FPS Series Compact Fuel
Polishing Systems

Clogged Filters, Dirty Tanks?

FPS Series Systems Clean Fuel

Frequent Filter changes and incurring the expense and inconvenience of cleaning fuel tanks have become acceptable periodic maintenance instead of a warning signal for engine failure. Filter elements should last a thousand hours or more, and your engine’s diesel fuel injectors some 15,000 hours. However, since diesel fuel is inherently unstable, solids begin to form and the accumulating tank sludge will eventually clog your filters, cause engines to smoke, and eventually ruin your engine’s diesel injectors.

Fuels and oils are susceptible to natural deterioration, like any other organic fluid. Oxidation, chemical incompatibility, water and microbial infestation all contribute to the process of polymerization and stratification of diesel fuel and other hydrocarbons. This results in poor Fuel Quality, and the formation of tank sludge, bio film and acids. These by-products of the process of fuel breakdown cause clogged filters, corroded injectors, pumps and tanks, incomplete combustion (evident from black smoke, caused by un-burned fuel, from exhaust), carbon build-up on engine components, and loss of power. As these problems build on each other, these individual symptoms of bad fuel ultimately lead to complete engine failure.

Filters, separators, and centrifuges remove particles and free water from fuel.  Biocides, commonly recommended by many mechanics to cure the ills of “algae” in fuel tanks, are really less than effective in the long term control of microbial activity. Neither, however, eliminates fuel instability or sludge buildup in tanks. Biocide treatments aggravate filtration problems by turning bio-sludge into solids. Removal of fuel tanks for cleaning with high pressure washers or steam (a favorite recommendation of equipment dealers) is expensive, takes equipment out-of-service, necessitates the removal and disposal of fuel from tanks, and is likewise ineffective and does not provide a long term solution.

A study by the University of Idaho determined that there could be as much as a 26% degradation in diesel fuel after just 28 days of storage.  See the article “Fuel Polishing: How It Really Works” on this website.

Diesel Fuel is Inherently Unstable

Diesel engines continuously return fuel not used for combustion back to the tank. The repeated exposure to the heat and pressure of the injection system accelerates this breakdown of fuel quality. Fuel quality and fuel chemistry is affected by transportation, storage tank conditions as well as time, and factors such as oxidation, water in the fuel, microbial contamination (contributing to acid formation), and incompatibility of fuel additive packages with after-market additives, etc. This toxic combination negatively impacts: (i) the filterability of the fuel through filters that become clogged; and (ii) causes a dramatic increase in the size of the fuel droplets emitted from the fuel injector into the combustion chamber. The degraded condition of the fuel, when combined with the injector degradation that occurs over time from the use of the degraded fuel, result in fuel not being completely burned in the combustion chamber and formation of carbon deposits on internal engine components, all evidenced by a noticeable increase in smoke from the exhaust, loss of power, and an increase in fuel consumption. (See “Diesel Fuel & Injector Failures” for additional information)

FPS Series Fuel Polishing Systems

The FPS Compact Systems are wall-attached systems for use in applications where space is at a premium (i.e.: marine engine areas or generator cabinets) or where the Fuel Polishing System will not be out-of-doors and otherwise protected from weather and the elements.

• Programmable Runtime Scheduling
• Fully Automated
• Digital Text Readout
• Primary Filter High Water Alert/Shutdown
• High Pressure/Vacuum Shutdown
• Leak Detection Shut Down
• Smart System Alerts/Alarms

12 Volt or 24 Volt Powered Systems (see detailed specifications at left of page):

• FPS DX-S – 80 GPH – Features economic Fuel Polishing that includes Programmable Digital Timer & Alert Functionality, primary filter screen, and secondary filtration spin-on filter
• FPS-Compact – 80 GPH – Features compact components for extremely small space usage, such as generator cabinets where space is especially cramped – features remote location of the Programmable Digital Timer & Alert System Monitor
• FPS-FX – 150 GPH Rating – features high volume Fuel Polishing in a compact package

