Clean Solutions Winning Strategy

Prevent problems before they occur

Protect your infrastructure investment

1 1.Clean at Inlet 2 Protect in Tank

2. 33. Polish at Outlet
 Things to identify @ Site
● Check tank size(18,000L, 20,000L & etc…)?
● How many tanks?
● Check current flowrate @ inlet & outlet?
● Pump Specs?
● Types of liquid stored?
● Liquid Specs(Diesel, Hydraulics or Lube)?
● Problems faced(Sludge, water or dirt)?
● Types of equipment used on-site? Tier 4? Tier 5?
● On-site photos?
DO NOT RECOMMEND ONLY STAGE 1 & 2 or STAGE 2 & 3.
It will not work effectively! All stages must be installed to
achieve the targeted ISO cleanliness.
Examples @ Site

Tank Size: 20,000L

Examples @ Site

Flowrate(Pump Specs): 5-30 GPM/ 20-120L/Min

Examples @ Site

Fuel Specs from Fuel/Lube Suppliers

 Examples @ Site

Big Particles

Sludge

Using Patch Test Kit X009329 to identify the Problems

Examples @ Site

Identify Inlet & Outlet

Why Donaldson?
(Why anyone else?)

● Cleanest Fuels and Lubes

● Compact and Easiest to Install
● Fastest to Service
● Lowest Cost
● Petroleum Customers
 Fuels, Lubes & Hydraulic Filters

1) Donaldson Filters are able to achieve Targeted ISO cleanliness rating

to meet equipment requirements

2) Efficiency of all the filters are achievable @ Beta 2000 ~ 99.95% to

remove particles in the liquids
Cleanliness Requirements
 Low pressure drops

Example: DBB8666 filter for diesel have low pressure drops during
operations based on test flow chart
 Low pressure drops

Example: DBB0248 filter for all applications have low pressure drops
during operations based on test flow chart
“How long will a bulk filter last?”

Generally speaking:

• Dirty Fuel (22/21/18) – About 25,000

gallons per element
• Average Fuel (20/18/15) – About 50,000
gallons per element
• Clean Fuel (18/16/13) – About 100,000
gallons per element

Field Topics
Compact, Flexible System Designs
Filter Manifolds

1 1.Clean at Inlet 2 Protect in Tank

2. 33. Polish at Outlet
Filter Manifolds

•Spin on design easy for installation and service

Filter Manifolds(Small Flowrate)
Single head # P570329 or # P570330 

Single head rated @ 246 l/pm
Use single heads for dispensers up to approx 80 l/pm
Consider DBB8777 7 um element
Clean and dry kit part # P506073 

Two single heads in series
First element to stop dirt DBB8666
Second element SAP DBB0248 blocks water
Clean and dry kit part # P506073 

US Fed Ex installation
Eliminate claims against fuel provider
Marketing of clean fuel to increase revenue 
Single head # P570329 or # P570330 

Volume of fuel cleaned will impact element life
Consider P568583 dual head
Slow flow across the media = long life 
Dual clean and dry kit # X011450 

For high flow or usage 160 l/pm dispensers  
Dirt first SAP second 
Flange adapters part # P506071 available
Dual head part # P568583 

Rated at 473 l/pm for diesel fuel
Ideal for smaller volume service trucks
Do not mix elements 
Filter Manifolds(Large Flowrate)
Filter Manifolds

From to low flow dispensers,

To the highest flow mine site applications
Filter Manifolds(Large Flowrate)

•I-12 manifold innovative design

of manifold to optimize space
Two way, 4 filter manifold part # P561880 

Rated at 946 l/pm for diesel fuel
Ideal for dispense rates of 200‐ 400 l/pm
Fit additional manifold in series to block water 
Four way, 8 filter manifold part # P568932 

Rated at 1893 l/pm for diesel fuel
Ideal for dispense rates of 600 l/pm
Fit additional manifold in series to block water 
Four way, 8 filter manifold part # P568932 

Two manifolds fitted in series 
First manifold used to stop dirt
Second manifold fitted with water blocking SAP 
Five way, 10 filter manifold part # P568933 

Flow rates to 2271 l/pm on diesel fuels
Suited for most 1200 l/pm offloading 
Ideal for dispense at high volume sites 
Five way, 10 filter manifold part # P568933 

Filters may be installed at any orientation
Vertical or horizontal 
I12 12 filter manifold part # DFF1012

Flow rates to 2650 l/pm on diesel fuels
In‐line configuration for cost effective installation
Blanking caps DFF1005 available to block side(s) 
I12 12 filter manifold part # DFF1012

The filter media captures and retains contaminant
Low OH&S risk maximum filter weight ≤ 5kgs
No special tooling required
Filter Manifolds

1) Different types of manifold up to 12 filters

variation depends on sizing of the system.

2) Flowrate of the system is important during

sizing of the system. Donaldson Clean
Solutions manifolds max flow range is up to
700gpm/2650lpm.

3) Fluid compatibility of the manifold are all types

of fuel and lubricants.

