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Generator Maintenance Tips from GenExpo 2016

Tiffany T. - Monday, July 25, 2016
GenExpo 2016 Products

Preventative maintenance on generators will ensure the engine starts and keeps running when you need reliable power. For prime power or backup, we shared the following tips at GenExpo to practice this maintenance more efficiently and effectively (e.g. diesel cleanliness, servicing filters, oil changes).

1 Automatic Fuel Polishing System


  A fuel polishing system maintains diesel cleanliness in bulk storage tanks, day tanks, and belly tanks. Diesel can begin to degrade after 30 days and can be faster in humid regions, with poor tank housekeeping, areas with unreliable refueling, and if the tank is not kept full. Dirty fuel is picked up by the permanently-installed system, passes the primary and secondary filtration, and the clean diesel is pumped back to the same tank. Optional enclosures are available for outdoor installations. The fuel polishing system will:
  • Ensure diesel in storage is free of water and particulate (i.e. improve fuel quality).
  • Prolong the lifespan of stored diesel (important when kept for backup power).
  • Avoid expensive engine repairs for corrosion and blown injectors.
2 Separ Filter SWK-2000 Series (link directs to Separ Filter site)


  We displayed a demo system of the SWK-2000 fuel water separator. This is the same filtration on the Reverso Automatic Fuel Polishing System. Install this in the fuel system (after the tank) to serve as a pre-filter before the engine. Separ Filter removes 99.9% of water and particulate down to 30 micron, therefore extending the time between maintenance of the engine-mounted filter(s). Separ Filter offers multiple sizes to match the engines' lift pump flow rate.
3 Fuel Primer
 

The electric fuel primer makes priming the fuel system of a diesel engine easier, faster, and safer than manually priming during routine filter changes. It pumps fuel into the lines to purge trapped air in the main feed line, primary filters, secondary filters, and engine. The bypass protects the system from pressurizing beyond the preset. On this pump the user will:

  1. Turn the valve.
  2. Hold down the momentary button to pump until the system is primed
  3. Release the button.
4 Hand Primer
  For smaller generators, or to only prime the filters, a manual hand primer can be installed in the fuel system. Separ Filter manufactures a compact one that pumps 0.85 oz. per stroke.
5 Oil Change Pump for buckets
  Complete faster oil changes with an electric oil change pump, especially if multiple generators are on site. This one is designed to sit on the lid of most 5-gallon buckets. Flip the switch to drain used oil into the bucket, move the hose to the new oil container, flip the switch the other direction to fill, and the job is done.

Three Point Approach to Fuel Cleanliness

Tiffany T. - Monday, March 07, 2016
Author: Jessica Fernandes

chart for three points

When it comes to diesel fuel cleanliness, there is no "one size fits all" solution. The solution is based on the needs. To understand the needs, you have to understand what the goal of the person or organization is regarding fuel cleanliness. What is it they are trying to accomplish? Are they trying to meet an ISO spec? Are they trying to reduce or eliminate water?

A simple, reliable way to know what issues exist is by conducting a fuel test. Fuel testing provides an indication of what is causing the diesel fuel to be unstable, be it water, sludge, or a combination of the two. Once it has been determined what the issue is, you can begin to create a solution to resolve it.

This is where the three point approach to fuel cleanliness is most useful. A solution is most effective when it encompasses all three tools. The first tool is a fuel polishing system which moves the failure point from the engine or equipment being fueled to the fuel storage tank. Better stated, address the poor fuel quality before it reaches the critical equipment.

The second tool is in line filtration which is installed in line, just before the on-engine fuel system. This provides a secondary failure point, again before the fuel reaches the critical equipment.

The third tool is fuel additive or stabilizer. This is used to stabilize fuel in harsh weather and remove emulsified water. These three tools, when used together, guarantee the cleanest diesel fuel, in turn protecting engines from damage and ensuring reliability of the equipment.

For more information on fuel cleanliness, please contact Reverso Pumps at contact@reversopumps.com. More information can also be found on our website at www.reversopumps.com.

