Katerina Swanson
Diesel fuel systems are a critical component of any diesel engine, and their optimal operation is essential for peak performance. Modern high-speed diesel engines use fuel transfer pumps to automatically supply fuel to the injection system. These pumps often have a hand primer lever for bleeding air from the system. Diesel fuel must be filtered multiple times in most systems, with a typical system featuring three stages of progressive filters. It is important to ensure that the diesel fuel is not biological and has not been subjected to major temperature changes, as this can cause sedimentation and water contamination, which can lead to issues such as injection component seizure and pump failure.
Characteristics and Values
| Characteristics | Values |
|---|---|
| Types of diesel fuel lines | Heavyweight, medium weight, and lightweight |
| Use of heavyweight diesel fuel lines | Between injection pump and injectors |
| Use of medium weight diesel fuel lines | Between fuel tank and injection pump |
| Use of lightweight diesel fuel lines | Where there is little or no pressure |
| Number of times diesel fuel must be filtered | Several times, typically three stages of progressive filters |
| Examples of progressive filters | Filter screen at the tank or transfer pump, primary fuel filter, and secondary fuel filter |
| Examples of filter setups | Series filters and parallel filters |
| Description of series filters | All the fuel goes through one filter and then through the other |
| Description of parallel filters | Part of the fuel goes through each filter |
| Simple fuel systems | Use gravity or air pressure to get fuel from the tank to the injection pump |
| Common enemy of diesel fuel systems | Water |
| Common grade of diesel fuel | 2-D, or ultra low sulfur diesel (ULSD) |
| Fuel transfer pump | Normally used in modern high-speed diesel engines |
| Fuel injection systems | Individual pump and injector for each cylinder, combined pump and injector for each cylinder (unit injector type), one pump serving injectors for several cylinders (distributor type), and pumps in a common housing with injectors for each cylinder (common rail system) |
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What You'll Learn
Filtering diesel fuel before use
Diesel fuel that has been sitting unused for an extended period can develop bacteria and a rancid smell. To prevent this, it's important to filter diesel fuel before use.
The first step in filtering diesel fuel is to remove any dirt or solid contaminants. This can be done by pumping the fuel through a high-efficiency filter element, either offline or inline when filling a diesel fuel reservoir from a holding tank. An inline filter can be added between the diesel tank and the dispensing nozzle, or you can use an offline system that recirculates the fuel through a conditioning skid.
After the solid particles have been removed, the fuel is directed through another set of filter housings to remove any free water. Water in diesel fuel can cause a loss of fuel efficiency and lead to corrosion over time. Standard diesel fuel has a saturation point of 50-75 ppm water content, while biodiesel has a saturation point of approximately 500 ppm.
In addition to filtering, it is recommended to add a biocide to the diesel fuel to prevent bacterial growth, especially if it will be stored for a long period. However, using a biocide can render the coalesce and separator filter elements ineffective by coating the media.
It is also important to regularly change the fuel filter, as a clogged fuel filter can cause damage to the vehicle and reduce fuel efficiency. When replacing the fuel filter, be sure to place a container underneath to prevent any spillages and ensure that all fittings are secure before starting the engine.
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Types of diesel fuel lines
Fuel lines are called hoses or pipes and are used to transfer fuel from one point to another or from a storage tank to a vehicle. The fuel line is a safety component in every car and must adhere to safety regulations.
Most fuel lines connecting to the body, frame, or engine are made of seamless steel tubing. A steel spring wraps around the pipe at certain points to prevent damage. Copper and aluminium pipes are not suitable replacements for steel pipes as they cannot handle normal vehicle vibrations or chemically react with gasoline. In some vehicles, rigid fuel lines are secured to the frame from the fuel tank to a location near the fuel pump. The gap between the frame and the pump is bridged by a short flexible hose that absorbs engine vibrations.
Fuel lines are typically made of reinforced rubber to prevent breakage and kinking. The most common fuel line is R6 for gasoline, but R10 is the only hose that GoodYear makes that is rated for diesel.
In older car models, the fuel line hoses were made of copper, which is easy to install and service but bulky and expensive. Modern vehicles often use plastic, usually nylon, for their fuel lines. Plastic fuel pipes do not rust and are lighter than metal pipes, but they melt at low temperatures and are difficult to repair.
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Using a fuel transfer pump
Fuel transfer pumps are essential for safely moving diesel fuel from storage tanks to vehicles, generators, or machinery. Here are some key considerations when using a fuel transfer pump:
Fuel Compatibility
Ensure that the pump is compatible with diesel fuel. Some pumps are specifically designed for diesel, while others can handle multiple fuel types. Using the wrong type of pump can be dangerous and may violate regulations.
Safety Features
Look for safety features such as thermal overload protection and automatic shut-off mechanisms. These features help prevent overloading and fuel spillage, reducing the risk of fire or explosions.
