Product Pricing

(You may also use these links to enter the Shopping Cart to place an order or to determine shipping cost) Product

FPS MX-F - Fuel Maintenance System with Separ Filtration & Secondary Fine Filter - 240 GPH

Your Price: $8209.00

Product Pricing

(You may also use these links to enter the Shopping Cart to place an order or to determine shipping cost) Product

FPS Controller Upgrade to TSC-7000 Controller

Your Price: $3382.00 Product

TSC-MPAC Alternation Controller - Multi-Point Valve Controller & Software

Your Price: $4612.00 Product

Multi-Point Flowpath - Valve Set - includes 2 Solenoid Controlled Valves and one Foot Valve

Your Price: $1182.00

Product Pricing
Optional Products

(You may also use these links to enter the Shopping Cart to place an order or to determine shipping cost) Product

FT-100 Liqui-Cult Fuel Test Kit - Box of 10 bottles

Your Price: $142.50 Product

FT-200KK Kolor Kut Water Finding Paste (3-oz tube)

Your Price: $7.00 Product

Amber Stack Light - 24V

Your Price: $189.00 Product

Audible Alarm - 24V

Your Price: $189.00 Product

WE-12 Water Eliminator - one per package, 12" unit

Your Price: $19.50

Product Pricing
Replacement Filters Elements

(You may also use these links to enter the Shopping Cart to place an order or to determine shipping cost) Product

01810 - 10 Micron Particulate Filter for Separ SWK 2000/18

Your Price: $45.00 Product

01830 - 30 Micron Particulate Filter for Separ SWK 2000/18

Your Price: $45.00 Product

01860S - 60 Micron Cleanable Stainless Steel Screen Filter for Separ SWK 2000/18

Your Price: $196.00 Product

30421 - Lid Gasket for Separ SWK 2000/18

Your Price: $22.00 Product

30423 - Bowl Gasket for Separ SWK 2000/18

Your Price: $12.50 Product

30387 - Lid Gasket for Separ SWK 2000/130

Your Price: $68.00

Smart FPS-MX F Series

Diesel Fuel Polishing Systems

Smart FPS MX-F Series Systems

FPS-FX System

Click on Graphic to Enlarge

Diesel Fuel Before and After

Before and efore and after fuel cleaned by the AXI Fuel Polishing System

Click on Graphic to Enlarge

Debris and Water Removed
from the Bottom of Tank

Sediment removed with ALGAE-X

Click on Graphic to Enlarge

System Specifications



Flow Rate

4 GPM / 260 GPH
(15.1 lpm / 906 lph)

Tank Size

3,000 to 6,000 gallons
(11,400 to 22,700 ltr)


1/3 HP single phase, continuous duty, thermally protected, TEFC


Helical Spur Gear Pump


110V / 60Hz 15A
230V / 50Hz 15A

Max. Fluid Viscosity

5 cST


Diesel Fuel, Hydraulic,
Engine & lube oil,
water, antifreeze


Stainless Steel

Port Size

3/4"-37 deg. Flare
3/4"-37 deg. Flare

Filtration Controller

Programmable SFC-50 Controller

Fuel Conditioner

AXI LG-X 1500

Primary Filtration

Separ SWK 2000/18

Primary Filter Elements

10µ, 30µ Fine Filter
or 60µ SS

Secondary Filtration

Spin-On Filter Element

Secondary Filter Elements

1,3,10,25µ &3µ X-Glass Fine Filter or
3 or 10µ Water Block Filter


Powder Coated Aluminum Back Plate

Operating Temperature

41 - 104 deg. F
(5 - 40 deg C)

Alarm Features

Pump Shut-Down
High Vacuum
High Pressure
Leak Detection


60 lbs / 10 lbs
27.2 kg / 4.5 kg

(H x W x D)

23" x 26" x 9"
58 x 69 x 23 cm

Not for use with fluids that have a
flash point below 100 deg. F.

