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.