Reverso Blog

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Fuel Polishing question - Injector Failures

Tammy Anstett - Thursday, May 05, 2011
A common question we receive:
…“One of the worst problems we face with the reliability of our engines is the effect of bad fuel on the fuel injection system. This is true for most diesel engine manufacturers that make use of the latest technology in their electronically controlled engines. Although the manufacturer specifies water separators as primary fuel filtration (10 microns) and a 2 micron high efficiency secondary fuel filter system, we still have issues (even using the fuel they recommend) due to the quality of the fuel that is standard in our environment… We find that even with the best precaution methods, injectors have premature failures due to free water that bypasses all the systems in place. What else can we do to reduce system failures due to fuel?”
– Application Engineer

Answer:
We understand your problem and agree that today’s high-tech engine fuel systems have an Achilles Heel - Water.

Our fuel polishing systems, utilizing Separ Filters, remove up to 99.9% of all water and particulate. The best way to illustrate the need for and success of these systems is to showcase the following case. This photo below is from the U.S. Embassy in the UAE taken by Embassy staff.

Their problem was similar to yours in that they had fuel deliveries that were badly contaminated with water. This water destroyed several Cummins injection pumps and countless injectors. The picture (below) is the before and after just one (1) pass through our fuel polishing system. Since they started using the Portable Cart system, they have not had a single fuel-system related failure.







Fuel Polishing question - Which element should I use?

Tammy Anstett - Monday, May 02, 2011
Q: Which element should I use for relatively clean (maintained) fuel. The stainless steel filter units last a long time, therefore, wouldn't it be practical to use this rather than keeping a stock of paper filters?

A: The Stainless Steel element is rated at 30 or 60 Micron and is designed for removal of large particulate in a very dirty tank to avoid wasting a large number of elements. Since your fuel is maintained (or of relatively clean quality), we recommend the paper elements.

If your tank was/is clean to begin with, and you are just removing the particulate, you would typically only use 2-3 elements per year. This option will extend the life of your fuel by at least 1-2 years and is much cheaper than replacing the fuel on an annual basis.

Fuel Polishing question - Fuel Replacement

Tammy Anstett - Wednesday, April 27, 2011
Q: We have a number of diesel fuel tanks for backup generators.  We normally replace our fuel once per year and use very little during the course of a normal year. Our tanks are inside and never exposed to very high or very low temperatures. Does fuel polishing improve this replacement time? By how much? 

A: Yes, fuel polishing systems when installed correctly will prevent the accumulation of water in the bottom of the tank and extend the life of your fuel thereby reducing your replacement time.

Water at the bottom of the tank allows bacteria, mold and other biological organisms to live in the tank, feed on the fuel and create sludge. In addition, fuel oxidizes over time which creates the dark brown color that you see. This too can all be filtered out with a polisher.

(The use of additives such as ILFC Ten-35 should be added to the tank every time you fuel or every six (6) months. This will cause all water in the tank to coalesce and drop to the bottom as Free Water where the polishing system can remove it before bacteria starts to grow. ILFC is also a stabilizer and Cetane enhancer.)

You can easily extend the life of the fuel beyond two (2) years and in some cases three (3) years with fuel polishing. The ROI on a large fuel polisher would be one (1) year or less. 

Customer question regarding OP-6

Tammy Anstett - Thursday, February 10, 2011
Q: I have purchased OP-6 12V oil change pump for my Perkins 4-107. Do I have to install a shut off valve between the hose from my oil pan to the OP-6 pump? The OP-6 pump is mounted on the forward bulkhead just in front of the engne. The OP-6 is level with the top of the enigine. My concern is bleed pass the impeller.

A: For the integrity of the oil system it is always wise to install a shut-off valve at the oil pan of the equipment. This insures that in the event of a failure in the hose or oil pump that the engine does not loose oil and fail.

Also, the pump would work better if you can mount it a little lower on the bulkhead. Your impeller will not have to work as hard to lift the oil and priming will be quicker.

Customer question regarding oil change system

Tammy Anstett - Wednesday, February 02, 2011
Q: "If I purchase a 4 port oil changer, can two lines be used for engine coolant and 2 for oil. Thanks Mike"

A: Good question. While the pump is quite capable of pumping both coolant and oil, it is not recommended using the same system to do both. The probability of cross contamination is so great that you could conceivably ruin an engine or cooling system causing yourself a great deal of expense.

We highly recommend against it. You would be ahead of the game by installing a GP3012 oil change system, then using a GP311 pump with a VP2 valve manifold to change the coolant. This will keep the two systems separate and eliminate the possibility of any contamination.





Customer question regarding cross-contamination

Tammy Anstett - Monday, November 08, 2010
Question - "I have just purchased a new boat and have requested to install a REVERSO pump system for the main engine, generator and transmission. The boat builder representative is telling me he can only install it for the engine and the generator, the reason being given to me is the possibility of engine oil and transmission oil contamination. I am a bit skeptical on his contamination concern. Could you help me on that issue please?"


Answer - Your representative could be right. On some of the newer vessels the transmission requires a more refined oil than that of the engine or generator. With our GP-3013, a 3 valve oil change system, there is the possibility of cross-contamination. If your transmission requires the more refined oil, and it is contaminated with engine oil, it could cause damage to the transmission. Typically, we have seen these new transmissions on the new, high performance vessels.