Available Options for
the FPS MX-F Systems

AXI Multi-Point Flowpath Valve Control System -- Most common in the Emergency Power sector, some diesel fuel tanks are constructed like low, rectangular boxes with the generator mounted on top. Due to internal baffles and structural supports that act as obstructions to the free flow of fuel, water and debris is often evenly dispersed over a wide area and single suction/discharge points do not adequately clean the tank. The Multi-Point package works through random solenoid valve actuation on both the suction and return plumbing to source fuel in up to seven suction zones and seven discharge zones, controlled by an independent controller and actuated on a random cycle, assuring all zones of a tank are cleaned. The base package includes two suction and two discharge points plus the controller. Each Expansion Kit contains one suction and one discharge point.

FPS MX Extended Warranty -- AXI Standard Warranty provides protection against defects in material and workmanship for a period of one (1) year. AXI offers an extended warranty plan that can extend your coverage for one, two, three, or four additional years. Contact us for additional information.

Other Products that
Enhance the Operation of the
FPS MX-F System

AFC-705 Diesel Fuel Catalyst -- A POWERFUL Full Spectrum Additive and tank cleaning agent. It is a unique broad-spectrum fuel additive that provides Superior Diesel Fuel Quality for Engines and Storage Tanks, lowering operating cost, maintenance and downtime.

AFC-710 Diesel Fuel Catalyst -- A unique and powerful Tier 4 compliant broad-spectrum fuel additive concentrate for use in Diesel, Bio-fuels, Gasoline, Kerosene, and HFO. Available in liquid and powder form.

AFC-805 Diesel Fuel Catalyst -- An effective means of decontaminating and cleaning storage tanks and stabilizing fuel fuel, ideally used for cold weather applications where there is long term fuel storage, such as bulk fuel farms, winterized recreational and work boats, and also smaller engines.

Fluid Tank Sampler -- Obtain samples from larger tanks using the AXI Stainless Steel Tank Samplers, available in 4 oz., 8 oz., and 16 oz. capacities

Fluid Sample Pump & Sample Bottles -- Use this hand pump to obtain samples of fuel. Sample is deposited directly into 4 oz. or 16 oz. bottle for further testing.

Tank Access Ports -- Easily create an access port in your fuel tank for obtaining samples or access for performing tank cleaning and fuel polishing.

Liqui-Cult Fuel Test Kits -- Test kits are used to detect microbial growth in fluids and determines the type and degree of infestation.

FUELSTAT® Fuel Test Kits -- Fuel Test kits for detecting microbial growth in fluids that can provide in-the-field instant test results.

Desiccant Fuel Tank Breathers -- Unlike tank installations that utilize open vents or conventional breathers, Desiccant Breathers provide a simple yet dependable defense against not only particulate contamination from entering the tank, but also moisture in the air from entering your storage or equipment tanks.

Water Eliminator -- Water Eliminator crystals are water specific and will swell many times their weight in water. Water specific means they will only absorb the water in your tank and will not absorb or adversely affect gasoline, diesel fuel, fuel oil, JP5 or hydraulic oil. Place a Water Eliminator in your fuel tank and monitor at each fill up for accumulated water.

Water Finding Paste -- Use some "Kolor Kut" paste on the end of a stick or a tank measuring rod that reaches through the top fill opening all the way to the bottom of the tank. Kolor Kut paste will show the water level in the tank by changing color where it comes in contact with water, indicating how much water and sludge will need to be removed.

Replacement Filter Elements for
the FPS FX & FX-R System

Primary Filter for Separ SWL 2000/18:

Click on filter element for pricing

Secondary Filter Element Options:

