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Diesel Generator Failure in Data Centers: How Fuel Filtration Can Prevent It?
Most people think of data centers as highly controlled environments—full of blinking lights, air conditioning, and redundant systems designed to keep everything running no matter what. But there’s one common weak spot that gets overlooked far too often: fuel quality in the backup generators.
In 2025, research indicates that over 90% of medium and large enterprises report losses exceeding $300,000 per hour of downtime. In high-risk environments like data centers, that makes backup power absolutely non-negotiable. And yet, generators still fail frequently. One of the top reasons? Dirty, degraded, or contaminated diesel fuel.
Let’s talk about why it happens, what it costs, and how fuel polishing in a data center can keep your data center out of downtime.
Why Generators Fail?
Diesel generators are critical for data centers. When the grid goes down, they’re expected to kick in within seconds and carry the full load without hesitation. However, diesel fuel isn’t static, it changes over time. And that’s where the problems start.
Water contamination is one of the primary reasons that enters tanks through condensation or poor seals. Once it’s there, it creates the perfect environment for microbial growth—what some technicians call “diesel bug.” The byproduct is sludge. Sludge clogs fuel filters and lines. That alone can stop a generator from running.
Particles and sediment build up over time as well—rust from tank walls, dust from air ingress, and other contaminants that settle and spread. And then there’s oxidation, which happens when diesel ages. It thickens and breaks down, turning gummy and unstable.
All of these issues can lead to something you never want to deal with in a crisis: your generator failing to start, or worse, shutting down mid-run.
The High Cost of a “Small” Problem
This isn’t just about inconvenience. It’s about real business impact. A recent study found that 54% of major data center outages in 2025 resulted in losses exceeding $100,000, with nearly one in five exceeding the $1 million mark.
And many of those were caused not by storms or hardware faults—but by failed generators that hadn’t been properly maintained, or had been running on contaminated fuel. It’s not hard to see the pattern: you can have the best generator money can buy, but if the fuel feeding it is compromised, the whole system is at risk.
How Fuel Filtration Solves the Problem?
Fuel filtration—especially when paired with an efficient fuel polishing system—helps ensure the diesel in your tanks stays clean, dry, and ready to use.
Here’s what a good filtration system actually does:
- Removes water before microbial growth or corrosion happens
- Traps particulates before they reach engine components
- Circulates and filters stored fuel on a regular schedule
- Extends the usable life of diesel so you’re not wasting fuel or risking poor performance
With the right setup, you’re not just fixing problems—you’re preventing them. And in a world where the average cost of a serious outage is so high, prevention becomes more essential.
How to get started in your facility?
If you’re responsible for a data center, here are a few practical steps you can take:
- Test your stored diesel fuel regularly – Contamination often goes unnoticed until the generator fails. Don’t wait that long.
- Invest in a quality fuel filtration or polishing system – It pays for itself the first time your generator starts up flawlessly during a power cut.
- Include filtration into your maintenance routine – It’s not just about equipment; fuel needs the clean-up, too.
- Train your team – Ensure that the facilities staff and operators understand how fuel degradation works and how to identify warning signs.
The bottom line
Even if you’ve got the best backup generator, it can’t help if the fuel running it is unstable or full of sludge. Fuel filtration isn’t just a technical upgrade—it’s a critical part of protecting uptime and avoiding costly outages. If your data center relies on diesel backup power—and most do—it’s worth asking yourself a simple question: Is your fuel as ready as your equipment? If you’re not sure, it’s time to find out.
Contact Njord Filtration today to learn how the best fuel polishing system for data centers can keep your generators running smoothly when it matters most.Clean Fuel on the Go: The Advantages of a Portable Fuel Polishing System
If you manage any kind of equipment that runs on stored diesel fuel, then you must also know that dirty fuel can be a big headache. Over time, any fuel tank can get contaminated with water and a thick sludge that can clog your engines. Cleaning out these tanks can be a very difficult and messy job. But there is a smart and simple solution: the portable fuel polishing system which brings the entire fuel cleaning process directly to your tank wherever it is.
Why is a Mobile Cleaning System a Good Idea?
The biggest reason to use a mobile system is that it is just so much easier. With a portable unit, you do not have to go through the trouble of pumping out all of your dirty fuel and moving it to another location to be cleaned. The machine comes right to your job site, boat, or building, which saves you a lot of time, money and hard work. It takes a big job and makes it so much simpler.