Original article from: LinkedIn

Can You Count On Your Backup Power After A Hurricane

Tiffany T. - Tuesday, June 03, 2014

Three Cummins Power Generation generators at a Jefferson Parish canal pumping station were located above the maximum high-water level and continued to operate as long as they had fuel.

Being prepared will make the difference between keeping the lights on and a generator that can't keep running using degraded fuel. Robert Hamilton, Sales Director at Cummins Mid South, shares some important lessons we all can learn from Katrina's aftermath in 2005. He explains how generator location, fuel choice, fuel re-supply, and lastly power system maintenance will improve your standby generator's reliability–especially during long-term outages. Whether you have a new install or an existing system, there are best practices to reduce vulnerability during critical power. Hamilton states, "by replenishing the diesel fuel supply on a regular basis and properly treating it, facility operators can be assured of a fuel supply that is free from contaminants and deterioration."

Contaminants like water and particulate accumulate in the storage tank and generator belly tank if left only partially full and diesel fuel is unused for as little as 3 months. If untreated, the diesel fuel can continue to degrade and those unwanted contaminants could lead to costly generator repairs and shutdown. Fuel polishing systems should be installed to get rid of them and improve fuel quality. The diesel is pumped out, filtered through the system, and returned to the same tank. Reverso manufactures commercial systems in a wide range to best accommodate a facility's needs. Wall mount versions can be permanently installed on single tanks and the portable Diesel Fuel Service Cart is ideal for servicing sites with multiple generators.

Read the full white paper
Lessons in emergency power preparedness: Planning in the wake of Katrina By Robert Hamilton, Sales Director, Cummins Mid South

See Reverso's Fuel Polishing Systems

Wall Mount Fuel Polishing System Wall Mount Systems Portable Fuel Polishing System Portable Cart System

National Oceanic and Atmospheric Administration (NOAA) and the Federal Emergency Management Agency (FEMA) are calling on individuals across the country to Be a Force of Nature: Take the Next Step. Be sure you are prepared at your home and business this hurricane season.

A Complete Solution for Fuel Tank Sludge

Tiffany T. - Friday, April 12, 2013

The following article is provided by CAT's Electric Power Advisor website. Click here to see original article.

"Preventive maintenance for generator sets should include a check of fuel condition. Clean fuel going into a tank does not assure clean fuel coming out. Condensation can occur in fuel tanks, whether a generator set is in regular use or sits idle for lengthy periods. Microbial growth can occur with the buildup of water. As the microbes feed on fuel and water, waste falls to the bottom of the tank. These microbial droppings are sometimes referred to as algae growth, but it bears no resemblance to real algae. It is sludge-like in nature and acidic, and can cause significant damage to engines.

This waste material can not only clog fuel filters, it can damage fuel injectors, causing downtime and expensive repairs. There is only one complete way to clean your fuel of microbial sludge – fuel polishing. Before discussing polishing, consider the drawbacks to partial steps that are not as effective. You can drain water and sludge from the bottom of the fuel tank or put biocides in the tank. Draining the tank removes most of the sludge but doesn’t remove entrained water, allowing new microbial growth. Biocides kill microbes but do not address the issue of existing sludge. And when additional fuel is added to the tank, the sludge is re-suspended.

With stricter environmental requirements, tight fuel system tolerances and pressures approaching 30-thousand psi, the smallest of contaminants or emulsified water can damage the fuel injectors and/or clog fuel filters. Fuel polishing removes the particulate matter and entrained water to greatly reduce the possibility of damage to fuel system parts. The process essentially loops diesel fuel out of and back into the fuel tank. There are three stages as the fuel is looped through the system – a centrifuge, a conditioning magnet and filters. By using this complete process to treat fuel, you eliminate the need to drain tanks.

You can make arrangements to polish fuel in one of two ways. You can add a polishing unit to your tank on site or you can include the process in preventive maintenance agreements to be performed at prescribed times. Either way, the cost is relatively inexpensive when compared to the damage the contaminated fuel can do to engines, and the cost of renting generator sets when downtime occurs.