FPS MX-F Literature

Smart FPS MX-F Systems


FPS MX-F Fuel Polishing System

Click on Graphic to Enlarge

1. Fuel Inlet (From Tank)

8. Pressure Gauge

2. AXI® Fuel Conditioner

9. Fuel Outlet (To Tank)

3. Separ SWK 2000/18 Primary
Filter/Water Separator

10. Drain valve

4. Vacuum Switch

11. Leak Detector (Float Switch)
in Spill Tray

5. Vacuum Gauge

12. Pump

6. Motor

13. Secondary Filter

7. Pressure Switch


FPS Series Automated and Programmable Functionality

AXI (formerly ALGAE-X®) SMART Fuel Polishing Systems (FPS) are programmable, fully automated Fuel Maintenance Systems that remove water, sludge and contaminants wherever fuel is stored or used. Adding a SMART FPS System that meets your requirement and needs will remove particulate, separate water, and condition fuel. This fuel polishing process conditions and stabilizes diesel and bio-fuels, eliminates microbial contamination, and ensures fuel remains clean and dry. These compact fuel maintenance systems are specifically designed for permanent installations indoors, as well as confined spaces, such as inside gen-set enclosures or engine rooms. SMART FPS Systems keep your tanks clean and your fuel in "Clear & Bright" pristine condition at all times providing maximum efficiency and minimal emissions. AXI’s LG-X Fuel Conditioner, included on every FPS System, reverses fuel deterioration and removes sedimentation to sub micron levels, preventing clogged filters, extending injection system service life, and reducing smoke, emissions and downtime.

All FPS Systems feature:

  • SMART Filtration Controllers

  • Fully Automated & Programmable Operation

  • Integration with Equipment Monitoring Systems

  • Modular "Plug & Play" Flexibility

  • Unique Safety and Alarm Features

  • Continuous-Duty Pumps, Viton Seals

  • Leak Detection with Emergency Shut-Down

An FPS Series Fuel Polishing System is the central component of a Fuel Management Plan. Establishing a fuel management and maintenance protocol should include removal of accumulated water, periodic fuel circulation for particulate filtration and polishing of the fuel, and treatment with a Diesel Fuel Catalyst made to work hand-in-glove with the Fuel Polishing System to clean the fuel tank without removing the fuel, assuring that the lights stay on when the power goes off.

FPS MX-F Series Systems

The SMART FPS MX-F system is a programmable, fully automated, fuel maintenance system that removes water, sludge, and contaminants wherever fuel is stored or used. Adding a SMART FPS MX-F system will remove particulate, separate water, and condition fuel. This fuel polishing process stabilizes diesel and bio-fuels, eliminates microbial contamination, and ensures fuel remains clean and dry. These compact fuel maintenance systems are specifically designed for permanent installations indoors, as well as confined spaces, such as inside gen-set enclosures or engine rooms. The Smart FPS MX-F Fuel Treatment and Tank Cleaning System is sized for facilities that require single tank fuel storage of 3,000 to 6,000 gallons.


Unlike smaller installations where a single generator may provide emergency power for a single building, the FPS MX-F has the capabilities to maintain larger installations, such as larger marine craft, office buildings, governmental administration facilities, or a fuel storage facility for fueling mining equipment, construction equipment, or a steady stream of trucks. The FPS MX-F can quickly treat fuel in high throughput situations where new fuel from a tanker truck is introduced into a large tank, requiring immediate treatment to assure the fuel is in optimal condition when the equipment comes calling for fuel fills.

FPS MX-F Functionality

The FPS MX-F Diesel Fuel Conditioning and Tank Cleaning System is available to operate on either 110V 60Hz 15A or 230V 50Hz 15A power. The FPS MX-F utilizes five-stage water removal and is capable of filtering the fuel in the storage tank to remove particulates down to one micron. This level of filtration insures that the diesel fuel that numerous and varied equipment that feeds from this tank will have fuel that meets the cleanliness requirements of engine manufactures. AXI’s patented Fuel Conditioner reverses fuel deterioration and polymerization to sub micron levels.

For safe operation the Smart FPS MX-F is equipped with an automatic pump shut-down and indicators when filter elements require service. Also included are sensors that monitor high pump vacuum, pressure exits, and a leak detector.

The principal components are a continuous-duty pump, the primary filter being a Separ SWK 2000/18 Fuel Filter / Water Separator, a vacuum sensor and gauge, an AXI LG-X Fuel Conditioner, a secondary spin on filter, and a SMART Filtration Controller.

AXI Fuel Conditioner

The fuel flow first enters the FPS MX-F System through the AXI Fuel Conditioner LG-X 1500. Operating on the principal of induction on the process of combining kinetic and magnetic energy to influence the behavior of electrons, the AXI Fuel Conditioner provides a powerful magnetic field and the flow of fuel provides the kinetic energy.