A mobile diesel cleaning unit is also very flexible. A single system can be used to clean a lot of different fuel tanks all at one location. For example, you can clean the tanks of all the heavy machines on a construction site. Or, you can easily move it to a totally different location like servicing a fleet of trucks at your main yard.
What Does a Portable System Do?
This system is designed to remove all the bad stuff from your fuel and leave it in a great condition. Here’s what all it does:
- It Removes Water: The system’s first and most important job is to pull the fuel from the bottom of your tank and run it through a water separator. This removes all of the water which is the main troublemaker that causes most fuel problems. Getting the water out of the tank stops new bacteria and fungi from growing.
- It Filters Out Dirt: After the water is gone, the fuel is then pushed through a series of very fine filters. These filters are made to catch and remove all the sludge, rust, and dirt that can clog up your engine’s filters and injectors. This is the main part of the diesel fuel restoration process.
- It Works on A Lot of Tanks: A portable system comes with its own pumps and long horses. This means it can be quickly and easily connected to a lot of different kinds of fuel tanks. It can be used on everything from the fuel tanks on your heavy equipment to the large backup generator tanks for a building.
- It Cleans the Whole Tank: This is much more than just a simple filtering job. The process of on-site fuel polishing circulates the entire amount of fuel in your tank at a high speed. This strong flow cleans both the fuel itself and also washed down the inside walls of the tank at the same time.
(Also Read: Fuel Maintenance Systems: Protecting Your Investment and Reducing Downtime)
How are These Systems Used in Different Industries?
These mobile systems are useful for many kinds of businesses:
- For Construction Sites: A single portable fuel polishing system can be moved around a large job site from one machine to the next. It can be used to clean the fuel tanks of all your heavy equipment like your excavators and bulldozers. This helps to stop unexpected engine problems that can cause downtime.
- For Marinas and Boats: Many boats sit for long periods of time which allows water to get into their fuel tanks. These systems are a great way to clean out a boat's fuel tank before the start of a new season. This makes sure that the boat's engine will be ready to go.
- For Backup Generators: A lot of important buildings like hospitals or data centers have large backup generators for emergencies. The fuel in these tanks can sit for years and go bad. A portable system is the best way to make sure that the fuel is clean and ready to go when it is needed the most.
Moving Forward
A portable fuel polishing system is a flexible and good way to clean your stored diesel fuel right where it is. It is also a great tool for any business that needs clean fuel to keep its important machinery running well. Visit our website to learn more about our mobile fuel polishing systems at Njord Filteration.
Feel free to contact us at Dit e-mailadres wordt beveiligd tegen spambots. JavaScript dient ingeschakeld te zijn om het te bekijken. if you need fuel tank cleaning services at your location and you don't know what to do.
Troubleshooting Diesel Fuel Polishing Systems Professionally
Generators are a lifesaver; Whether we talk about hospitals, manufacturing units, data centers, or other industrial estates, emergency backup generators are the backbone of almost every small and big industry across the globe. But, the only problem? These backup power suppliers are entirely dependent on the quality of the fuel, and the generator can experience unnecessary outages if the engine becomes jammed. However, the good part is that we will inform you about the common issues with diesel fuel polishing systems and how to address them professionally.
In this blog, we will explain how your generator can start to malfunction, identify the signs to look for, and guide you on how to repair them. Keep reading to learn more about it.
However, first, let us revisit our understanding…
What is a Diesel Fuel Polishing System?
Now, as you know, a diesel fuel polishing system is a setup to remove water, sludge, microbial growth and solid contaminants from stored diesel fuel. It circulates the fuel through filters, water separators and sometimes coalescers to ensure long-term integrity of the fuel. This system uses fuel suction from the storage tank, pre-filters the fuel to remove large particulates and removes moisture from the water. Once done, the Fine filtration traps the microbes and acceptable debris. After this process is maintained correctly, the polished fuel returns to the tank to power the engine.
Now, what are the signs your diesel fuel polishing system needs repair?
If you maintain the fuel polishing system for diesel generators on time, you may not have to deal with generators that can be really expensive to repair. But if maintenance is out of the book, then you must look out for the following key signs that mean your generator needs immediate repair or expert supervision:
- Alarm or Shutdown Signals
When you invest in advanced systems offered by Njord Filtration, it comes with trigger alarms for high filter pressure or water levels. If you notice frequent shutdowns, it may indicate that your filters are clogged. - Visible Sludge in Tanks
Keep checking for floating particles, black slime microbial growth or sediment buildup and remove them before they start to spread and worsen the situation. - Generator Performance Issues
Look out for significant signs, such as hard starting, misfiring, or black smoke, while the generator is operating. This may be a sign of dirty or water-laden fuel in the power engine. - High Filter Replacement Rate
If you're replacing filters more often than usual, it indicates an excess of contaminants in the system. - Cloudy or Smelly Diesel Fuel
Diesel should be clear with a mild odor, so if you notice dark, cloudy or foul-smelling fuel, it could directly indicate fuel contamination.