4) High flow rate & pressure system

TRAP Breathers

1 1.Clean at Inlet 2 Protect in Tank

2. 33. Polish at Outlet
TRAP Breathers
TRAP Breathers

High dirt holding capacity breathers are the single most cost 
effective means of improving cleanliness
TRAP Breathers

Complete assembly including positive pressure check valve
Replacement breather part # P923075
Size breathers at one unit per 500 l/pm in or out flow
TRAP Breathers

Large capacity tanks will require two breather assemblies
Allowance for thermal cycling in addition to flow rates
Duplex manifold not a Donaldson part
TRAP Breathers

High capacity breathers 97% efficient down to 3 micron
One part number suits all Australian environments
Breather change outs critical
System Pump

1 1.Clean at Inlet 2 Protect in Tank

2. 33. Polish at Outlet
 System Pump
Assume:

• DFF1012 x 2units
• DFF1012 x 1unit
• DBB8666 x 12pcs
• DBB8666 x 12pcs
• DBB0248 x 12 pcs
 System Pump
Assume:
• DFF1012 x 1unit
• DBB8666 x 12pcs

● DBB8666 pressure drop (standard market pump flowrate ~100lpm -150lpm) ~ 0.1 bar x 12 = ~ 1.2bar
● DFF1012 pressure drop (standard market pump flowrate ~100lpm -150lpm) ~ 0.1 bar
● Total pressure drop @ Inlet ~ 1.3bar
 System Pump
Assume:
• DFF1012 x 2units
• DBB8666 x 12pcs
• DBB0248 x 12 pcs

● DBB8666 pressure drop (standard market pump flowrate ~100lpm -150lpm) ~ 0.1 bar x 12 = ~1.2bar
● DBB0248 pressure drop (standard market pump flowrate ~100lpm -150lpm) ~ 0.1 bar x 12 = ~1.2 bar
● DFF1012 pressure drop (standard market pump flowrate ~100lpm -150lpm) ~ 0.1 bar x 2 = ~0.2 bar
● Total pressure drop @ Outlet ~ 1.2bar + 1.2bar + 0.2bar = ~ 2.6bar
 System Pump
Assume:
• DFF1012 x 2units
• DFF1012 x 1unit • DBB8666 x 12pcs
• DBB8666 x 12pcs • DBB0248 x 12 pcs

● Total Pressure Drop @ Inlet = ~ 1.3bar

● Total Pressure Drop @ Outlet = ~ 2.6bar

● In the situation when filters need to replace = Pressure drop @ 2.75bar

● Total pressure loss when filters replace @ inlet = 1.3bar + 2.75bar = ~

4.05bar

● Total pressure loss when filters replace @ outlet = 2.6bar + 2.75bar = ~

5.35bar

● Propose to use a 10bar pump with a flowrate of 100lpm-150lpm

System Pump(Electrical)

● User need to have power source of 230VAC for the pump

● User may need to purchase gensets to power up electrical pump
System Pump(Battery)

● User need to have battery source of 12-24VDC for the pump

● User may found pump flowrate and pressure is slower
● Cheaper alternative than Electrical pump
Competitors Are Bulky & Expensive!

Less effective filtration Cross contamination

Complicated installation Require electrical power
Hours to service Difficult, messy filter change
Cost prohibitive $50-100k to end user
Vs Competitor

BEFORE AFTER
Less efficient Higher efficiency
Difficult to service Easier to service
Higher pressure drop Lower pressure drop
Lower capacity Longer life
Vs Competitor

• No mention of Target ISO cleanliness after liquid is filtered

• Filter have lower Beta ratings(Efficiency)
• No mention of pressure drops
Vs Competitor

●CAT – Polish
●Cummins – Polish
●PALL – Clean, Protect & Polish
●Cimtek – Polish
●Facet – Polish
●Velcon – Polish
●Parker – Clean& Polish
●Mahle – Clean, Protect & Polish
Savings Calculation Examples
a) Number of Machines (Eg, 50 units?)

b) Operating Hours per year (Eg, 750 hrs)

c) Current Availability(Uptime) (Eg, 90%)

d) Downtime Costs per hour (Eg, USD $ 200)

e) Total Downtime Costs = ?

Savings Calculation Examples
What if Downtime Costs Due to Parts ?

1. Short injectors usage hours

2. Filters short life

Savings Calculation Examples
Quick Calculation Base on Injectors Damage

a) Number of Machines : 20 trucks

b) Operating Hours per year : 750 hrs or ~45,000km/yr (60km/h)

c) Current Availability(Uptime) : 90%

d) Downtime Costs per hour : ($200)

e) Total Downtime Costs = (20 x 750 x [(100%-90%)/100%] x $200

f) Injectors & parts cost per year : ($5000 x 2 x 20trucks)

g) Total cost(Downtime + Parts) :

$300,000 + ($10,000 x 20) = $500,000

Savings Calculation Examples
Assume, Standard 18,000L tank @ 150Lpm

Assumed cost of the system:

• Fixed System cost ~ 20,000USD
• Consumable filters per year cost ~ 10,000USD
• Maintenance cost of fleet ~ 500,000USD
• A ~30,000USD system that can save ~10%-20% of 500,000USD,
saving is ~100,000USD
• Compared USD30,000 spent, ~USD100,000 is saved.
Why Donaldson?
In addition to the cleanest fluids….
● Compact, Modular System Design
Much smaller footprint than competitors

● Flexible
Customize by configuration, fluid, capacity, flow
● Fast, Uncomplicated Install and Service
No electrical, can be prefabricated to “drop in”
Spin-on elements are fast, clean & easy to change
● Lowest Cost of Ownership
And did we mention...
UNSURPASSED FLUID CLEANLINESS LEVELS
IN A SINGE PASS?!