AXI LG-X 1500 Fuel Conditioner

Click on Graphic
to Enlarge

As fuel deteriorates, clusters of fuel components break down and residue begins to accumulate, resulting in dark, hazy fuel with poor combustibility. The increase in size and mass of the fuel breakdown products lead to clogged filters and the build up of tank sludge. The AXI Fuel Conditioner dissolves the clusters, stabilizes the fuel, and eliminates tank sludge. The results are Clear & Bright Fuel, improved filterability, optimal combustion and clean fuel systems. The process of how the AXI Fuel Conditioner makes clear, bright and more combustible fuel as well as restoring degraded fuel and eliminating the effects of microbial contamination is compelling. As the AXI Fuel Conditioner does not filter the fuel, but treats it as it passes through the unit, there is seldom any reason to suspect that a restriction is in the AXI Fuel Conditioner. But you can remove the face plate, remove the magnet and wipe it off with a shop rag and replace the filter and face plate. A spare parts kit for the AXI Fuel Conditioner includes a new face panel O-Ring and replacement screws to fasten the face plate.

Primary Filtration

SMART FPS Systems reverse fuel deterioration while decontaminating, cleaning and optimizing the fuel for guaranteed continuous, uninterrupted service.

The FPS MX-F System utilizes a Separ SWK 2000/18 Fuel Filter / Water Separator that incorporates an effective five stage system for the separation of water and particulates from the fuel. Both water and particulate matter can result in high levels of wear for fuel pumps and injectors, resulting in reduced reliability and expensive engine repairs:

The following is the five stage fuel system of the Separ 2000/10 Fuel Filter/Water Separator:

  • Stage 1: From the inlet port, fuel flows through the interior vane system which imparts a circular motion to the fuel.

  • Stage 2: Still in circular motion fuel reaches the bowl section where, due to this centrifugal motion water droplets and heavier particles are forced to the wall of the bowl eventually settling in the bottom of the bowl.

  • Stage 3: In this stage the fuel has to pass the vane system positioned on the "outside" of the central housing. Due to differing length of the vanes and the twofold rapid change of fuel flow direction, smaller water droplets and finer particles will settle on the vanes. These settlements will agglomerate and when heavy enough fall to the bottom of the bowl. Already at this point the major portion of any contaminates in the fuel have been separated.

  • Stage 4: Just below the filter element the flow area of the filter is increased significantly thus reducing the fuel flow rate. This calming effect allows even smaller water droplets and particulate to fall out settling on the inner surfaces of the housing forming larger droplets which eventually fall into the bottom of the bowl by gravity. Due to the before described pre-separation process the major portion of water and particulate present in the fuel will be in the bowl or on the inner surfaces of the filter thus greatly extending the filter element life.

  • Stage 5: The final filtration of the remaining water and particulates still contained in the fuel will be effected by a replaceable filter element. These filter elements are produced from a special filter media and are available in different pore sizes. The clean fuel leaves the filter via one of the two outlet ports.

A Vacuum Gauge is provided on the top lid of the Separ Fuel Filter/Water Separator to allow for visual monitoring of Vacuum. When the Vacuum reading increases, indicating that the replaceable filter element has reached its capacity for holding particulate material, you know the filter needs changing. No more guessing or changing the filter too soon.

Secondary Filtration

WBS-3 Water Block Filter Element

The FPS MX-F Secondary Filter is a spin-on filter for fine filtration down to 1 micron. The filter housing includes a gauge that reads the back pressure and, when the back pressure increases indicating that the flow of fuel is being restricted by the accumulation of particulates or other debris on the filter element inside the spin-on filter, it is time to change the filter. This assures that you are not leaving a filter on too long, compromising the filtration process, or changing the filter too soon and not receiving all the value for the filter and increasing your operating costs.

For most applications where fuel is stored for future use, a circulation system that consistently maintains water-free fuel storage and fuel filtered to a particulate level of 10 microns is acceptable. AXI offers seven different filters for the FPS MX-F. The fine filter spin-on filter elements are rated at 1, 3, 10, 25 and a 3 micron filter that is an X-Glass element. Also offered are 3 and 10 micron Water Block Filter elements. (see pricing at the links in the table to the left under "Replacement Filter Elements for the FPS MX-F System".

