http://p2library.nfesc.navy.mil/P2_Opportunity_Handbook/6_II_1.html
BYPASS FILTER FOR VEHICLE MOTOR OIL
Revision Date: 11/03
Process Code: Navy and Marine Corps: SER-002-99; Air Force: PM05; Army: VHM
Usage List: Navy: Low; Air Force: Low; Army: Low; Marine Corps: Medium
Alternative For: Waste oil generation and disposal
Compliance Impact: Low
Applicable EPCRA Targeted Constituents and CAS Numbers: N/A
Overview:
Bypass filters are designed to remove smaller particulates than would be removed by an engine's normal filter, so that the need for additional oil or oil changes can be reduced. High-density bypass filtration extends the useful life of oils. In addition to reducing waste oil generation, collateral benefits include reduced acquisition of petroleum-based lubricants, reduced-labor hours in the management of waste oil, and an extension of engine life through improved lubrication.
Bypass filtration is a system that provides high density, slow filtration (one to six quarts per minute at engine operating temperature) of engine oil without affecting the primary OEM filtration system. Bypass filters also remove solid contaminants down to 3 microns, control moisture content in oil, are compatible with all MIL-SPEC oils and extend oil drain intervals. Bypass filters are installed in the engine compartment of a vehicle or, nearby a stationary engine. The bypass filter is fed a slip stream of oil that bypasses the engine.
Oil added during filter changing, and to replace burned oil, is normally sufficient to replenish the oil's additive package (the component of the oil that is responsible for maintaining pH and preventing deterioration of the oil).
Installing bypass filters may not be feasible on some vehicles in a fleet. The climate in which the vehicle is used, the duration of engine run time, and the age of the vehicle can all influence the feasibility of bypass filter use.
In warm climates where 15W40 is used year round, all vehicles benefit from the additional filtration because flow through the filter starts almost immediately. However, in colder climates, engines need to run at the manufacturer's normal operating temperature for at least ten minutes to reduce the oil's viscosity and to allow flow through the bypass filter. Longer run times are necessary in extremely cold climates.
Several different types of bypass filters are available. Those manufactured by Gulf Coast and Enviro Filtration rely on filter elements that remove particles down to the 1 to 10 micron range. The Gulf Coast unit is distinctive in that it uses a commonly available roll of toilet paper (or paper towels for larger units) as the filter element. The TF Purifier unit filters down to 0.5 to 1.0 micron, and then refines the oil by passing it through a heated element refiner that is vented back into the engine air intake. The heated element volatilizes any unburned fuel, water, or glycols that contaminate the oil and cause the oil's additive package to breakdown. These systems reduce the need for complete oil changes, but the engine's conventional canister filter along with the bypass filters still need to be changed in accordance with manufacturer's recommendations.
Along with filter changes, engine oil must be sampled and analyzed to determine the physical and chemical properties of the oil (see data sheet 6-II-3 for Lubricant Analysis Programs). Using a bypass filter system in conjunction with a lubricant analysis program may reduce the number of oil changes without decreasing the life expectancy of engine parts. The use of bypass filters has been approved for use in Air Force vehicles.
According to Mr. Mike Schleider, Chief Engineer for the Support Equipment and Vehicle Management Directorate at the Warner Robins Air Logistics Center, the use of oil bypass filters in Air Force vehicles has been approved for use once a base has petitioned their MAJCOM for an exemption from the periodic oil change intervals called out in T.O. 36-1-171. However, if approved, these filters will be required to be used in conjunction with an oil analysis program. The oil analysis program is to be used to determine oil change intervals.
Compliance Benefit: Use of a bypass filter for vehicle motor oil will decrease the amount of used oil generated and, as a result, may reduce the used oil management requirements under 40 CFR 279 or 40 CFR 262. In addition, if used oil is not recycled, using a bypass filter may help a facility meet the requirements of waste reduction under RCRA, 40 CFR 262 and Executive Order (EO) 13148. Moreover, since less oil should be stored on site, a facility will decrease the likelihood of reaching the reporting thresholds for that chemical under SARA Title III (40 CFR 300, 355, 370, and 372). A decrease in oil stored on site may also put a facility below storage requirements for developing and implementing a Spill Prevention, Control and Countermeasure Plan under 40 CFR 112.
The compliance benefits listed here are only meant to be used as general guidelines and are not meant to be strictly interpreted. Actual compliance benefits will vary depending on the factors involved, e.g., the amount of workload involved.
Materials Compatibility: Bypass filters must be used in conjunction with a lubricant analysis program. The oil analysis program is used to determine oil change intervals.
Safety and Health: Use of vehicle motor oil poses minimal safety and health concerns. Care must be taken when handling oils that are high in temperature. Proper personal protective equipment is recommended.
Consult your local industrial health specialist, your local health and safety personnel, and the appropriate MSDS prior to implementing this technology.
