filtration ?Tighter and tighter tolerances

Less wear/tear - High Engine life
Over 75% of all system failures are a
direct result of contamination
Clean oil, air & Fuel to Engine
Reduced Engine maintainence

Optimum Filtration - To reach desired cleanliness

level and to maintain it at lowest possible cost

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 SOURCES OF CONTAMINATION

BUILT IN CONTAMINATION
Metal burrs, sand and other damaging particles
from the manufacture, assembly and/or testing
of components
INGRESSED CONTANMINATION
From the environment surrounding the system,
usually via leaking seals, breather caps, and/or
worn out parts
WEAR GENERATED CONTAMINATION
Caused by contaminants within the system,
usually particles generated by contact with
surfaces of the moving parts of the engine
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 Filtration Types

For surface filtration –

Medium should contain uniform small pores
smaller than the smallest particle to be
removed

For Depth filtration -

Medium must contain an infinite number of
small, irregular, continuos passages which
give the solids a torturous path to travel
through
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 MODES OF FILTRATION

For heavy particles, particles get

Inertial impaction trapped when fluid changes direction

For smallest particles, particles get

Diffusion collided with fiber and are trapped

For medium sized particles, particles

Interception touch fiber and are collected

For large particle sizes, particle

Sieving gets trapped between two fibres

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 TYPICAL PARTICLE SIZES

Grain of Table Salt 100 micron

Human Hair 79 micron
Lower limit of visibility 40 micron
White blood cell 25 micron
Talcum powder 10 micron

Red blood cell 8 micron

Bacteria 2 micron
Silt <5 micron

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 PAPER OR FILTER MEDIA
• Media is the term used to define the material that removes the
particles from the fluid.The paper is cellulose fibers (wood pulp)or
synthetic fiber (man made ) or sometimes cotton linter(cotton
pulp).
• For oil filters the pore size is 25 to 35 micron
• For Fuel filters the pore size is 4 to 15 micron
• For air filters the pore size is 12 to 30 micron.
• Thickness of paper can be 0.3 to 1mm depending on the
application .
• Burst strength is 3-7 kg /cm sq
Note. All these tests can be done on one Apparatus which we have
in Purolator.

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 Part No Starting with Application/ Code for

1 Oil
2 Air
3 Fuel/ Fuel kits
4 Oil
5 Misc
6 Air
71 Oil
72 Air
73 Fuel
8 Industrial
9 Fuel
19 Oil, Kits

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 9 digit code of filters

ABCD 00 I 99 00 is Spin on , I is Individual packing , 99

is AM .
ABCD EL I 99 EL is element

ABCD EL B 99 B is for bulk packing

1774 00 I 99 Oil spin on in individual packing

2744 EL I 99 Air Element in individual packing

3331 EL I 99 Fuel Element in individual packing
1917 EL I 99 Oil fuel kit with elements
3494 00 I 99 Oil fuel kit with spin on filters

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 Inline 4 Cylinder Engine

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 This animation shows the
route taken by the oil
within an engine. The oil
pump draws oil from the
oil pan, then forces it
through the filter, into the
crankshaft passage,
through the connecting
rods to the pistons and
rings. Oil is pushed
through the lifters and
pushrods, and covers the
rocker arms. It then flows
back down into the pan to
complete the cycle.

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 PARTS OF A SPIN-ON FILTER
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 Components of Filter

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 Spin On testing for Leakage
• 100 % Spin on’s are tested after seaming for
leakage at a pressure of 6-7 bar , which
means that there is no possibility of leakage in
the vehicle where the pressure is not more
than 2-3 bar .
• The common problems found in leakage cases
are over tightening , surface of housing not
clean , gasket not seated properly.

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 Filter Components
OIL FILTER / FUEL FILTER
Bowl - Casing
Element - Filtering Component
Paper pack - Media
End Caps - Hold paper pack
Sealant - Holds pleat to caps
Bypass valve - Prevents starving
Spring - Alignment of Element
Gasket - Sealing
Cover Assembly - Partition between oil channels
Check Valve - Anti Drain
Centre tube and outer tube
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 Filter Components
Air Filter
Housing - Plastic / Metal
Top cover
Bottom cover - Dust Holder
Hose fitments
Rubber sealing
Holding members

Element
Paper
End Sealing - PU / Rubber / Plastic

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Wide range of Oil Filters :
products… *Cartridges
* Spin-on
* Housing Adapters
Air Filters :
* Plastisol
* Metal-end cap
* Panel
Fuel Filters :
* Namda
* In- line
* CAV Type