Common Diesel Fuel Polishing Systems Issues and How to Fix Them?
Now, if you need to troubleshoot diesel fuel polishing systems in emergency backup generators, then here are the common issues with diesel fuel polishing systems, with expert instructions on how to fix them:
- Water Buildup
Water Buildup is caused by Condensation inside tanks. To fix it, you need to drain the water separator regularly. Then use water-detecting paste for regular checks. Finally, consider upgrading to an automated water sensor if you think it can notify you during higher-risk conditions.
(Also read from our previous blogs: The Importance of a Water Separator in Diesel Fuel Polishing: Expert Advice ) - Clogged Filters
Clogged filters are often caused by excessive contamination or inadequate maintenance. But it's easy to fix if you follow the instructions correctly. So all you need to do is shut off the system and replace the clogged filter. Use high-efficiency filters rated for your fuel type and monitor the pressure gauges to detect clogging early. - Pump Failure
Pump Failure is caused by constant overheating, wear and tear or airlocks. To fix it, check the power supply and motor wiring first. Once done, bleed air from the pump, and you're good to go!
Step-by-step guide to resolving diesel fuel polishing system failures
If your fuel polishing system isn't working to its full potential, follow these steps to troubleshoot:
Step 1: Visual Inspection
First, check for fuel leaks, loose wires or damaged parts. Make sure the unit is powered on and the control panel is functioning correctly.
Step 2: Check Fuel
Next, check the fuel. Look for colour, clarity and smell. You can also use a fuel sampler to collect fuel from the bottom of the tank for laboratory testing.
Step 3: Inspect and Replace Filters
For the next step, turn off the system, remove the filters and replace both pre-filters and fine filters. Record the pressure differential to track future performance. That way, you can take better care of the filters and manage them before they get damaged.
Step 4: Drain Water Traps
Now, empty all water traps manually if your system doesn't have an auto-drain feature. Then wipe out the growth of microorganisms around the fuel tank.
Step 5: Test Pump Operation
Next, test the pump operation by turning on the system and checking the pump pressure and flow rate. If the flow is low or inconsistent, check for faulty components.
Step 6: Clean the Tank
Once the major tasks are done, check if contamination persists. If yes, then you need to do a complete tank cleaning. Reach out to experts for better services.
Step 7: Run a Test Cycle
Finally, after maintenance, just run a complete polishing cycle. And, do not forget to monitor system readings and check that the fuel returns are clean and dry.
Bottom Line
Now that you know the common issues with diesel fuel polishing systems and how to fix them, you can worry a little less about the power backup not offering its best performance. However, if you are looking forward to a polishing system that not only ensures your fuel tanks are clean but also keeps you updated on the current fuel or engine condition, then invest in Njord Filtration's fuel polishing systems.
Have queries? Reach out to our experts. Contact us here.
Is Dirty Fuel Silently Damaging Your Fleet's Engines?
Running a fleet is a challenging job that involves juggling schedules, fuel costs, maintenance, and ensuring every truck operates smoothly without a hitch. The last thing you need is an engine acting up or a truck breaking down unexpectedly. But here's the thing—a lot of those issues might be coming from something most people never think about: dirty fuel.
Even if you're getting your fuel from a reliable source, it doesn't stay clean forever. Over time, things build up—water, gunk, even microbes—and start causing real problems. There's a simple fix: fuel polishing.
What's Dirty Fuel Exactly?
It sounds odd, but fuel can go "bad" just sitting in your tanks. Here's what tends to sneak in:
- Dirt and debris – These clog up your filters and make engines work harder than they need to.
- Water – Usually from condensation. It can cause rust in your tank and mess with fuel quality.
- Microbes – Bacteria and fungi actually grow in fuel, especially when water's present.
- Sludge – All the above builds up into thick, sticky gunk that kills performance.
If your trucks are acting sluggish, going through filters too fast, or you're noticing more breakdowns than usual, your fuel could be the problem.
So What's Fuel Polishing?
