Intake System

AE Basics Brasil 2012

Daniel M Ribeiro
August, 2012
 Air Intake Systems

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 Air Intake Systems

PURPOSE OF AN AIR INTAKE SYSTEM

To provide the engine with a supply of clean,

dry combustion air within temperature and
restriction limits to minimize engine wear and
maintain optimum engine performance.
Service interval – Dirt holding

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 Air Intake Systems

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 Air Intake Systems
Why is an Air Intake System Necessary?

 Dirt is the basic cause of wear for components within a diesel engine. Most of the dirt
that gets into the engine enters through the air intake system.
 Water will cause filter damage/plugging and possible engine and intake system
corrosion.
 High intake air temperatures will mean less dense air enters the engine which may result
in more engine smoke, lower power, higher engine heat rejection, and higher engine
temperatures.

 Low intake air temperatures may result in failure to ignite the fuel, ignition delay, irregular
combustion which may result in smoke, detonation (fuel knock) higher peak combustion
pressures, rough-running (particularly at idle) and fuel dilution of the lube oil.

 High intake restriction will mean less air enters the engine which may result in more
engine smoke, lower power, higher heat rejection, and higher engine temperatures.

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 Air Intake Systems
Definitions - Classification of Dust Environment

LIGHT DUST
 Permanently paved or grassed surfaces, free from dust-laden
winds. Typical contaminant level 0.01 milligrams(mg)/cu ft.

MEDIUM DUST
 Crop lands, areas subject to dust-laden winds, temporary
local unpaved surfaces. Typical contaminant levels 0.1 to 0.5
mg/cu ft.

HEAVY DUST
 Construction, mining and quarry sites; areas subject to dust
storms. Typical contaminant levels 1.0 to 10 mg/cu ft.

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 Air Intake Systems
Definitions - Classification of Air Filters

LIGHT or NORMAL DUTY

Single-stage (primary) type dry media filters having at least 3 g/cfm dirt holding capacity.
For use in light dust environment.
Typically used on on-highway vehicles that operate off road in dusty applications.
Seldom used for industrial applications.

MEDIUM DUTY
Two-stage filters with an inertial or centrifugal 1st stage, followed by a dry media filter
stage, having at least 10 g/cfm dirt holding capacity. For use in medium dust
environment.
Sometimes used for light industrial equipment and for on/off highway vehicles used
occasionally in a heavy dust environment.

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 Air Intake Systems
Definitions - Classification of Air Filters

HEAVY DUTY
Two-stage filters with an inertial or centrifugal 1st stage, followed by a dry media filter
stage, having at least 25 g/cfm dirt holding capacity. For use in heavy dust
environment, recommended for all construction, mining, & agricultural equipment.
Filters of this class include a 'safety' element or third stage, to protect the engine
when changing the main element.

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 Air Intake Systems
Requirements - Performance Curves &
Data Sheets
INTAKE SYSTEM RESTRICTION
The system, when equipped with all offered optional air intake accessories,
shall not exceed the specified restriction limit (typically 10 - 15 in H2O) at
the turbocharger compressor inlet when tested at the maximum air flow
condition.

DIRT HOLDING CAPACITY

Dirt holding capacity of air cleaner should exceed the specified limit
(typically 25g/cfm) per ISO 5011 dust capacity test when restriction reaches
25 in H2O at the maximum operating airflow.

INLET AIR TEMPERATURE RISE OVER AMBIENT

The air temperature rise from the surrounding ambient air to turbocharger
compressor inlet must not exceed the specified limit (typically 20 - 30o F).

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 Air Intake Systems
Requirements - Design Guidelines
FILTRATION

Two stage air filters with a safety element are required for all applications.
The first stage, the pre cleaner stage, uses inertial or centrifugal dust separation to
remove the dust and then passes it out of the filter area through a manual bleed
valve or an evacuation system

The second stage is a paper element.

The safety element is a paper element inside the second stage element and is
there to protect the clean side of the intake system when the main element is
serviced.
The engine must have an air filter of at least 99.9% full life efficiency (ISO 5011),
with sufficient capacity to provide full protection for the duty and duration of
service intended.
Capacity should be sized based on the operation dust environment, desired filter
change interval, duty cycle, OEM experience. The 25 g/cfm value is just a
minimum value as estimated by Cummins and may not be high enough for some
applications.
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 Air Intake Systems
Requirements - Design Guidelines cont.
ADDITIONAL PRE CLEANERS
Be aware that there are many pre cleaners available that are sometimes added
by the OEM or the end customer to a two-stage air filter with the intention of
increasing filter life. Doing this is essentially adding two pre cleaners in series,
and will increase the system restriction.
If there is any question about the effect of this pre cleaner on effectiveness of the
two-stage filter, the two-stage filter manufacturer should be consulted.