When you consider fuel polishing, remember to use a system that includes all three stages of treatment. Some competitive offerings simply put a hose on the bottom of tanks and suck sludge from the bottom. As mentioned earlier, that is not a total solution and certainly does not remove entrained water. Remember, fuel polishing does not replace, but rather augments the filtering of fuel as it enters the tank.

Fuel polishing is an important part of your fuel quality management and will help generator sets perform up to expectations, giving you fewer worries.  Please contact us for more information.

A special thanks to Dennis Albers with Carter Machinery for their participation in the development of this article."

Get Stable Diesel Fuel with UltraGuard+

Tiffany T. - Wednesday, January 09, 2013

UltraGuard™+ fuel additive keeps fuel stable for an extended storage period and is a unique multifunctional diesel additive that improves combustion and reduces emissions. More complete combustion results in emission reductions and increased fuel efficiency. It is designed to improve the overall performance of diesel equipment. Also, the demulisifiers keep fuel free of water and corrosion inhibitors protect the storage system and equipment.

A majority of fuel additives blends the water into the fuel. UltraGuard™+ will separate the water from the fuel.

A half gallon bottle will treat 5,000 gallons of diesel fuel.

Click here to see

UltraGuard+ fuel additive

The Low-Down on Ultra-Low-Sulfur Diesel Boat Fuel

Tammy Anstett - Friday, November 18, 2011
The Low-Down on Ultra-Low-Sulfur Diesel Boat Fuel - Anything to Worry About?

http://www.boatus.com/seaworthy/magazine/SeaOct11_UltraLowSulfurDiesel.pdf

ALEXANDRIA, Va., November 17, 2011 - As a way to reduce particulate matter, ultra-low-sulfur diesel (ULSD), with only 15 ppm or less of sulfur, was mandated for use in most vehicles, boats and machinery as of December 2010. As a practical matter, however, ULSD has been around since late 2006 when 2007 model year vehicles with more advanced emissions control devices began requiring its use in cars. And since most fuel refiners don't have the capacity to offer more than one type of diesel, it's also been sold at marinas ever since.


During that time, the BoatUS Damage Avoidance Program has kept a close look out for any potential problems with the newer, environmentally-friendly fuel. Recently, the boat owner association's Damage Avoidance Program publication, Seaworthy, The BoatUS Marine Insurance and Damage Avoidance Report, investigated the issue and has these findings to share:

Lubricity: In diesel engines, having enough "lubricity" in the fuel is critical - without it, the engine would grind itself to a premature death. A lot of publicity has been given to ULSD because the process of removing sulfur from diesel fuel also removes much of the fuel's lubricity. Contrary to what some have said, however, lubricity is not a problem with ULSD. Minimum lubricity is a requirement of the ASTM-D975 diesel fuel standard and oil companies typically use a synthetic additive to return fuel to its pre-ULSD lubricity levels.  

Cetane: All diesel fuel must have a cetane rating of at least 40. Most regular diesel fuel has a cetane rating of 43 to 45, which should be fine for most boat engines.  The good news is that the cetane numbers remained the same with ULSD.

Gaskets: When the transition was made to low-sulfur diesel (LSD) in 1993, there were problems with leaking gaskets. Newer gaskets that resist leaking were developed, but there were some fears that the gaskets might not stand up to ULSD. After talking to numerous marina owners and engine manufacturers, leaking gaskets don't appear to be a problem.

Water and "Bugs": Microbial growth - bugs - need water to grow and have always been a concern with diesel fuel. ULSD holds less water than older, higher-sulfur fuels, which means that any water entering the tank is less likely to be absorbed and instead more likely to become a breeding ground for bugs. Biocides (and cold weather) kill the bugs but their tiny little carcasses pile up in funereal goo at the bottom of the tank. Tanks may need to be cleaned more often to prevent clogged filters and corrosion. The best defense is to keep tanks as full as possible (especially over winter storage) and keep a routine eye on the water separator.