Fuel polishing is just a smarter way to clean up your fuel before it reaches the engine. Think of it like giving your fuel a deep clean: Here is what a fuel polisher does-
- Removes the dirt and sludge
- Remove the water
- And in many cases, even kill off bacteria or fungi.
- Then, the fuel gets circulated and cleaned multiple times.
By the end, what goes back into your system is clean, healthy fuel that your engines will thank you for.
Why Is This Important?
Because clean fuel means fewer headaches. Here's what you really get-
- Less downtime – No one likes dealing with breakdowns in the middle of a route.
- Lower repair costs – Clean fuel means fewer clogged injectors and filters.
- Better fuel mileage – Your engines run more efficiently with clean fuel.
- Longer engine life – You're protecting one of your fleet's biggest investments.
- Cleaner emissions – Helps keep you compliant and a little more eco-friendly.
The bottom line
At Njord Filtration, we make fuel polishing systems designed for fleet managers who just want their trucks running without all the drama. Our systems are fast, simple to use, and they work. If you're tired of engine issues or high maintenance costs, give your fuel some attention. A little polishing goes a long way. Let's keep your trucks moving and your costs down.
Check out our fuel polishing systems today—and see the difference clean fuel can make.The Role of Data Analytics in Optimizing Fuel Consumption in Industries
If you are an old member of the industrialisation club, you must already know how fuel consumption remains one of the most significant operational costs when it comes to powering backup generators, transport fleets, heavy machinery, etc. However, over the years, after investing so much, these industries started looking for an efficient way of saving both money and fuel, and that is when fuel polishing data centers came into the picture. These centers offered performance tracking and monitoring that allowed many big and small industries to optimise the data for better and enhanced performance.
However, thanks to modernity, you do not need to look out for such centres specifically; instead, get a data analytics tool that helps you study fuel performance without the need for an expert.
In today’s blog, we will tell you how exactly that will happen, what the benefits of using such tools are, and everything else you must know. Keep reading to learn more about it with Njord Filtration.
But first, let us understand…
What is Data Analytics?
In simple terms, data analytics is the process of collecting, organizing, and analyzing large sets of data to uncover valuable patterns, insights, etc. Different types of data analytics are used in other industries. Some of the most popular ones are:
- Descriptive analytics is used to determine what has happened. For example, how much fuel was consumed over time?
- Diagnostic analytics is used to explain why something happened, for example, figuring out why fuel consumption spiked.
- Predictive analytics is used to forecast what might happen, for example, when filters will need replacement.
- Prescriptive analytics recommends the action you must take. For example, you may need to polish the fuel to avoid downtime in heavy machinery.
And, what is fuel polishing?
As our old readers, you may already know what fuel polishing is, but if you are here for the first time, let us explain it to you in the most simple way: Clean fuel ensures smooth engine performance, reduces maintenance costs, and minimizes the risk of breakdowns, and this is achieved with the help of fuel polishing.
Fuel polishing is the cleaning process that removes water, sludge, microbial contamination, and other impurities from stored fuel. This plays a vital role in Data centers, Marine vessels, Construction machinery, Backup power generators, etc.
(Also read from our previous blogs: How to Use Fuel Conditioner to Prevent Microbial Growth in Tanks)
The Role of Data Analytics in Fuel Polishing Data Centers
The role of big data in enhancing fuel efficiency for industrial processes has helped many small and prominent businessmen save fuel. Here’s how data analytics supports fuel polishing in data centers:
- Monitoring Fuel Quality in Real Time
This tool helps you track fuel contamination levels, such as microbial growth, water content, and particulate matter. It also detects early signs of fuel degradation and helps you schedule polishing cycles proactively. - Predicting Maintenance Needs
It uses historical data to forecast when filters, separators, or polishing units will need servicing, allowing you to prevent unexpected equipment failures. - Improving Generator Readiness
Data analytics ensures backup fuel is always clean and ready to use, and reduces the risk of generator failure during power outages. - Automating Alerts and Reports
Finally, these data analytics will send real-time alerts for any drop in fuel quality, generating compliance reports for audit and safety reviews.
Benefits of Using Data Analytics in Fuel Polishing Systems
The benefits are the following:
- Enhanced fuel efficiency
- Extended lifespan
- Better resource
- Eco-friendly
- Minimised fuel loss
Bottom Line
These fuel polishing data centers have allowed many big industries to save fuel, especially during tough times. The right tool will enable you to read real-time data and fix issues before they become severe and costly. With the expert assistance of Njord Filtration, your industry can save money and improve fuel efficiency.
Need help? Get in touch with us today!