Portability
Determine whether you need a stationary or portable pump. Battery-operated or manual pumps offer portability and are ideal for situations where electricity is not readily available. Stationary pumps may be more suitable for permanent installations.
Installation and Maintenance
Proper installation and regular maintenance are crucial for the efficient and safe operation of your fuel transfer pump. Install the pump in a well-ventilated area away from ignition sources. Ensure the pump is properly grounded to prevent static electricity buildup. Regular maintenance includes using appropriate filters to remove impurities from the diesel fuel and protect the pump.
Pump Type and Flow Rate
There are different types of fuel transfer pumps available, including electric and manual pumps. Electric pumps are the most common choice due to their consistent flow rates and ease of use. However, consider the flow rate requirements for your specific application. If you need to transfer fuel quickly, a higher-flow pump, such as an engine-driven centrifugal pump, may be necessary.
Self-Priming vs. Straight Centrifugal Pumps
Choose a self-priming pump if you need to lift fuel from a lower level, such as an underground tank. Use a straight centrifugal pump when the pump inlet is permanently lower than the liquid level of the tank. Additionally, consider the compatibility of the pump materials with diesel fuel to prevent corrosion and ensure longevity.
By following these considerations and choosing the right fuel transfer pump for your needs, you can safely and effectively transfer diesel fuel. Remember to prioritize safety and proper maintenance at all times when dealing with diesel fuel.
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The importance of lubricity
Historically, diesel fuels contained high levels of sulphur, which provided necessary lubrication for these critical components. The presence of sulphur acted as a natural lubricant, helping to reduce friction and wear. However, due to stringent environmental regulations, there has been a push to reduce sulphur content in diesel fuel. This has led to the widespread use of ultra-low-sulphur diesel (ULSD). While this transition has had positive effects in terms of reducing engine wear and tear and improving emissions, it has also resulted in a decrease in the lubricity of diesel fuels.
The loss of lubricity in ULSD can have serious consequences for engine performance and longevity. Without proper lubrication, fuel injectors and high-pressure pumps can wear out prematurely, leading to increased maintenance costs and reduced engine performance. Eventually, this can result in a shorter engine life. The fine tolerances of the components within the fuel injection system, measured in ten-thousandths of an inch, further emphasize the importance of adequate lubricity.
To address the issue of low lubricity in ULSD, fuel additives have emerged as a popular solution. Biodiesel, in particular, has gained attention as an eco-friendly alternative. Studies have shown that biodiesel blends can improve the lubricity of ULSD without the negative environmental side effects associated with other additives. These bio-additives provide a renewable, lower-emission option that enhances lubricity and reduces wear in diesel engines.
In conclusion, lubricity plays a crucial role in maintaining the performance and longevity of diesel engines. While the reduction of sulphur content in diesel fuel has brought about positive environmental changes, it has also highlighted the importance of ensuring adequate lubricity through the use of effective additives. As the diesel industry continues to evolve, the focus on lubricity will remain vital to meet the dual challenges of environmental regulations and engine protection.
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Water in diesel fuel
While it's normal for diesel fuel to contain a certain percentage of water, higher concentrations can cause significant issues. Water in diesel fuel can occur during transit, storage, or handling. As such, it's important to treat your diesel fuel with water-dispersing formulations to prevent water from freezing in your fuel tank during winter, which can lead to frozen fuel pumps and lines.
Water provides a breeding ground for bacteria and microbes, which multiply rapidly and produce acids that corrode tanks and fuel systems, as well as clog fuel filters. This microbial growth can also lead to the formation of slimes that foul your fuel.
To prevent water-related issues, it's essential to implement effective water management strategies. This includes regularly monitoring water content and keeping water levels within acceptable limits, well below the saturation point. Additionally, it's crucial to understand how to measure water content and interpret the results to make informed decisions about water removal or treatment.
There are several methods for measuring water content in diesel fuel, ranging from laboratory tests to onsite inspections. Visual inspections for fuel cloudiness, rough starting, and erratic idling can also indicate the presence of water.
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Frequently asked questions
The FASS Diesel Fuel Systems are vehicle-specific and come with all parts required for installation. For Class 8 kits, a fuel return line kit is necessary for complete installation.
Pumps larger than 150gph can cause issues in stock or slightly modified trucks. Larger pumps are generally intended for purpose-built competition vehicles that can handle higher pressures and louder noise levels.
Facet low-pressure fuel pumps operating at 12v or 24v require a 5 Amp source, with a DC average of 1.4 amps. It is recommended to install a 3 AMP fuse for each installation.
It is recommended to mount the fuel pump no more than 12 inches from the fuel supply to ensure optimal performance.
Factory fuel modules are equipped with filtering screens that can become clogged over time due to contaminants in diesel fuel. Regular maintenance and monitoring of fuel levels are crucial to prevent clogging and ensure uninterrupted fuel supply.