Benefits:
* Reduces the number of oil changes required.
* Reduces new oil purchases.
* Reduces the generation of oil waste and the associated costs of waste oil handling and disposal.
Disadvantages:
* Payback period may be longer than life span of the vehicle.
Economic Analysis: TF Purifier
A bypass filter with a capacity of up to 12 quarts has a payback period of approximately 14 years for systems operated with conventional oil. If synthetic oil is being processed, the payback period is reduced to approximately 3 years. For a bypass filter with up to 24 quart capacity, the payback periods are 5 years and 1.5 years for conventional and synthetic oils, respectively.
Oil Guard
A bypass filter with a capacity of up to 12 quarts has a payback period of approximately 2.9 years for systems operated with conventional oil. If synthetic oil is being processed, the payback period is reduced to approximately 1.4 years. For a bypass filter with up to 24 quart capacity, the payback periods are 1.6 years and 0.7 years for conventional and synthetic oils, respectively.
Enviro Filtration
A bypass filter with a capacity of up to 12 quarts has a payback period of approximately 2.2 years for systems operated with conventional oil. If synthetic oil is being processed, the payback period is reduced to approximately 0.8 years. For a bypass filter with up to 24 quart capacity, the payback periods are 1.3 years and 0.4 years for conventional and synthetic oils, respectively.
Assumptions:
Motor Oil Cost
* Conventional: $4/gallon
* Synthetic: $17/gallon
* Oil Disposal Cost: $0.75/gallon
Table 1. Cost Comparisons for Oil Changes Alternatives
TF Purifier Enviro
Filtration
Bypass Filters Oil Guard
Bypass Filters Status Quo
Capital Cost
(Installed) 12 qt 24 qt 12 qt 24 qt 12 qt 24 qt 12 qt 24 qt
Number of Oil
Changes per Year $510 $560 $140 $160 $175 $189 N/A N/A
Operating Labor 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr
Supplies $55/yr $66/yr $10/yr $30/yr $23/yr $27/yr $0 $0
Payback Period:
* Conventional
14 yrs 5 yrs 2.2 yrs 1.3 yrs 2.9 yrs 1.6 yrs N/A N/A
* Synthetic
3 yrs 1.5 yrs 0.8 yrs 0.4 yrs 1.4 yrs 0.7 yrs N/A N/A
Click Here to view an Active Spreadsheet for this Economic Analysis and Enter Your Own Values.
To return from the Active Spreadsheet, click the Back arrow on the Tool Bar.
NSN/MSDS:
Product NSN Unit Size Cost MSDS*
Bypass Filter 4940-01-411-9831 Each $1.94
Bypass Filter 4940-01-411-9832 Each $4.48
Bypass Filter 4940-01-411-9833 Each $4.05
Bypass Filter 4940-01-411-9834 Each $5.59
*There are multiple MSDSs for most NSNs. The MSDS (if shown above) is only meant to serve as an example. To return from the MSDS, click the Back arrow on the Tool Bar.
Approving Authority: Appropriate authority for making process changes should always be sought and obtained prior to procuring or implementing any of the technologies described herein.
Points of Contact: Air Force:
Mr. Michael Schleider
Chief, Systems Engineering Division
Support Equipment and Vehicle Management Directorate
WR-ALC/LEE
295 Byron Street
Robins AFB, GA 31098-1611
Phone: (478) 926-7918 x 166
DSN: 468-7003
FAX: (478) 926-7731
DSN FAX: 468-7731
Vendors: This is not meant to be a complete list, as there may be other suppliers of this type of equipment.
OilGuard
305 Airport Road
Oceanside, CA
Phone: (760) 967-0892 or (800) 671-0777
FAX: (760) 967-0893
DSN FAX: 468-7731
E-mail: [email protected]
URL: http://www.oilguard.com/
Gulf Coast Filters
P.O. Box 2787
Gulfcoast, MS 39505
Phone: (228) 832-1663 or (800) 398-8114
FAX: (228) 832-1171
Contact Mr. Jerry Simms
Puradyn Filter Technologies, Inc.
2017 High Ridge Road, Suite 100
Boynton Beach, FL 33426
Phone (561) 547-9499 or (800) 488-0577
FAX: (561) 547-8629
URL: http://www.puradyn.com/
Enviro Filtration
4719 Roosevelt Street
Gary, IN 46408
Phone: (800) 368-4763
FAX: (773) 734-8884
URL: http://www.envirofiltration.com/
Contact Mr. Mike Kovach
Related Links:
None
Sources: Mr. Michael Schleider, Robins Air Force Base, December 1999.
Oil Guard Environmental, January 1999.
Air Force Manual 24-307, "Procedures for Vehicle Maintenance," September, 1995.
"Pacific Air Forces Automotive Analysis Program Guide," HQPACA/LGT, Draft.
