CARS, LIGHT COMMERCIAL, TRUCKS & HEAVY EQUIPMENT – DPF Cleaning Australia
Diesel Particulate Filters (DPF) are installed in most modern diesel powered passenger vehicles manufactured since 2005.
All 2007 and newer on-road trucks are equipped with diesel particulate filters to reduce particulate matter (soot) and ash in accordance with Euro 5 specs. Trucks newer than 2010 are also equipped with additional systems such as SCR (Selective Catalyst Reduction/Diesel Emissions Fluid and /or EGR (Exhaust Gas Recirculation) technology to control Nitrogen Oxides (NOx).
A clean DPF ensures optimum engine power, performance and fuel economy reducing the risk of unplanned maintenance expenses and down time.
Diesel Particulate Filters are a widely used, proven emissions control product in the Mining Industry on varying sizes of equipment from drill rigs to loaders, dump trucks, heavy transport and stationary diesel powered equipment.
In all these sectors an automatic regeneration mode is initiated by sensors that monitor the level of diesel particulate matter.
Excessive oil or fuel contamination, incorrect or by-passing of scheduled burns, short distance city driving, excessive engine hours and various other factors leads to over-sooting and ash loading where the vehicles or equipment experience frequent and ineffective regenerations, loss of power, decreased fuel efficiency and eventually cease to operate altogether.
The MTM-ICS Servicing System can safely recover all types of DPF / DOC / CAT type filters across all industry sectors at a fraction of the cost of replacement. As Western Australia’s only locally owned and operated DPF Recovery and Supply Company, we understand the importance of Good Customer Service. We aim to work closely with our customers to ensure Great Savings, Guaranteed Professional Standards and Results and Fast Turnaround Times.
Please contact us for further information on our Service Exchange Option and our very competitive pricing structure.
OUR PROCESS – DPF CLEANING AUSTRALIA
What sets us apart…
1. DPF Recovery Capability
MTM-ICS technical staff can regenerate all types of DPF/DOC/CAT/ including open-ended canister type and enclosed one piece units.
95% of enclosed CAT /DOC and DPF combinations do not have to be cut open for cleaning which means no interfering with the integrity of the original unit.
Our process allows us to inspect the unit internally then using our MTM designed Thermal Regeneration and Hydro Flush technology, we can thoroughly clean and recover all types of DPF’s, eliminating the need for cutting and re-welding of filter units.
THERMAL REGEN OVEN
2. Hydro-Flush Technology
The Hydro-Flush technology is used in conjunction with Thermal Regeneration and or Ultrasonic Cleaning and Air Knife blasting.
Our DPF cleaning system is a proprietary aqueous based technology that doesn’t use conventional limited pneumatic methods alone. Designed by our team at MTM, the cleaning method efficiency regenerates DPF filters back to OEM specifications and is capable of cleaning any configuration of DPF from small cars, buses, trucks, earthmoving equipment, off road and stationary power equipment without cutting, welding or structural modifications to access the filter core. Flow rate and back pressure is monitored during the hydro-flush process to meet OEM specifications and when achieved the unit proceeds to the pneumatic drying stage and is dried completely before final flow and pressure testing and inspection is conducted.
This technology excels at salvaging DPFs that have a high soot and ash load or those that are heavily oil soaked, without the risk of damage to the DPF. MTM-ICS specializes in recovering oil or coolant contaminated DPFs. Our method targets and breaks-up soaked ash and soot deposits which cannot be cleaned effectively with other conventional pneumatic filter cleaning processes.
3. DPF Before/After Flow Restriction
All filters are tested before and after on our custom-designed flow bench using a variable frequency drive.
This allows us to test DPF, CAT and DOC in a simulated exhaust flow environment, from idle to full load conditions, providing accurate CFM flow and differential pressure measurements for engines up to 2000HP.
Using our baseline of recorded information our staff can accurately determine how much exhaust flow is needed for every type of engine then simulate the reading on the flow bench. In contrast, most commercial DPF flow benches provide only a single pressure measurement at one low flow rate.
MTMs flow and back pressure measurements provide an accurate evaluation of the filter’s performance on the engine. Our ability to accurately test simulated exhaust flow and quantify the results ensures your DPF is restored to its peak performance.