INLET LOCATION
The air inlet shall be located so as to avoid ingestion of snow, rain, exhaust gas
and hot air from the radiator, coolers or the engine compartment. (A heated air
diverted option may be fitted for use only in low ambient temperatures). See
AEB 24.21.

WATER REMOVAL
For all equipment that may operate in an environment of water splash or spray, a
water separator must be installed before the filter, to avoid wetting the filter
element and/or ingesting salt solution.
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 Air Intake Systems
Requirements - Design Guidelines cont.

Intake Restrictions Indicators

An Intake restriction indicator is required and should be set to the maximum intake
restriction value on the engine data sheet for a dirty filter (typically 25 in H2O).
Mechanical indicators and remote mounted electronic indicators must have a filter
element at the fitting connection into the clean air duct to prevent dirt ingestion in
the event the indicator or hose connection is broken.
Direct mounted electronic indicators do not require a filter element because
damage will not typically result in an air leak.

Air Shutdown Devices

The air intake system must include a shutdown device if the vehicle will be
operated in the presence of combustible fumes as outlined in AEB 24.21 Air
Shutdown Systems.

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 Air Intake Systems
Requirements - Design Guidelines cont.
INTAKE SYSTEM PIPING & CONNECTIONS
All connections between the clean side of the air cleaner and the engine air
intake connection should be chosen with care. All junctions between rigid piping
must be made by hose connectors specially designed for this purpose, to provide
leak-free service for long periods under wide temperature extremes.

The piping layout must provide accessibility for all scheduled 'A' & 'B' maintenance
operations without disturbing the clean side connections.

The connections must accommodate the relative motions of engine & vehicle
structure without damage, leakage or collapse.
The materials used must be compatible with system operating temperatures, and
must resist the effects of corrosion, clamping load and capable of withstanding
the vacuum of a complete flow obstruction without deformation.

If an exhaust aspirator device is used to evacuate dirt from the air filter, a check
valve must be fitted to avoid the possibility of reverse flow of combustion gas into
the filter during idling conditions.
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 Air Intake Systems
Requirements - Design Guidelines cont.
CLAMPS
Hose clamps must provide 360 degrees of sealing without pinching or raising the hose for the full
life of the application.

T-bolt clamps (SAE type TB, which do not have a constant tension spring) are recommended for
all the clean side non-pressurized air intake connections.

Heavy duty worm screw clamps with an internal band liner (SAE type HD, SLHD) are acceptable
clean side non-pressurized air intake connection clamps.

Spring loaded T-bolt clamps designated as SLTB per SAE J1508 are required for the pressurized
air intake connections (charge air cooler side).

Be aware than many stainless steel hose clamps do not have stainless steel screws. And will
corrode and fail in corrosive environments.

Standard worm screw clamps (SAE type F, I, M) are not acceptable. These are typically identified
by a 1/2” band width.

AEB 24.20 Hose Connection Design Guidelines and Recommendations is a resource for more
information.

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 Air Intake Systems
Requirements - Design Guidelines cont.

TB with
flared edge
floating bridge

TB with
band liner

SLHD with
band liner

HD with
band liner

HD

F,I,M

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 Air Intake Systems
Requirements - Design Guidelines cont.

INTAKE PIPE SIZE

Typical intake pipe size for various engine sizes are:
Engine Displacement Pipe Size (OD)
6.0L and below 5.0 in (125 mm)
6.0L - 10L 5.5 in (140 mm)
10.0L - 12.0L 6.0 in (150 mm)
12.0 L and above 7.0 in (180 mm)

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 Air Intake Systems
Additional Information

INLET RESTRICTION CALCULATION

Total system restriction is simply the sum of the restriction of the components.
(It is analogous to resistance in a series electrical circuit.)
Restriction values for inlet caps, pre-cleaners, and filters need to be
obtained from the manufacturer for the rated airflow (cfm).

Restriction can be calculated manually using the monographs included in the AEB
24.21 or using Cummins Advisor.

Note: Calculating restriction for air filters in series and parallel is done in the same
manner as electrical resistance.