The 3 micron Water Block filter is usually the preferred filter for ongoing preventative maintenance, using a 10 or 30 micron filter in the Primary Fuel Filter / Water Separator. The WB3 filter element will remove free water and emulsified water from the fuel stream along with the removal of particulates. Most engine manufacturers want the fuel entering their engine to be filtered at 4 microns, removing particulates and organic debris from the fuel preventing these contaminants from causing problems with the tolerances of fuel injector systems. Although modern engines have a factory-provided filter, usually in the 4 micron range, supplying fuel to the filter that already meets these requirements will extend the life of the factory filter and also assure the fuel is in optimal condition for use in these highly developed injector systems.

A Vacuum Gauge is provided on the top lid of the Secondary Filter housing to allow for visual monitoring of Vacuum. When the Vacuum reading increases, indicating that the replaceable filter element has reached its capacity for holding particulate material, you know the filter needs changing. No more guessing or changing the filter too soon.

The System Controller

The system is automatically operated by the a SFC-50 programmable UL508A SMART Filtration Controller with text readout. The controller’s alarm functions and pump shut-down are triggered if filter elements require service, if high pump vacuum or pressure occurs, if system flow rate varies or if there is water in the separator. The wiring harness with plugs easily connects the SMART Filtration Controller, which can be remotely mounted, with the FPS MX-F allowing for greater flexibility in installation and access where it’s most convenient.

Water Level Probes are provided on the Primary Filter bowl to sense when the water level in the bowl reaches a critical level. The WATECT Water Sensor is monitored by the Controller and will provide an alert when the water level is too high. Upon receiving an alert, the water may be manually drained. An Automatic Water Drain is available as an option to automatically discharge the accumulated water from the Primary Filter bowl into a holding container for later disposal.

As clean fuel leaves the Primary Filter via the outlet port and passes through the Vacuum Switch connected to the Controller, constantly monitoring vacuum and, upon detection of high vacuum, caused by a clogged Primary Filter or obstruction in the suction line, the Controller will send an alert that high vacuum is occurring, and likely the filter needs replacement. The fuel then continues to the suction side of the Internal Gear Pump. Fuel then exits the pressure port of the pump and passes through a Pressure Switch with Gauge that allows for both visual reading of the pressure in the discharge side of the pump and monitoring of the discharge pressure by the Controller. If discharge pressure is too high, an alert shut down the system. This typically indicates a clogged Secondary Filter or obstruction in the discharge pipe.

Leak Detection by way of a float switch in the bottom of the drip tray should the unexpected happen and fuel collects in the tray. Upon detection, the Controller will shut down the system.

Sample the Tank Bottom

If a tank has a straight-line access to the bottom of the fuel tank from the fuel fill hole or through another inspection port, a length of PVC or similar material pipe, 1/2 inch in diameter, can be used like a soda straw to sample what is in the bottom of a tank. Cut the pipe to length to allow insertion of the pipe to the bottom of the tank while allowing your thumb to cover the exposed end of the pipe. With your thumb over the end, insert the pipe to the bottom of the tank, remove your thumb so what is at the very bottom will rush into the tube to the level of fuel in the tank. Again place your thumb over the end of the pipe and extract the pipe, maintaining the liquid and other materials inside the tube. Place an empty clear plastic 2 liter soft drink bottle upright in the bottom of a empty 5-gallon bucket. Direct the end of the tube into the drink bottle (any spilled liquid will be caught inside the five gallon bucket). Perform this action several times. Allow the contents of the bottle to settle (ideally overnight) and inspect the materials in the bottom of the drink bottle. Any debris or water should be apparent.

If your tank is larger and using a tube to recover fuel, water or other debris from the bottom of the tank is not possible, you can use a Tank Sample (TS) Fluid Sampler. You can take 4 oz., 8 oz, or 16 oz. samples using the AXI Tank Sampler or you can use a hand-held Sample Pump (at bottom of the AXI Tank Sampler page) to remove a sample, as described on the Tank Sampler page.