Courtesy of NEWS From BoatUS
Boat Owners Association of The United States
880 S. Pickett St., Alexandria, VA 22304
BoatUS Press Room at http://www.BoatUS.com/pressroom 

 

September Special - Free Additive with DFS Cart Purchase

Tammy Anstett - Friday, September 16, 2011
 
 
Increased Combustion Efficiency and Less Maintenance  

ILFC Ten 35 Combustion Catalyst, Burn Rate Modifier and Lubricant offers complete combustion thereby producing more useful energy while reducing soot and smoke. It’s also highly concentrated – 1 oz. treats 80 gallons of diesel fuel.  

ILFC Ten35 Provides:

  • Greater Fuel Efficiency
  • Stabilized Fuel in Storage
  • Reduced Combustion System Wear
  • Reduced Particulate              

ILFC Ten35 Helps:

  • Demulsify Fuel
  • Inhibit Fuel Tank Corrosion
  • Eliminate Algae Growth
  • Prevent Catalytic Oxidation
 
A Primary Filter is Already in Place – Use It to Polish Your Fuel

The only true Fuel Polishing Module available. Just add the filter of your choice.

  • Easy to install module turns any filter into a comprehensive fuel polishing system.
  • Works with most standard filters. Choose the filter that suits your needs. (e.g. Separ Filter, Racor, Fleetguard, Yamaha, Sierra, Baldwin, Cummins, Mallory, Dorman, Fram, etc.)
  • Compatible with middle-distillate fuels and fuel oils (not gasoline)
 
 
Learn More About Portable Fuel Polishing

You can have the efficiency of a built-in system with the convenience of portability. With a 630 GPH (2,400 LPH) flow rate, the DFS Cart provides the power necessary to remediate and clean tanks up to 3000 gallons. Utilizing a Separ Filter, the Cart eliminates sludge and water buildup in the tank, has 99.9% water separation (Certified TUV report using SAE J1839) and 99% particulate removal.

An electronic control box with 5-hour mechanical timer, LED indicators for element replacement and backflushing, safety shutdown and alarms for clogged filter and water make cleaning your diesel fuel easy, convenient and economical. Learn more here.

 

Fuel Polishing - Keeping Genset Fuel Flowing During Disasters

Tammy Anstett - Friday, June 10, 2011
Keeping Genset Fuel Flowing During Disasters
Developing A Strategy To Ensure The Availability Of Fuel For Your Generator System Is A Key Element Of Disaster Planning.

By Robert M. Menuet, PE, GHT Limited, Arlington, Va.
06/01/2011

Originally published at: Consulting-Specifying Engineer

Mr. Menuet states that as part of your disaster plans you should "consider installing a fuel filtering or polishing system that will remove moisture and help prevent fuel degradation. Sediment that can build up in the bottom of storage tanks can be stirred up when fuel is delivered, often resulting in clogged filters and injectors, or decreased engine performance.

Fuel polishing and filtration helps minimize this buildup. Also consider fuel additives that will prolong fuel life, suspend contaminants so they can be trapped by the system filters, protect against corrosion, and prevent biological growths."

To view the article in its entirety, read below or click here.



Full Article
Our commercial, government, and institutional operations depend on the continuous availability of electrical power to run critical equipment. Prolonged, large-scale power outages, though rare, have significant financial and service delivery impacts. You need to be ready when disaster strikes.

Disasters vary in type and severity. Fuel supply planning for local severe weather events and regional blackouts is vastly different from the strategies required to defend against an unforeseeable terrorist attack or an extraordinary natural catastrophe such as Hurricane Katrina. The considerations outlined in this article are intended to guide you through the planning process to defend against reasonably predictable disasters.

Diesel vs. natural gas

Diesel-fueled generators are better suited for larger power requirements than natural gas-powered generators, yet require more physical space and maintenance to sustain a reliable fuel source. Building owners typically select natural gas generators when they require a lower initial capital investment and prefer not to maintain an on-site fuel supply.

