Katerina Swanson
Diesel fuel contamination can have serious consequences for engines, vehicles, equipment, and the environment. It can occur at any time in the supply chain, even when the fuel leaves the refinery, and can be caused by water, dirt, rust, dust, pollen, microbes, or other airborne contaminants. Water contamination, in particular, is a common issue due to rainwater entering through openings in the tank or vent, or condensation. Microbial contamination, also known as diesel bug or diesel fungus, can also occur and lead to the production of corrosive acids that damage fuel systems and tanks. To prevent issues, it is important to regularly check for signs of contamination, such as clogged fuel filters, changes in diesel appearance, and tank corrosion. Testing methods include visual screenings, in-lab quantitative analyses, and water detection pastes.
Characteristics of Diesel Fuel Contamination
| Characteristics | Values |
|---|---|
| Water contamination | Water can enter a fuel tank through rainwater or condensation. It sinks to the bottom of the tank, creating a separate layer. Water can also mix with the fuel, causing it to appear cloudy. |
| Particulate contamination | Dust, rust, pollen, and other airborne contaminants can enter the fuel tank when open or improperly sealed. |
| Microbial contamination | Microorganisms , such as bacteria ("diesel bug") and fungi, can survive and grow in fuel, leading to the formation of sludge and corrosive acids. |
| Injector malfunction | Contaminated fuel can disrupt the fuel spray pattern, causing incomplete combustion and soot buildup. Injector tolerances may be compromised, leading to larger fuel droplets and blockages. |
| Filter clogging | Contaminants can accumulate on the filter media, restricting fuel flow and leading to frequent filter replacements. |
| Engine issues | Contaminated fuel can cause power loss, increased emissions, engine distress, and even complete engine failure. |
| Acid formation | Contaminants can react with diesel fuel to form corrosive acids, damaging plastic, rubber, and metal parts of fuel systems. |
| Visual screening | ASTM screening standards can be used for a quick visual assessment of fuel contamination. |
| Quantitative testing | In-lab ASTM-standard testing can provide definitive results for flash point, PPM count of particulate contamination, water contamination, cloud point, and pour point. |
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What You'll Learn
Testing for water contamination
Water contamination in diesel fuel is a common issue, caused by rainwater getting into the diesel tank through an open fill point or vent, or condensation. Water can enter fuel at any time in the supply chain once the fuel has left the refinery, and it is important to regularly remove any water present. The industry standard should show no more than 30 parts per million of water present in the fuel.
There are several signs that your diesel fuel has water contamination:
- The diesel will appear cloudy, as opposed to its usual clear and bright appearance.
- Your fuel filters are getting clogged more frequently than recommended service intervals. This is because the filters are designed to catch and hold water, so if there is a large amount of water in the fuel, the filters will need to be replaced often.
- There is black or brown sludge on the filter. This is a key indicator that water contamination has progressed, as the area between the fuel and water is the perfect environment for the growth of bacteria, known as "diesel bug". The bacteria feed and multiply, creating colonies that are hard to break up, resulting in the sludge.
- Your tank shows signs of rust and corrosion. If left untreated, diesel bug will eventually start to eat away at the tank, so check for rust, cracks and holes.
If you suspect water contamination, you can have your fuel tested in a lab, or use water-finding paste to detect water sitting at the bottom. Alternatively, drain a small amount of fuel from the tank into a glass container and see if the water separates and sinks to the bottom.
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Fuel filter issues
Fuel filters are designed to remove contaminants such as dirt, rust, water, microbial growth, and air from diesel fuel. They are a critical component of a vehicle's fuel supply system, and when they become clogged, they can cause serious engine problems.
A clogged fuel filter will restrict fuel flow to the engine, leading to noticeable symptoms as the engine gets starved of fuel. These symptoms include engine misfires, lags, and stalling. The engine may not fire correctly and may misfire or lag during acceleration, resulting in a sudden decrease in the engine's efficiency. This can lead to a loss of power, reduced acceleration, and difficulty overcoming aerodynamic resistance. In addition, contaminants that get past a dirty fuel filter can damage, clog, or cause fuel injectors to leak, leading to various engine drivability problems.
A clogged fuel filter can also make a diesel engine difficult to start. Dirty filters limit the fuel flowing into the engine, and this issue is more pronounced when temperatures are colder. The check engine light may illuminate when the fuel pressure sensors detect low pressure, indicating a clogged fuel filter.
To prevent these issues, regular maintenance is essential. Fuel filters need to be replaced routinely, and the recommended interval for diesel vehicles is typically between 10,000 and 30,000 miles, although some newer diesel vehicles may specify changes at 40,000 to 60,000 miles. It is important to refer to the vehicle's user manual for specific recommendations.