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 PUROLATOR TEST FACILITIES
OIL/FUEL/HYDRAULLIC FILTERS
- IMPULSE TEST
- ADB VALVE OPENING TEST
- RELIEF VALVE OPENING TEST
- BURST TEST
- LIFE AND EFFICIENCY TEST
- COLLAPSE PRESSURE TEST
- BETA RATIO TESTING
- VIBRATION TESTING
MATERIALS
- TENSILE & COMPRESSION TESTING
- SALT SPRAY CHAMBER
- COULTER POROMETER
- STIFFNESS TESTER-FILTER PAPER
- COLD CHAMBER TESTING

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 PUROLATOR TEST FACILTIES

AIR FILTERS
- LIFE AND EFFICIECY
- INITIAL RESTRICTION
- VIBRATION TESTING
- COMPRESSION SET FOR PU
- COMPUTERISED AIR RIG WITH
AUTOMATIC DUST FEEDER
- BETA RATIO AND PARTICLE COUNTING

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 Figure 1.

Figure 2.

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 Air filter cleaning

• For all air filters cleaning , dry air to be

used.

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 Fuel Filter & Water separation

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Displacement
The combustion chamber is the area where compression and combustion take place.
As the piston moves up and down, you can see that the size of the combustion chamber
changes. It has some maximum volume as well as a minimum volume. The difference
between the maximum and minimum is called the displacement and is measured in liters or
CCs (Cubic Centimeters, where 1,000 cubic centimeters equals a liter).
Here are some examples:
•A motorcycle might have a 500 cc or a 750 cc engine.
•A sports car might have a 5.0 liter (5,000 cc) engine.
Most normal car engines fall somewhere between 1.5 liter (1,500 cc) and 4.0 liters (4,000
cc)
If you have a 4-cylinder engine and each cylinder displaces half a liter, then the entire
engine is a "2.0 liter engine." If each cylinder displaces half a liter and there are six
cylinders arranged in a V configuration, you have a "3.0 liter V-6."
bhp
Brake horsepower was a term commonly used before the 1970s in the USA, and is still
common in the UK. It indicates the brake, the device for measuring the true power of the
engine. Stating power in 'bhp' gives some indication this is a true reading, rather than a
calculated or predicted one. However, several manufacturers started to strip their engines
of essential ancilliaries for the purposes of getting a high horsepower figure to use in
marketing the car. In the USA the term fell into disuse after the American Society of
Automotive Engineers (SAE) recommended manufacturers use "hp (SAE)" to indicate the
power of the engine, given that particular car's complete engine installation. The British
market seemed not to need the correction.
HP is the torque *RPM/5252

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 WHAT IS COALESCING
• Water can get dissolved in Fuel up to about 50
ppm but if the concentration of water is high it
will form droplets.At very low temp. these water
droplets will freeze and flow of Fuel may get
interrupted.
• Removal of water from Fuel by the formation of
big droplets from small droplets is known as
coalescing.
• For Military application water must be reduced
to 5ppm and for Civil application to 15 ppm.

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 HOW COALESCING IS DONE
• Separation of one liquid from other depends on
difference in surface tension and density.
• Very small water droplets are retained on the
surface of fine fibers.Then they merge with
other droplets to grow in size till they become
big enough to be pushed downstream to a layer
of coarser fibers.
• The Coarser fibers are able to hold the bigger
droplets they grow again and step by step
droplets move through the filter.
• Finally they become so heavy to fall due to
gravity at the bottom,while clean fuel continue
to flow through element in horizontal direction.

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 COALESCING PROCESS
LIQUID-LIQUID SEPARATOR

FIRST STAGE SECOND STAGE DRAINAGE

DROP SIZE

ATF VELOCITY

WATER DROP FACE

VELOCITY

WATER VELOCITY
PROFILE

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 HOW WATER SEPARATION TAKES PLACE

• Coalesced water droplets tends to mix with fuel

again if not drained in time.
• Water Separator media is coated with
Hydrophobic Resins and Chemicals to make the
contact angle high and surface energy lowest so
that water droplet do not wet the media surface
and prevent the entry of coalesced water in to
flow stream again.

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 HOW WETTING OF SURFACE
TAKES PLACE
CONTACT CONTACT CONTACT
CONTACT ANGLE=90 ANGLE>90
ANGLE=0 ANGLE<90

MATERIAL CONTACT SURFACE

MEDIA ANGLE ENERGY MEDIA

PTFE 112 18
PARAFIN 110 19
POLYPROPYLENE 108 26

MORE POLYETHELENE 96 33 MORE

HYDROPHILIC HYDROPHOBIC
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 SURFACE ENERGY
• SURFACE ENERGY:- At a liquid solid
interface if molecules of liquid have a
stronger attraction to the molecules of
solid surface than to each other (Adhesive
forces are stronger than Cohesive
forces)Then wetting of surfaces takes
place.Incase liquid molecules are strongly
attracted to each other than molecules of
solid then liquid beads up and do not wet
the surface.