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 Air Intake Systems
Additional Information

RESTRICTION AND DIRT HOLDING CAPACITY CURVE

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 Air Intake Systems
Additional Information

DIRT HOLDING CAPACITY CALCULATION

The air filter manufacturer can provide a graph of life (hours) versus Air Flow (cfm)
for your filter to reach 25” H20 (381 mm) restriction when subjected to a course dust
feed rate of 0.025 gm/cubic-foot (per ISO 5011)
Pick off the hours at your airflow associated with maximum rated speed and load or
maximum operating speed and load.
2 Dirt holding capacity = (hours you picked off) X (0.025 g/ft3) X (60 min/hr)
3 If it exceeds 25 gms/cfm, it passes

 0.025 g   60min 
(18hr )x  x  = 27 g / cfm
 1 ft   1hr 
3

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 Air Intake Systems
Sample Data Sheet Requirements

AIR INTAKE SYSTEM

Maximum Intake Air Restriction with Heavy Duty Air Cleaner
— Clean Element ...............…………………— mm H2O (in. H2O) 381 (15)
— Dirty Element ..............…………….......…— mm H2O (in. H2O) 635 (25)
Minimum Dirt Holding Capacity with Heavy Duty Air Cleaner………..— g/litre/sec. (g/cfm) 53 (25)
Maximum Temperature Rise from Ambient to the Inlet of the Turbocharger..... — °C (°F) 17 (30)
(1) Maximum Pressure Drop from the Turbocharger Outlet to the Intake Manifold — mm Hg (in. Hg) N/A

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Reference

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 Air Intake Systems
Rules of Thumb

A drop of 60o F (33o C) in intake temperature results in a 160o F (89o C) drop

in compression temperature.

Engine horsepower falls about 1% for each 10 degrees F of intake air

temperature rise above 100o F (38o C), refer to the Engine performance Curve
footnote for exact numbers

The heat rejection of the engine to coolant will increase approximately 1.5%
for each 10o F above 104o F (3% for each 11oC above 40o C).

Ideal intake air temperatures for a diesel engine are between 60o F and 90o F
(16o C and 33o C)

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 Air Intake Systems
References
AEB 24.21 Industrial Installation Requirement - Air Intake System
AEB 24.20 Hose Material and Hose Connection Design
Requirements and Recommendations
AEB 21.10 Automotive Installation Recommendations - Air Intake
Systems
AEB 24.41 Air Shutdown Systems

SAE J726 Air Cleaner Test Code

ISO 5011 Inlet Air Cleaning Equipment for Internal Combustion
Engines and
Compressors - Performance Testing

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 Intake Systems
Advisor Design Review
1

Intake System

1- Fleetguard Bonnet XYZ

2- Fleetguard Air Cleaner

AH19259

3- 6”to 5” Reducer x 5”L

4- 3 90-Degree Elbows
Diameter 5”

5- 5” to 4” Reducer x 5”L
2 3 4 5

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 Intake Systems
Charge Air Cooling - CAC

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 Intake Systems
Charge Air Cooling - CAC
AEB 24.06 Requirements Overview
In order to obtain Cummins concurrence with an installation:

The charge air cooling system must meet the required “Maximum Intake Manifold
Differential (IMT to Ambient)” (IMTD) specification on the Engine Data Sheet.

The charge air cooling system must maintain an intake manifold temperature less then
or equal to the“Intake manifold air temperature derate/alarm set point” specification on
the Engine Data Sheet when tested at the machine’s Limiting Ambient Temperature.

The charge air cooling system must not exceed the “Maximum pressure drop from turbo
compressor outlet to intake manifold (IMPD)” on the Engine Data Sheet.

The charge air cooler core fin density (fins per inch) and fin type must be selected to
prevent fouling during operation in the machine’s expected environment.

The charge air cooler core and its mounting must be designed and constructed to
handle cyclic pressure and thermal expansion.

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 Intake Systems
Charge Air Cooling - CAC
The charge air system piping, hoses, clamps, and mounting must meet the
recommendations outlined AEB 24.06
4-ply Nomex reinforcement hoses (or equivalent) with external reinforcing
rings.
T-bolt style clamps with a torque retention
Aluminized steel charge air piping fully protected form both internal
and external corrosion.

The charge air system must meet the cleanliness recommendations outlined in
this document.

Temperature modulated engine cooling fans must operate in response to intake

manifold temperature in addition to engine coolant temperature.

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Charge Air Cooling - CAC
CAC Location
Series – in line with radiators and other cores
 Must be first to receive cooling air
 Special considerations for debris and cleaning

Parallel – side by side with radiator and other cores

 Advantages over series
• Does not pre-heat other coolers
• Less fan air flow restriction
• Less likely to plug with debris
• Easier to service

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 Air Intake System

Questions??

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