Multi-Point Tank Cleaning for Base/Belly Tanks

Generator with basetank

FPS Fuel Polishing and Tank Cleaning Systems are well suited to the task of maintaining fuel in its optimal condition and the removal of sludge, water, debris and organic growth from fuel tanks in primary power and secondary/backup power applications. The common power generator unit is typically located within a metal enclosure and positioned atop a rectangular steel structure that acts as the fuel tank. Due to the weight of the generator, diesel engine and numerous control components, the base or belly tank contains internal structural bracing that supports the weight but allows fuel to move between the internal compartments. These structural supports within the fuel tank often have only small holes between the internal compartments allowing the fuel to move between the compartments. While this works for supplying fuel, this presents considerable problems when the need arises to remove accumulated fuel tank sludge, water, debris, and organic material that accumulates over time in the tank bottom and on the sides of the tank and on the internal supports.

AXI offers a Multi-Point Flow Path System that interacts with the FPS Fuel Polishing and Tank Cleaning System utilizing a multiple solenoid valve system that involves installation of one suction and one discharge valve into each compartment, and through a separate Multi-point Alternation Controller can randomly cycle through the array of valves to treat the fuel in each compartment.

Base or Belly Tank Flow Path

An upgrade from the standard FPS Controller to the TSC-7000 LED Touch Screen Controller is necessary as well as the incorporation of the TSC-MPAC Alternation Controller to control the valve system. The TSC-MPAC can control up to 16 Suction Valves and 16 Discharge Valves.

Visit the Multi-Point Tank Cleaning page for more detailed explanation

Recommended Tank Cleaning & Fuel Treatments

AFC-705 Diesel Fuel Additive

It is recommended that diesel fuel be treated with the AXI Fuel Catalyst AFC-705 (for pre-2007 engines) or AFC-710 (Tier 4 compliant) Diesel Fuel Catalyst prior to the initial tank cleaning and at least every six months thereafter to assure the fuel tank remains clean and the fuel is stabilized. This will enhance and accelerate the tank cleaning process by breaking down and dissolving existing tank sludge. Always check the fuel tank for an accumulation of water in the bottom of the tank. Using a rod, sometimes used to measure fuel in a storage tank, or a length of PVC pipe, spread a line of Kolor Kut Water Finding Paste on the side of the rod or pipe and insert to the bottom of the tank. If the paste touches water, it will change colors, showing how much water is in the tank requiring removal.

AFC-710 Diesel Fuel Additive

Pump accumulated water out of the tank for proper disposal. It is often the case that all of the water is impossible to remove. AFC-705 contains a surfactant that will emulsify the residual water up into the fuel for removal by a Water Block Filter on the AXI Fuel Polishing System AFC-710 does not include this surfactant component). Depending on the condition of the fuel and the amount of sludge build-up, it is recommended to initially use a double dose of one to twenty-five hundred (1:2500 - one oz. to 20 gallons of fuel) and circulate the capacity of the tank five times. Always treat the tank when the tank is full of fuel. If you perform a treatment with a half tank of fuel, you will only be cleaning the bottom half of the tank. The use of AXI Fuel Catalyst has proven to be essential in accelerating the tank cleaning process. AFC-705 and 710 contains detergent, dispersant, corrosion inhibitor, lubricity enhancer and combustion catalyst. AXI Additives do not contain biocides.

AFC-710 Powder Diesel Fuel Additive

For engines manufactured in 2007 and later, use AFC-710, available in both liquid and powdered form. AFC-710 does not contain the surfactant (used to emulsify residual water into the fuel for removal in the circulation process as does AFC-705), a component that does not allow for qualification as a Tier 4 product. AFC-705 and AFC-710 should always be used periodically in particular to stabilize fuel that is stored for longer periods of time.

After the initial cleaning, the AFC-705 or AFC-710 in the fuel will continue to stabilize the fuel for six months or more. Every six months, or more often if the region in which you reside is a humid climate, treat the fuel again and circulate the capacity of the tank three times. In applications where fuel from a treated tank is distributed to other equipment, the additive will also clean the downstream tanks and continue to stabilize the fuel.