Because natural gas is supplied by the local utility and delivered underground, the primary factor that building owners can control in relation to disaster defense is the purchase of non-interruptible service. Your utility will typically charge a slightly higher rate in exchange for a guarantee of fuel availability during a local disaster event, but many owners find this preferable to managing a diesel fuel supply for their generator.

When choosing between natural gas and diesel, it is important to note that natural gas generators may not satisfy local life safety requirements. If the utility source is not deemed reliable for emergency operations by the local authority, diesel engine generators are generally the only practical alternative.

For buildings that shelter critical business functions or have other high availability requirements, the decision to use an on-site diesel-powered generator is often made as part of overall disaster planning. Once this choice is made, there are numerous factors that can influence the configuration of the fuel supply. Considerations that can make this process more manageable include:

  • Fuel quantity
  • Refueling availability
  • Storage and compartmentation
  • Fuel quality
  • Safety and security

Fuel quantity

Identifying the amount of fuel needed to power your critical equipment during a reasonably predictable natural catastrophe is the first step. A rough consumption calculation for diesel generators is 7 gallons of fuel per hour for each 100 kW of generator rating; i.e., a 200 kW generator would consume 14 gallons of diesel fuel per hour. A typical goal for on-site storage is three days’ worth of fuel. A site requiring a 2 MW generator installation should have approximately 10,000 gallons of available stored fuel to provide a three-day supply. To ensure the necessary amount is on hand in the event of a disaster, you should factor engine exercising into your equation, and understand that refilling a partially depleted storage tank may not be practical until sufficient fuel is depleted to justify a fuel delivery. Purchase a storage system that will accommodate your disaster-threshold fuel plus the amount you will consume for engine testing as part of regular maintenance.

When determining the amount of fuel to store on-site, you must consider the criticality of your location and the nature of your operation at the site. If your facility provides critical functions required for your business that are not duplicated in another location, a larger quantity of fuel should be considered to ensure continued operations during an extended power outage. Consider the impact an extended utility outage would have on your organization’s bottom line. The data center of an online retailer would likely face far greater revenue losses during an extended power outage than the administrative office of a sales force that telecommutes and travels on a regular basis. Storing fuel can be expensive, so a business case should be developed that considers capital expenses and risk factors. Weigh the installation costs and maintenance requirements of storing fuel against the financial impacts of downtime—including the direct costs of lost revenue, recovery of operations, and the potential loss of customers.

According to the American Red Cross, “As many as 40% of small businesses do not reopen after a major disaster like a flood, tornado, or earthquake. These shuttered businesses were unprepared for a disaster; they had no plan or backup systems.”

Refueling availability

Refueling availability will impact your decision on how much fuel to store on-site. Is it financially and logistically feasible to store all or some of the desired amount in your building or on your property? Can you arrange to have a supplier outside of the region bring fuel when needed? In the second scenario, the fuel supplier down the street may be affected by the same natural disaster, so arranging delivery assurances from several geographically disparate suppliers may make sense. Selecting remote suppliers that use different transportation routes can further ensure refueling availability when a disaster has a widespread impact. Typically it is not practical—logistically or economically—to store more than several days’ supply on-site, so a balance between on-site storage and delivery assurances from suppliers should position you to survive an extended loss of electrical power.

Storage and Compartmentation

On-Site Storage—For the fuel you store on-site, the first consideration is conforming to local and state codes, Environmental Protection Agency (EPA) regulations, and National Fire Protection Association guidelines. Codes are intended to safeguard buildings and their occupants, while EPA is primarily concerned with the environmental impact of spills. Sustainable design certifications that encompass building energy usage, such as the U.S. Green Building Council LEED program, may also influence how much and where the fuel is stored.

The amount of on-site fuel storage will likely dictate storage locations and configurations. Large amounts of fuel are typically stored outside the building, either in above- or below-ground tanks. Below-grade storage requires EPA compliance for leak monitoring, and may necessitate groundwater monitoring and other spill detection methods. Local and state codes may have additional requirements for outdoor storage solutions.