A/C Powered System (see detailed specifications at left of page):

• FPS SX-F – 150 GPH – Features remote mounted Automated Intelligent Controller and remote mounted Controller
• FPS MX-F – 260 GPH –
• FPS LX-F – 600 GPH

Fuel Conditioner

Critical to the Fuel Polishing process is the Fuel Conditioner.  Without this component, all you accomplish is the filtering of your fuel.  The Real Story of Bad Diesel Fuel is that there are two main causes of Fuel Problems:

• Micro-organisms, bacteria and enzyme activity, fungus, yeast and mold get into your fuel that cause diesel fuel degradation and the formation of waste products that can be visible floating around in your fuel tank (commonly, but erroneously, referred to as “algae”).
• Diesel Fuel begins to degrade with age as soon as it leaves the refinery.  The asphaltene component of diesel fuel (the heaviest asphalt portion of the crude oil) that is in suspension in the fuel when it leaves the refinery, but begins agglomerating and leads to larger and larger clusters and solids, which are very difficult to completely combust (causing exhaust smoke).  As these solids grow, they will not pass through the filter element and result in filter plugging after a very short period of time.

The Fuel Conditioner not only prevents both problems, it will prevent the microbial contamination from growing, and will reverse the breakdown of the heavy constituents of diesel fuel that cause the fuel to become dark or black, restoring the fuel to the clear, bright condition it had when it left the refinery and return the fuel to the state of optimal quality, hence the term “Fuel Polishing”.  For a complete understanding of the importance of the Fuel Conditioner in your fuel maintenance program, read the “Diesel Fuel Polishing” article on this website.

Primary Filter Fuel / Water Separator

The Primary Separ Fuel / Water Separator will remove water from the fuel as your FPS Compact Series Fuel Polishing System operates.  The water accumulates in the bowl of the filter unit.  The water should be removed periodically when the capacity of the bowl is reached (see details on the Separ Fuel / Water Separator web page).

Secondary Filtration

Except for the FPS Compact (inside generator cabinet model) and FPS FX Fuel Polishing Systems (12 Volt powered systems), all other FPS Compact Series Fuel Polishing Systems are equipped with a secondary spin on filter.  These filters are typically rated at three to ten microns and may be elements that are treated to retain water as the fuel passes through the cartridge, commonly referred to as a Water Block Filter.  The filter head, which the filter cartridge is fastened to, is equipped with a pressure gauge that will display the “back pressure” indicating that a filter is approaching maximum  capacity.

Programmable Digital System Monitor

Three of the FPS Series Compact Fuel Polishing Systems (those configured for DC power) are Standard with the Programmable Digital System Monitor.  Use this link to review the operating features of this System Monitor.

• FPS DX-S — 80 GPH
• FPS Compact — 150 GPH
• FPS FX — 150 GPH

SFC-70 Automated System Controller

Three of the FPS Series Compact Fuel Polishing Systems (those configured with AC power) are available with the SFC-70 Programmable Automated System Controller.  Use this link to review the operating features of this System Controller.

• FPS SX-F System — 2.5 GPM
• FPS MX-F System — 4 GPM
• FPX LX-F System — 8 GPM

The SFC-70 Controller features programmable runtime scheduling, system alerts and alarms, including automatic pump stop, Modbus TCP/IP & Summary Dry Contacts.

An upgrade to the optional TSC70 Controller provides the convenience of LCD/Touchscreen controls.

Powder Coated Enclosure

The FPS DX-S 80 GPH Compact Fuel Polishing System (available in either 12 V or 24 V) has the unique feature of being available with the option of a Powder Coated Steel Enclosure.    The enclosure measures 20 in. x 20 in. x 12 in.

If you are considering the FPS-SX-F, FPS MX-F, or the FPX LX-F, and your requirements include an enclosed cabinet, consider the STS 6000 SX-F, STS 6003, STS 6004 or STS 6010 Systems.  These Systems have the equivalent functionality with an enclosed cabinet.  Systems placed into service in regions that experience very cold conditions benefit greatly from enclosed cabinets and the addition of an optional cabinet heater to protect the Systems components from damage.

