Diesel Fuel Filtration Challenges for HPCR. ADS National Convention August 4-7, 2015 San Antonio, TX

Diesel Fuel Filtration Challenges for HPCR ADS National Convention August 4-7, 2015 San Antonio, TX Fuel Injection Designs are Changing! New Techn...
Author: Posy Kelley
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Diesel Fuel Filtration Challenges for HPCR

ADS National Convention August 4-7, 2015 San Antonio, TX

Fuel Injection Designs are Changing!

New Technology Higher Pressures Common Rail (H.P.C.R.) New level of filtration and fuel delivery requirements

The Challenge ! • Filter & capture fuel contaminants to avoid worn, clogged, corroded, or failed fuel system components. • Function efficiently for thousands of miles or hundreds of hours.

• • • • •

Transfer Pumps Injection Pumps Unit Injectors Injector Nozzles Fuel Dispensing Systems

OEM Performance Requirements: • > 99% water removal • High performance in 20% Biodiesel (B20) • Longer life • Higher flow rates • Material compatibility with ULSD and Biodiesel

Source of Contamination • Fuel leaving the refinery is typically “clean” and meets specifications. • The principal source of contamination – particulates and water – is in the….

• Transportation and

• Storage …of diesel fuel.

Fuel Contaminates: • • • • • • • •

Natural Asphaltines Quartz, Silica Water Condensation Rust and scale Fuel Degradation Microbial growth Biodiesel effects Dissolved Air

What Plugs Fuel Filters? • Diesel fuel filters are not usually plugged by hard sand and dirt, but by soft organic asphaltines that are captured by the filter. • Asphaltines are complex, naturally occurring contaminants dissolved in #2 diesel fuel. • Engine heat and oxidation contributes to the formation of sticky asphaltine particles, which clog fuel filters, shorten filter life, and degrade water removal efficiency.

Proposed Asphaltine Molecular Structure

Tar & Asphaltines Naturally occurring contaminants in diesel fuel.

What Else Plugs Fuel Filters? • Dead bacterial slimes • Soil bacteria grow in water/fuel interface as slime mats. Bacteria die and slime plugs filters.

• Cold fuel • Non-winterized fuel with high cloud or pour point + cold weather + no fuel heater.

• Dissolved fuel tank deposits • ULSD and Biodiesel team up to dissolve years of tank deposits which then clog filters.

• Rust • Water condensing inside steel fuel tanks rusts the tank. Chips of rust clog filters.

Typical contaminants Algae on filter media Often present with water. Worse in bio fuels

Wear Contaminants in Diesel • Fine, wind blown silica dust (sand) enters fuel systems through vents and during filling. • Fuel system components corroded through the action of water and bacteria become wear contaminants. • Damage and wear to injector nozzles & valve seats • Loss of power, leading to poor fuel economy • More emissions, smoking

What did they find? Typical diesel fuel contaminants:

• Solid contaminants; • Ash • Dirt • Dust

• Water & Rust • Algae & Bacteria

Dirty Fuel

Clean Fuel

What’s on the inside?

Contamination Damage

Water, An Engine’s Worst Enemy • Condensation – Warm, humid air is drawn into a cool fuel tank through the breather at night, and water condenses on the tank walls. • Poor fuel handling practices; rain and run-off water allowed into tanks. • Iron oxide (rust) particles cause injector wear • Soil bacteria & water form corrosive acids that erode fuel system components • Water displaces diesel’s lubrication, damaging valve seats and injectors.

Typical contaminants

Water Probably the #1 problem Mainly from condensation

Typical contaminants Condensation – Dew on Grass

This water will also be present in fuel tanks

Typical contaminants

Rust in a fuel tank

Source of Contamination • 2.5 million miles of fuel pipelines in USA

• Tens of thousands of tanker trucks.

• Hundreds of thousands of storage tanks

Why Filtration is Important • Filter plugging First layer

Second layer

Fuel Stream

Asphaltene contamination on filter medium flowed in series.

First layer

Second layer

What does this mean to ADS Members? • Fuel quality concerns are a major opportunity for ADS members. • Recognize the symptoms caused by bad fuel. • Rough running? • Short filter life? • Become an expert in diagnosing fuel quality issues. • Ask questions about fuel storage, age of fuel, etc. • Operating conditions? Dusty? Humid? • Change filters regularly.

• What type of filters are used?

It is Important to Stay with the OEM Filter • OEM Fuel filters meet stringent Fuel System manufacturer’s requirements:

• Dirt holding capacity (Grams of contaminant) • Efficiency (Micron rating) • Water removal capabilities (Percentage)

Aftermarket “Will Fit” Filters • Element or Spin-on filter may fit OEM housing or filter head, but:

1. Does media meet OEM requirements for contamination holding capacity, efficiency and water removal? 2. Just saying it does is not the same as laboratory test results.

Internal Components of Genuine OEM Coalescing Filter

Internal Component of “Will Fit” Filter

Cross Section of Another “Will Fit” Filter

OEM Filter vs After Market “Will Fits”

Thank you!