For outdoor generators, engineers often specify that the fuel be stored in belly tanks under the generator. This can be a convenient, space-saving option, though there is a practical limit to the amount of fuel a belly tank can hold. If a tank is too large, stairs, platforms, or ladders may be required to gain access to service the generator. If a belly tank is too small, your operating time will be limited if it is your only method of storage. Discuss these considerations with your operations and maintenance staff.

In-building storage may be the best solution for smaller amounts of stored fuel. It also offers better protection from temperature fluctuations, weather events, and tampering. An example from Hurricane Katrina illustrates this point. As noted in “FAILURE OF INITIATIVE: Final Report of the Select Bipartisan Committee to Investigate the Preparation for and Response to Hurricane Katrina,” “Many of the parish EOCs [Emergency Operations Centers] and public safety facilities were wiped out or flooded. Jefferson Parish…was in better shape to respond because it had protected its EOC. Jefferson Parish Emergency Manager Dr. Walter Maestri explained the EOC was in a hardened facility—an old incinerator with cement walls—with the command center, living quarters, and emergency generator all on upper floors...[and] it was able to keep operating at some level.”

Fuel stored within your facility will require compliance with building codes, local and state codes, and building insurance requirements. Building and structure insurance policies often have strict requirements for the type and amount of fuel and storage equipment.

Compartmentation—While compliance with building codes and other mandatory requirements will result in a safe installation, there are other choices a user can make to improve the availability of the stored fuel. Compartmentation can help safeguard some or all of your reserve if a single localized event occurs, such as an explosion or fire. With compartmentation, the total amount of fuel is divided among multiple tanks. Fire- and blast-resistant separating-structures ensure there are barriers between tanks to prevent a local event from affecting the entire supply.

Compartmentation also supports the availability of backup fuel if one tank develops quality problems. Also, the use of multiple storage vessels helps limit cross-contamination should one tank be replenished with contaminated fuel.

Fuel quality

If you store fuel on-site, consider installing a fuel filtering or polishing system that will remove moisture and help prevent fuel degradation. Sediment that can build up in the bottom of storage tanks can be stirred up when fuel is delivered, often resulting in clogged filters and injectors, or decreased engine performance.

Fuel polishing and filtration helps minimize this buildup. Also consider fuel additives that will prolong fuel life, suspend contaminants so they can be trapped by the system filters, protect against corrosion, and prevent biological growths.

Temperature Considerations—Atmospheric temperatures can affect fuel quality. At approximately 30 F, fuel begins to cloud as the paraffin in the fuel starts to solidify. At 15 F, this solidification can turn into wax and can be severe enough to clog filters in the system.

Most providers offer winter blends designed to minimize clouding. If financial or logistical reasons necessitate the use of a summer blend fuel as you enter colder weather, other strategies to prevent this problem include additives, heat trace of piping, and immersion tank heaters.

Safety and security

Ensuring the safety of building occupants and the security of your fuel supply is fairly straightforward. During facility design, provide a rated room for fuel and generators stored in the building. Locate it near a loading dock or other low-traffic area, and provide controlled access. When using outdoor storage, critical facilities will likely have perimeter security in place to safeguard their fuel supply and generators. For less intensive facilities, secure walls or fencing around the fuel storage tanks is the most common protection strategy.

Planning ahead

It is impossible to predict every disaster scenario that could impact your fuel supply. But with early, careful planning, you can determine the amount, availability, storage, protection, and quality of a fuel supply that can support your operations through many of the most common natural catastrophes that occur in your region. A balanced strategy that considers costs and risks will ensure the success of your plan.
*****************
Menuet is a senior principal with GHT Limited, where he focuses on the design of mission-critical facilities for many clients with high availability needs. A professional engineer with more than 26 years of experience, he earned a Bachelor of Science in Mechanical Engineering from the University of Virginia.

Limited Time Sale - Diesel Fuel Service Cart

Gary Glass - Monday, May 16, 2011


UPDATE: SALE EXPIRED

Fuel Polishing - The Reverso Difference

Tammy Anstett - Tuesday, May 10, 2011

The Reverso Pumps DFS Cart Difference






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