AIR FLOW BENCH
DPF Cleaning Australia – OUR 6 STEP METHOD:
1. Recording of Details /Initial Inspection Cell Pin Depth Testing / Before Air Flow and Back Pressure Bench Testing.
2. Simulated Thermal Regeneration / Reverse pulse Pneumatic Air Knife Blast Through.
3. Ultrasonic Bath or Water Hydro Flush Chemical Clean / Hydro flow and Back Pressure testing.
4. Pneumatic Warm Air Drying
5. Final Flow / Back Pressure Testing and Final Internal Substrate inspection
6. Record Keeping /Packing and Tagging.
Basic DPF cleaning begins with a visual internal inspection for evidence of damage such as cracking, melting or loose substrate and where possible internal pin depth testing to determine if the cleaning process is valid. Imputing of client data for accurate record keeping is then recorded. If the unit is deemed unserviceable we can offer our aftermarket option at very competitive pricing from our extensive range in stock with a 2 year manufacturers warranty.
Before Air flow and back pressure bench test will determine the amount of restriction. Air flow is measured in 2 mediums 1: flow differential pressure H2o and 2: CFM restriction. This data is used in conjunction with OEM specifications and compared to a base line of historical data.
If the flow restriction and other data show the unit is not to OEM specifications the DPF is then placed into a thermal regeneration oven overnight. The temperature cycle is pre programmed for individual conditions and the type of DPF. The bond between any remaining hydrocarbon based particulate matter is fractured and burnt off between the substrate walls, allowing the remaining ash to be easily removed in the next step.
Once thermal regeneration is completed the DPF unit is placed in an enclosed chamber for reverse pulse pneumatic air knife blast through to remove all loose soot and ash.
The next step determines the process for the final cleaning required.
1. Ultrasonic Bath for the cleaning of Catalytic Converters / DOC units to loosen any PM from the substrate and a clean water flush. Warm air pneumatic drying.
2. Warm water Hydro Flush with chemical clean. Once the thermal process is completed the DPF is placed in our Hydro Flush Unit where the final part of cleaning is done. This technology is far superior to traditional pneumatic methods. Warm water and specialized anti rust cleaning chemicals are flushed through the DPF until clear water is sighted. A clean flush rinse is followed to eliminate any residual chemicals. During this cleaning process, pressure restrictions and flow can be measured.
While still connected to the Hydro flush machine, a pressure differential test is conducted , this shows any restriction within the DPF substrate confirming the unit is free flowing , then compressed air is introduced to expel any excess water and allowing for better drying times.
The DPF is then placed on our pneumatic warm air drying bench to dry completely and enable further accurate testing.
Once dry, a final inspection of the substrate is conducted
Finally the DPF is flow and back pressure bench tested and readings are measured against base line historical data to confirm maximum air flow and minimum restriction to meet OEM specification.
All the data is collated for the clients records then recorded with additional relevant information.
The DPF is then tagged and packed according to its size, to minimize any damage during transit and is then ready for shipping back to the client.
Oil & Coolant Contaminated DPF Recovery:
Mechanical failures of a turbocharger, injectors, head gaskets and EGR system can cause excessive amounts of wet hydrocarbon loading. Oil and/or coolant soaked DPFs can be restored to serviceable condition if exposed to the correct regeneration cycles in the regeneration oven. Most DPF service providers will often refuse to clean oil saturated DPFs or destroy an otherwise salvageable DPF due to inexperience. MTM – ICS specializes in recovering oil or coolant contaminated DPFs to serviceable standards without the risk of damaging the DPF or interfering with the units’ structural integrity.
NOTE: It’s important to note that particulate matter does not load uniformly throughout or across the face of a DPF.
Our DPF cleaning process identifies and removes PM (particulate matter) and micro-pore restrictions from these high soot load zones ensuring a cleaner more flow efficient result. Filters that are heavily loaded with PM (particulate matter) may need to have the thermal regeneration process repeated a couple of times to restore the DPF to serviceable condition.
Inspection, Testing & Quality Control Standards:
The MTM-ICS DPF Cleaning process incorporates a rigorous inspection and data recording process tracking each DPF by serial number throughout each stage of the cleaning process. Baseline and historical data is used to track and assess the lifecycle and maintenance requirements for each DPF. Every unit is shipped with a data report to the customer for their fleet management records.
MTM-ICS provides professional and reliable servicing and supply for all DPFs – DOCs and CATs on the market today. If you need to replace a damaged filter or downtime is crucial, we can offer our clients both a Service Exchange or High Quality Aftermarket replacement option.
We carry a large number of exchange DPFs already in stock for your convenience:
If you can’t be without your vehicle for our standard turnaround service (usually 2 days) then you are welcome to use our Express Exchange Service. Your blocked but serviceable DPF is exchanged for an already cleaned, re-conditioned and fully tested unit.
Please call us for further information on our Service Exchange Option and our very competitive pricing structure.