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Injector problems
One of the most common symptoms of a faulty fuel injector is engine misfiring, which can cause the engine to sputter and shake. Misfiring occurs when one or more cylinders fail to ignite the fuel properly, resulting in uneven power delivery and a noticeable jerking motion in the engine. This can also cause a decrease in engine power, which refers to a significant drop in the machine's performance and output capabilities.
Another indicator of a faulty injector is the smell of diesel fuel, which can indicate a leak or improper combustion within the engine. This often occurs when there is a problem with the fuel injector, such as a leak or inefficient fuel atomization. A fuel leak can also be identified by checking the injector for fuel or by noticing a drop in the fuel gauge.
Clogged injectors are a common issue with diesel engines, and can be caused by debris, corrosion, or other impurities. Clogged injectors can lead to reduced engine performance, including difficulty starting the vehicle, rough idling, lack of power when accelerating, and stalling. A clogged injector may also cause the check engine light to come on, as the vehicle's computer system monitors the fuel system and will trigger a warning if the injector isn't delivering the right amount of fuel.
In addition to these issues, dirty or damaged injectors can cause the engine to vibrate or hiccup as it completes each cycle, and in rare cases, may even prevent the vehicle from starting. Poor injection timing can also affect engine performance, as it refers to the precise moment when the injector releases fuel, and can be disrupted by worn or malfunctioning components.
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Microbial contamination
Diesel bugs thrive in the area between the fuel and water, where they feed and grow, creating colonies that are difficult to break up. Over time, the bacteria produce a nasty brown or black sludge that can block filters and damage pumping systems, leading to costly repairs and downtime for machinery or equipment.
To prevent diesel bug contamination, it is recommended to drain water from tanks as frequently as possible, even daily, especially in warm regions. Tanks should be protected from rainwater and other sources of water entry, such as loose filler caps or worn seals. Automatic tank gauging systems (ATG) can detect water with sensors and alert the operator. Regularly removing water from fuel and using diesel fuel contamination tests are crucial to prevent microbial growth.
The presence of diesel bug can be indicated by visible signs of rust and tank corrosion. Additionally, the contaminated fuel may exhibit power loss, spluttering, and involuntary speed changes due to restricted fuel flow or improper combustion.
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Visual screening
One of the most common types of fuel contamination is water contamination, which can occur due to leaks, humid air entering the tank, or water vapour that condenses inside the tank. Water can also enter fuel at any time in the supply chain after it has left the refinery. Over time, fuel will have some level of water contamination. A simple test can be performed to check for water contamination by draining a small amount of fuel from the tank into a glass container. If there is water present, it will sink to the bottom of the glass. Industry standards recommend that the fuel should contain no more than 30 parts per million of water. Water draining is recommended as frequently as possible, even daily if necessary, especially in warm regions.
Another common type of contamination is particulate contamination, which can include rust, dust, pollen, or other airborne contaminants that enter the fuel tank when it is open or improperly sealed. Particulates can also include asphaltenes, which are black, tar-like substances that form in diesel fuel when it ages, is heated or pressurized, or becomes contaminated by other substances. If the particulates are too small to identify visually, chemical analysis can be used to detect their presence.
Microbial contamination, also known as diesel bug or diesel fungus, is another form of contamination that can affect diesel fuel. Microorganisms such as yeast, fungi, and bacteria are always present in the air and can contaminate fuel at any time. Diesel bug can develop when diesel comes into contact with water, appearing as a slimy, sludgy deposit that ranges in colour from dark brown to black and often has a rotten-egg smell. Microbial contamination is harder to identify through visual screening, and fuel samples usually need to be sent to a lab for analysis.
Visual inspections are important to catch signs of contamination early on, but they may not always detect all types of contamination. Some contaminants, such as sludge or other substances, may be hidden at the bottom of the tank and may only be discovered when the fuel level runs low. Therefore, it is recommended to have tanks professionally cleaned and maintained regularly to prevent and treat contamination.
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Frequently asked questions
Diesel fuel contamination can be identified through qualitative and quantitative testing. Qualitative testing involves taking a sample and performing a standard visual screening of the fuel, while quantitative testing involves in-lab, ASTM-standard testing to obtain definitive results. You can also look out for signs such as clogged fuel filters, compromised injector tolerances, and engine distress.
Diesel fuel usually appears clear and bright. Contaminated diesel fuel may appear cloudy due to suspended water, or you may notice a layer of water at the bottom of the tank, known as free water. Other signs of diesel fuel contamination include the presence of sludge, rust, and tank corrosion.
Diesel fuel contamination is often caused by water, which can enter the tank through rainwater or condensation. Microbial contamination, also known as diesel bug or diesel fungus, is another common cause of diesel fuel contamination. Other contaminants may include rust, dust, pollen, or other airborne particles that enter the fuel tank when it is open or improperly sealed.