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 CONTACT ANGLE
• To quantify liquids surface wetting
characteristics is to measure the contact
angle.Contact angle is angle formed by
solid/liquid interface from side of liquid.
• Higher is the measure of contact angle
least in surface wetting ( In case contact
angle is more than 90 Deg.wetting of
surface does not take place)

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 THE COALESCENCE PROCESS
Water Distribution Across a Fibre Bed
Graping
FUEL
Tributaries

Ballooning

Flow Droplet Chains

Pointing
Fuel / water
Emulsion Fuel
Water Film Fibrous Bed
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 Contents

• 1. TC Fuel filter and

water separator new
media.
• 2. TC Oil filter new
media .
• 3. Metal free Primary
and secondary fuel
filters with special
media and special
manufacturing process.
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 Test Data for Fuel filter and water separator assembly

% Efficiency

78 90 99 90 97 100
100
> 3 mic
50 > 5 mic
> 10 mic
0
FG (OE) MFSI

Life in grams

100 81
80
60
40
26
20
0
FG (OE) MFSI

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 New technology in Fuel Filters
• Double layer media gives
more efficiency and life.

• Meltblown / paper
combination .

Cellulose paper saturated Silicon coated Paper Melt blown

w/thermosetting resins + for Water separation layer to trap
meltblown layer and fine filtration heavier
contaminants

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 Test Data for Tata Cummins Oil filter
% Efficiency

92 93
100
61 68
Initial
50
Final

0
FG (OE) MFSI

Life in grams

100
80
60
21 31.5
40
20
0
FG (OE) MFSI
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 Increased life in oil filters

• Dimpling done in paper for

better pleat separation which
provides more dust holding
and increased life .

Dimpling in paper for better filtration

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 Metal Free technology

• 1. Being metal free it does not contaminate

the environment ( no plating which can
later cause soil contamination ) and only
recyclable nylon which is non polluting .

• 2. It is more efficient in water separation

( acrylic coated paper which is hydrophobic)
and filtration efficiency > 95 % to 98% ,

• 3. 100 % leak proof (visible that there is no

adhesive and the paper is embedded in the
nylon under specific conditions where the
other side of cap stays normal ( no
deformation).

• 4. It is very difficult technology to duplicate

due to its special process requirements for
embedment of the caps.

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 Primary and Secondary kits for
diesel filtration

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 Purolator Metal Free Primary & Secondary

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 Automotive terms
• DTSi Digital Twin Spark ignition
• CDI Computerised Direct Ignition
• TRICS III Throttle responsive Ignition control system.
• CRDI Common rail diesel injection
• VE Pump Verteil Einstell Pumpe
• EDC Electric Governing VE Pump

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 PIL Parwanoo
Plant Organization

Vadiraj K Meghlal
Plant Head

QCDGP, ERP, 5S
Improvements
Employee & Customer
Satisfaction

Tanuj Bharadwaj
NS Sohal Anil Banta Vinay Agrawal Reetu Jain Anand Kumar Ajat Shatru
MR TS/ISO
Head Manufacturing Head QA Head Finance HR ERP IT
AM Quality and Dev

COQ reduction, productivity ERP Implementation, APS Coach

QCD, Past Dues, COPQ, Over head control, ERP, Employee Satisfaction, Training, Uptime, training,
In process & customer quality Dispatch Stores Prod dev Mahle and Puro AM
Process improvements Stores, MIS Compliance, Cost Control Support, BaaN
Export product dev Customer Satisfaction TS 16949 / ISO 9001

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 PIL Parwanoo
Operations Organization

NS Sohal
Head Operations

Georgekutty Thomas Kadavan

(Pawan Dhiman) SS Kaith Keshav Mahajan
MR EHS
Production Vendor & Jobwork Head Materials
Process Engineering / Projects

Neeraj Bhatia Sunnit Bector

PPC / Dispatch Purchase
Shift Engineer Maintenance

Anjana (OE) Satish Sharma Manoj Mishra

Gurjinder Singh Ravinder Singh
BaaN & Support Planning Process & Projects

Arun Nair Saurabh Batala Geeta Chauhan C Goel

Amar Singh Hiteshi
Production Planning & Purchase BaaN & Support Process Engineering

PS Rawat
Kuldeep Kumar Shakia (OE)
Dispatch / Stores

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 PIL Parwanoo
Finance Organization

Vinay Agrawal
Head Finance

Vacant
PK Goel P Chakraborthy Vikas Rawat Vikram Singh Stores/Dispatch
One CA Required

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 PIL Parwanoo
QA Organization

Anil Banta
QA

Sukhdeep Mor Vacant Bupesh Sharma

Receiving In Process Final

Sumit Sharma Reena Sharma

Anita Negi (OE)

Surekha Bhatia (OE)

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 PIL Parwanoo
HR Organization

Reetu Jain

Parnita Yadav

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