AFC Series Fuel & Tank Cleaning Additives

Critical to maintaining fuel in its optimal quality and the management of fuel tanks and engine injector components is the use of an additive treatment program.

The AFC Fuel Catalyst family of additives are formulated for use in diesel, gasoline, bio-fuels, kerosene and Heavy Fuel Oil (also known as heavy fuel oil or residential fuel oil).

AFC Fuel Catalyst is not like other additives readily available at truck stops, auto and truck parts retailers, marine supply stores, or sold by numerous on-line suppliers.  AFC is formulated and blended for the focused dual-purpose of:

First – working hand-in-hand with the LG-X Series Fuel Conditioners, and the FPS Series  of Compact Fuel Polishing and Tank Cleaning Systems cleaning fuel tanks in preparation for periodic circulation and treatment of the fuel; and

Second – as a continuing part of a Fuel Management Plan to maintain the cleanliness of storage tanks and fuel systems and assuring that your fuel maintains Optimal Fuel Quality, that we define as fuel that is like it was when it left the refinery, for as long as you depend on the fuel to efficiently operate your equipment.

Optional Features

• Manual Additive Injection – Manually draw additive into the Fuel Polisher with a dedicated supply port and ball valve.  Also see the Tank Cleaning Additives below
• Auto Water Drain (AWD) – Automatically drain water separator of collected water for decreased frequency of maintenance.  Includes water collection tank and Controller control when tank reaches capacity.
• Flow Transmitter – Replace standard flow switch for detailed monitoring of flow rate in the system
• Multi-Tank Polishing/Transfer – Polish and transfer fuel between multiple fuel storage tanks (up to 2-tanks, 4-tanks with TSC-70 Controller upgrade)
• Multi-Port Flow Path – Add multiple supply and return valves for better tank cleaning coverage (Requires upgrade to TSC-70 Controller)
• Fuel Heater – Warm up circulated fuel to resist gelling in freezing temperatures

Upgrade to the TSC-70 Advanced Automated System Controller may be required for certain option combinations.

Additional Optional Features

• Power Converter –  for 12 / 24 Volt systems to operate from 110-Volt to 230-Volt power.
• Alarm Strobe: provides flashing light signal that System shut down and maintenance service is required.
• Audible Alarm: provides audible signal that System shut down and maintenance service is required
• Digital Flow Meters:  provides digital readout of volume of fuel treated.
• Replacement Filters: for your FPS Series Fuel Polishing System.  Also see the “Additional Information” section below for Replacement Fuel Filters for the various FPS Series Systems.
• Extended System Warranty – Maximum 4 years (contact us for details).

An Ounce of Prevention is Worth a Pound of Cure

The following are products that are available on the diesel-fuels.com website that will help you in preventing debris, microbes and moisture from entering your fuel tank, and removing them early before they may cause problems.  Also, other products to help with fuel and fuel tank maintenance:

• AFC Series Fuel Additives for fuel conditioning, stabilization, tank cleaning, and combustion catalyst.  Also see the “Additional Information” section below for information on Tank Cleaning Additives.
• Breather Vent Filters with desiccant material that will stop debris and moisture from entering your fuel tank through the vent breather.
• WE-12 Water Eliminators capture and hold water from condensation that may accumulate in your fuel tank.
• Diesel Recovery quickly dissolves gelled fuel caused by cold temperatures and thaws frozen fuel lines and filters.
• Access Plates for creating a removable access port in fuel tanks to accommodate inspections and tank maintenance.
• Fuel Sampling Devices ease the recovering of fuel for testing from your fuel storage tank.  TS Series Samplers are dropped into the tank and capture a sample from different depths.  A hand pump is also available for obtaining samples.  Sample bottles are also available for use with both options.
• Fuel Testing Kits provide an early warnings of the presence of contamination in your fuel.