We would suggest that you confirm the oil requirements of your transmission. If it requires, for example, a 30W, like the engine, then you should have no problem using a 3-valve system with no worry of cross-contamination.   If you find that you need a different oil for the transmission, you can use our GP-3012, a 2-valve oil change system, for your engine and generator.  Then use our GP-311 or OP-6, reversible pump, solely for the transmission.

You can find the products mentioned above by clicking on the product names below:

GP-3013
GP-3012
GP-311
OP-6



Great Customer Question Regarding Elements

Tammy Anstett - Tuesday, October 19, 2010
How long will the element last? How often should I replace the element?

How dirty is your fuel? Unfortunately, there is not single answer this question.

The time it takes before the filter element reaches max dirt load can vary from 10 minutes to 300 hours.  It is completely dependent on the dirt load and type of contamination in the tanks.

Often we find masses of solids settle in the bottom of tanks, and these can clog elements, quickly.  It is for this reason that we have the 60 micron Stainless Steel element.  This can simply be backflushed, a procedure detailed in the operating manual, and available in Product Literature.

When clogged, the stainless steel element can be removed, and cleaned for reuse. When using our standard 10 or 30 micron paper elements the number of times it can be backflushed, depends on the type (sticky or not) of dirt lodged in the element.

In some installations in the U.S., where the fuel is like water, we have customers that replace the filter element only once per year in a permanent installation.

For mobile tank cleaning where the tank is dirty to begin with, we recommend the use of the 60 micron Stainless Steel element. This can be removed and cleaned many, many times. It is best to have two stainless steel elements, so that the machine can continue to work during the element cleaning process.

Once the 60 micron filter comes out clean, then you can switch to the 30 micron paper element and continue the process. This will prevent the expenditure of a large number of paper elements.

Customer questions regarding Fuel Polishers

Tammy Anstett - Friday, October 15, 2010
Here are some good questions we have received lately from customers regarding our Fuel Polishers. All of these answers (and many others) are located in our FAQ section.

How can we know that diesel is flowing from inlet to outlet? Is there a minimum reading on the vacuum gauge to indicate that?

You cannot tell from the vacuum gauge if fuel is flowing. The pumps are capable of creating a vacuum in the filters when fuel is NOT present. One method for determining if flow is present is to check the discharge hose. When you first start the unit, you listen to the pump. Depending upon the length of your inlet hose, and the height of the suction lift, it will take from 30 seconds up to a minute to take suction. As liquid reaches the pump you will hear a change in pitch and volume from the pump. At the same time you will see the black needle on the vacuum gauge move to the left. How far this moves is a function of the length and diameter of the hose, as well as the height of the suction lift. The lower the number the better, as the gauge reads the total system vacuum, and not the condition of the filter.  The best method for determining flow, and measuring it, is to install our optional flow meter to the outlet of the system.


How do I prime the fuel system?

If the pump does not take prime in the first minute, or this is the first time the unit has been run, it may be necessary to prime the system. There are several ways in which to do this. Perhaps the easiest way to do this is to attach a very short hose to the inlet of the system, and place the hose into a container of diesel fuel, start the system, and allow the pump to run until the 2-3 gallons of fuel have been moved thru the system. If this is not possible, remove the lid of the filter, remove the filter element and spring cage. Instructions for removing the lid, and filter element are contained in your operating manual. Manually fill the filter housing with clean diesel fuel. Replace the filter element, and spring cage. Re-install the lid and tighten lid screws to proper torque. Proper torque specifications are located in your operating manual. It is suggested to install a foot valve, check valve, or non-return valve to ensure that system maintains its prime after initial prime.


Is there Dry Run protection for the pump?

The pump is not equipped with "Dry Run" protection. The operator must pay attention to the machine.   Normally, our systems are used to circulate fuel in a tank - pull fuel from the tank, and return it to the same tank. In this scenario, it would be very unlikely that the pump would ever run dry.  If your application is different, (such as pulling fuel from multiple tanks or using the system as a clean fuel dispenser), then running the tank / pump dry is more likely.

What is the high-pressure alarm?

The high-pressure alarm is used in situations where the discharge line can be closed with either a valve or hose kink.  This will protect the system and prevent hoses bursting which could leak fuel.  The high-pressure alarm is used on units equipped with a gear pump. This protects the pump from damage due to high pressure caused by closing the discharge or accidentally blocking the hose. It prevents excess current in the motor. Units equipped with the vane pump do not have this safety as the vane pump is equipped with a built in pressure bypass.

Question from customer regarding Separ Filters

Tammy Anstett - Monday, October 04, 2010
We received a great question from a customer the other day and I know that many of you have asked similar ones in the past. Here's the Q&A. And don't forget to check out our FAQ section regularly. We are always adding more information.

Question:  I have installed four Separ Filters on two haulers and two loaders. The filters get stuck very easily and fast. We even have to take off the valve in order to liberate the bowl. Should we clean the filter more often?

Answer: If the filter is equipped with a vacuum gauge you can monitor it and do a back flush at about 8-10 inches of vacuum. This will extend the life of the filter. There are two other options that you may want to consider as well.

1. Clean the fuel with a portable fuel polishing/dispensing cart when the equipment is fueled.  Click here for more info.

2. Install a second filter as a strainer with a 60 micron cleanable stainless steel element in from of the primary filter. This will have no effect on the restriction to flow and will remove much of the heavy dirt and water before it get to the primary 30 micron element, as seen on this John Deere combine.


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