Diesel Particulate Filter Cleaning Service
ATR Performance cleans diesel particulate filters for customers on either an as-needed basis or under contract.
Inspections and Testing
FSX inspects and tests the filter at every step of the cleaning process. When we are finished processing the DPF we know the exact condition of the filter and have absolute confidence and knowledge of the level of recovery. Cleaning results are documented and given to the customer, and can be compared with historical recovery levels for the filter.
ATR Performance inspects, cleans, tests and returns the filters to the customer who sent it in. We do not exchange or substitute filters. All filters are recorded by serial number in our database with the associated results from cleaning.
FSX equipment and the cleaning process has been subjected to rigorous testing by engineering teams from three major engine OEM’s. These tests determined that the FSX equipment, processes and thermal cleaning programs provide the best cleaning available without damaging the ceramic sub-strait, wash-coats or packing materials. The FSX thermal programs adhere to all filter manufacturer specifications for cleaning.
FSX and ATR Performance cannot and do not guarantee or warrant that we can achieve recovery of the filter. Filters can fail for a variety of reasons as a result of operating conditions. The primary source of failure is unusual thermal events that have caused sintering, failure of the cell walls or melting of the ceramic sub-strait. Filters can also be damaged by dropping them, thermal shocking them, oil soaking, coolant soaking, chips and vibration. Due to design and materials some filters last longer than others or can with stand higher temperatures.
FSX and ATR Performance have an overall average cleaning success of about 95% of the filters. A recovered filter reaches Green Tag or Orange Tag status as set by FSX statistical analysis. Approximately 5% of the incoming filters will not move out of the Red Tag range for a variety of reasons or have failed or been damaged prior to receipt. These filters are Red Tagged and deemed un-cleanable.
Overall Filter Life
Overall filter life decreases when impacted ash is left in the filter cells. The deeper the impacted ash becomes the harder it is to remove in subsequent cleanings. The risk of sintering increases when ash is left in the filter. Ash stuck in the filter causes cold cells and leads to premature soot plugging. The cleaner the filter is kept the longer the overall life. FSX has repeatedly cleaned the same filters pulled annually on a preventative maintenance basis over four years and returned them to the Green Tag range every time. Filters cleaned on pneumatic cleaning machines that do not clean each cell individually are more difficult to recover.
Time Between Cleanings
FSX and ATR Performance cannot control the time between cleanings and make no guarantees. Filters can be re-plugged within hours if the engine is malfunctioning, operating temperatures are out of specification or if the wrong fuels or lubricants are used. ATR has seen filters run 240,000 miles after cleaning and filters that re-plugged in two hours. The ash that plugs a filter loads lineally in the filter based on engine hours and rpm. The loading rate of ash will vary due to the lubricants used, engine condition, and fuel quality. Usually it takes quite a period of time to plug a filter with ash. Soot plugging can occur very quickly and is usually due to a very unfavorable operating condition such as low filter temperature or engine problems.
Retrofit filters without passive regeneration systems typically plug with soot much more often than engine systems equipped with active onboard regeneration systems. Active regeneration systems have the ability to burn off accumulated soot and thereby keep the filter clear.