[Back]
BYPASS FILTER FOR VEHICLE MOTOR OIL
Revision Date: 11/03
Process Code: Navy and Marine Corps: SER-002-99; Air Force: PM05; Army: VHM
Usage List: Navy: Low; Air Force: Low; Army: Low; Marine Corps: Medium
Alternative For: Waste oil generation and disposal
Compliance Impact: Low
Applicable EPCRA Targeted Constituents and CAS Numbers: N/A
Overview:
Bypass filters are designed to remove smaller particulates than would be removed by an engine's normal filter, so that the need for additional oil or oil changes can be reduced. High-density bypass filtration extends the useful life of oils. In addition to reducing waste oil generation, collateral benefits include reduced acquisition of petroleum-based lubricants, reduced-labor hours in the management of waste oil, and an extension of engine life through improved lubrication.
Bypass filtration is a system that provides high density, slow filtration (one to six quarts per minute at engine operating temperature) of engine oil without affecting the primary OEM filtration system. Bypass filters also remove solid contaminants down to 3 microns, control moisture content in oil, are compatible with all MIL-SPEC oils and extend oil drain intervals. Bypass filters are installed in the engine compartment of a vehicle or, nearby a stationary engine. The bypass filter is fed a slip stream of oil that bypasses the engine.
Oil added during filter changing, and to replace burned oil, is normally sufficient to replenish the oil's additive package (the component of the oil that is responsible for maintaining pH and preventing deterioration of the oil).
Installing bypass filters may not be feasible on some vehicles in a fleet. The climate in which the vehicle is used, the duration of engine run time, and the age of the vehicle can all influence the feasibility of bypass filter use.
In warm climates where 15W40 is used year round, all vehicles benefit from the additional filtration because flow through the filter starts almost immediately. However, in colder climates, engines need to run at the manufacturer's normal operating temperature for at least ten minutes to reduce the oil's viscosity and to allow flow through the bypass filter. Longer run times are necessary in extremely cold climates.
Several different types of bypass filters are available. Those manufactured by Gulf Coast and Enviro Filtration rely on filter elements that remove particles down to the 1 to 10 micron range. The Gulf Coast unit is distinctive in that it uses a commonly available roll of toilet paper (or paper towels for larger units) as the filter element. The TF Purifier unit filters down to 0.5 to 1.0 micron, and then refines the oil by passing it through a heated element refiner that is vented back into the engine air intake. The heated element volatilizes any unburned fuel, water, or glycols that contaminate the oil and cause the oil's additive package to breakdown. These systems reduce the need for complete oil changes, but the engine's conventional canister filter along with the bypass filters still need to be changed in accordance with manufacturer's recommendations.
Along with filter changes, engine oil must be sampled and analyzed to determine the physical and chemical properties of the oil (see data sheet 6-II-3 for Lubricant Analysis Programs). Using a bypass filter system in conjunction with a lubricant analysis program may reduce the number of oil changes without decreasing the life expectancy of engine parts. The use of bypass filters has been approved for use in Air Force vehicles.
According to Mr. Mike Schleider, Chief Engineer for the Support Equipment and Vehicle Management Directorate at the Warner Robins Air Logistics Center, the use of oil bypass filters in Air Force vehicles has been approved for use once a base has petitioned their MAJCOM for an exemption from the periodic oil change intervals called out in T.O. 36-1-171. However, if approved, these filters will be required to be used in conjunction with an oil analysis program. The oil analysis program is to be used to determine oil change intervals.
Compliance Benefit: Use of a bypass filter for vehicle motor oil will decrease the amount of used oil generated and, as a result, may reduce the used oil management requirements under 40 CFR 279 or 40 CFR 262. In addition, if used oil is not recycled, using a bypass filter may help a facility meet the requirements of waste reduction under RCRA, 40 CFR 262 and Executive Order (EO) 13148. Moreover, since less oil should be stored on site, a facility will decrease the likelihood of reaching the reporting thresholds for that chemical under SARA Title III (40 CFR 300, 355, 370, and 372). A decrease in oil stored on site may also put a facility below storage requirements for developing and implementing a Spill Prevention, Control and Countermeasure Plan under 40 CFR 112.
The compliance benefits listed here are only meant to be used as general guidelines and are not meant to be strictly interpreted. Actual compliance benefits will vary depending on the factors involved, e.g., the amount of workload involved.
Materials Compatibility: Bypass filters must be used in conjunction with a lubricant analysis program. The oil analysis program is used to determine oil change intervals.
Safety and Health: Use of vehicle motor oil poses minimal safety and health concerns. Care must be taken when handling oils that are high in temperature. Proper personal protective equipment is recommended.
Consult your local industrial health specialist, your local health and safety personnel, and the appropriate MSDS prior to implementing this technology.
Benefits:
* Reduces the number of oil changes required.
* Reduces new oil purchases.
* Reduces the generation of oil waste and the associated costs of waste oil handling and disposal.
Disadvantages:
* Payback period may be longer than life span of the vehicle.
Economic Analysis: TF Purifier
A bypass filter with a capacity of up to 12 quarts has a payback period of approximately 14 years for systems operated with conventional oil. If synthetic oil is being processed, the payback period is reduced to approximately 3 years. For a bypass filter with up to 24 quart capacity, the payback periods are 5 years and 1.5 years for conventional and synthetic oils, respectively.
Oil Guard
A bypass filter with a capacity of up to 12 quarts has a payback period of approximately 2.9 years for systems operated with conventional oil. If synthetic oil is being processed, the payback period is reduced to approximately 1.4 years. For a bypass filter with up to 24 quart capacity, the payback periods are 1.6 years and 0.7 years for conventional and synthetic oils, respectively.
Enviro Filtration
A bypass filter with a capacity of up to 12 quarts has a payback period of approximately 2.2 years for systems operated with conventional oil. If synthetic oil is being processed, the payback period is reduced to approximately 0.8 years. For a bypass filter with up to 24 quart capacity, the payback periods are 1.3 years and 0.4 years for conventional and synthetic oils, respectively.
Assumptions:
Motor Oil Cost
* Conventional: $4/gallon
* Synthetic: $17/gallon
* Oil Disposal Cost: $0.75/gallon
Table 1. Cost Comparisons for Oil Changes Alternatives
TF Purifier Enviro
Filtration
Bypass Filters Oil Guard
Bypass Filters Status Quo
Capital Cost
(Installed) 12 qt 24 qt 12 qt 24 qt 12 qt 24 qt 12 qt 24 qt
Number of Oil
Changes per Year $510 $560 $140 $160 $175 $189 N/A N/A
Operating Labor 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr 1 hr/yr
Supplies $55/yr $66/yr $10/yr $30/yr $23/yr $27/yr $0 $0
Payback Period:
* Conventional
14 yrs 5 yrs 2.2 yrs 1.3 yrs 2.9 yrs 1.6 yrs N/A N/A
* Synthetic
3 yrs 1.5 yrs 0.8 yrs 0.4 yrs 1.4 yrs 0.7 yrs N/A N/A
Click Here to view an Active Spreadsheet for this Economic Analysis and Enter Your Own Values.
To return from the Active Spreadsheet, click the Back arrow on the Tool Bar.
NSN/MSDS:
Product NSN Unit Size Cost MSDS*
Bypass Filter 4940-01-411-9831 Each $1.94
Bypass Filter 4940-01-411-9832 Each $4.48
Bypass Filter 4940-01-411-9833 Each $4.05
Bypass Filter 4940-01-411-9834 Each $5.59
*There are multiple MSDSs for most NSNs. The MSDS (if shown above) is only meant to serve as an example. To return from the MSDS, click the Back arrow on the Tool Bar.
Approving Authority: Appropriate authority for making process changes should always be sought and obtained prior to procuring or implementing any of the technologies described herein.
Points of Contact: Air Force:
Mr. Michael Schleider
Chief, Systems Engineering Division
Support Equipment and Vehicle Management Directorate
WR-ALC/LEE
295 Byron Street
Robins AFB, GA 31098-1611
Phone: (478) 926-7918 x 166
DSN: 468-7003
FAX: (478) 926-7731
DSN FAX: 468-7731
Vendors: This is not meant to be a complete list, as there may be other suppliers of this type of equipment.
OilGuard
305 Airport Road
Oceanside, CA
Phone: (760) 967-0892 or (800) 671-0777
FAX: (760) 967-0893
DSN FAX: 468-7731
E-mail: [email protected]
URL: http://www.oilguard.com/
Gulf Coast Filters
P.O. Box 2787
Gulfcoast, MS 39505
Phone: (228) 832-1663 or (800) 398-8114
FAX: (228) 832-1171
Contact Mr. Jerry Simms
Puradyn Filter Technologies, Inc.
2017 High Ridge Road, Suite 100
Boynton Beach, FL 33426
Phone (561) 547-9499 or (800) 488-0577
FAX: (561) 547-8629
URL: http://www.puradyn.com/
Enviro Filtration
4719 Roosevelt Street
Gary, IN 46408
Phone: (800) 368-4763
FAX: (773) 734-8884
URL: http://www.envirofiltration.com/
Contact Mr. Mike Kovach
Related Links:
None
Sources: Mr. Michael Schleider, Robins Air Force Base, December 1999.
Oil Guard Environmental, January 1999.
Air Force Manual 24-307, "Procedures for Vehicle Maintenance," September, 1995.
"Pacific Air Forces Automotive Analysis Program Guide," HQPACA/LGT, Draft.
[Back]