AFC-710 Powder

Tank Cleaning & Fuel Treatment for Cold Weather Use

For cold weather operations, AXI Fuel Catalyst AFC-805 is a unique and powerful anti-gelling broad-spectrum fuel additive specifically formulated for use in Diesel, Bio-fuels, Gasoline, Kerosene, and HFO. AFC-805 should be used as part of any preventative fuel maintenance program, and is ideal for use in bulk storage fuel tanks in cold weather environments. AFC-805 enhances the breakdown and removal of sludge, slime, and bio-fouling from tank walls and baffles that are difficult to access.

AFC-805 effectively decontaminates and cleans an engine’s entire fuel and injection system. It continues to work in storage tanks cleaning and stabilizing fuel for up to 12 months with a single dose. AFC-805 is ideally used for cold weather applications where there is long term fuel storage, such as bulk fuel farms, winterized recreational and work boats, and also smaller engines. AFC-805 is recommended at a ratio of 1:5000 (one oz of AFC-805 to 40 gallons of fuel)

The Following Guides
Tell the Story

Fuel Management System Operation

The fuel you depend on should always be in optimal condition. Periodic circulation of fuel assures optimal combustibility and fuel cleanliness. All major diesel engine manufacturers have set minimum fuel standards for the diesel fuel to be used in their engines, and failing to maintain fuel that meets those standards could lead to engine component failures and denied warranty claims. As an example, Caterpillar has published "Cat Commercial Diesel Engine Fluids Recommendations" (SEBU6251-17 September 2014 [a more recent version may be available]) that states "In order to meet expected fuel system component life, 4 micron(c) absolute or less secondary fuel filtration is required for all Cat diesel engines that are equipped with common-rail fuel systems." (Page 34) You should not assume that fuel being delivered to you meets the engine manufacturer’s requirements, and certainly fuel that has been in your storage tank for an extended period of time is unlikely to meet requirements of diesel engine manufacturers without a Fuel Management Program.

Cleanliness standards for diesel fuel, established in the late 1990’s by the International Organization for Standardization (ISO), apply to diesel fuel. Caterpillar recommends that the fuel dispensed into the machine tank meets "ISO 18/16/13" cleanliness level." (Page 49) For more information on fuel cleanliness specifications and what those requirements mean to you, review the "Diesel Fuel & Injector Failure" web page on this site.

Continued vigilance to assure that your fuel is in the best condition possible and always meets the requirements to maintain engine manufacturer's warranty requirements is a major challenge without the use of an AXI Fuel Conditioning & Tank Cleaning System to address the need for periodic Fuel Polishing.

Fuel Maintenance Plans

Clogged Fuel Filter

A Fuel Maintenance Plan should be a part of every periodic engine Preventative Maintenance Program. Preventative Maintenance Programs are common in all major industries today, but monitoring the fuel condition is often taken for granted and not included in the Preventative Maintenance Program. Many of today's maintenance personnel have many years of experience, but until changes in sulfur content in diesel fuel were regulated within the past decade, and with the government’s push for blending some amount of bio-diesel into regular diesel fuel, maintenance professionals were never presented with the problems that we are experiencing today. With today’s advances in design and engineering of diesel engines, especially the new fuel injection systems, and with more emphasis being placed on critical requirements that equipment have longer life cycles and near 100% uptime, fuel management can no longer be ignored. It is now just as important as changing the oil, ensuring the batteries are charged, and the air filter is clean.

Service Agreements with an outside contract company to perform Preventative Maintenance typically do not cover fuel-related management and monitoring unless specified. In-house maintenance personnel are usually pressed for time, and fuel management can be easily glossed over. Fuel has a limited shelf-life and even "fresh fuel" could contain water, sediment, microbes, asphaltene agglomeration, or other contaminate components upon delivery and cause immediate engine performance issues.

Emergency power installations are especially susceptible to unexpected interruptions due to fuel related issues. Periodic generator tests-runs are too short to determine if fuel quality is adequate for the demands of continuous, full-load operation. In fact, generator test runs have been found to significantly accelerate the fuel polymerization and degradation process, resulting in the accumulation of gums and resins in the fuel system, by returning fuel that has been compromised by heat and pressure back to the tank. Thirty minute tests, often performed every month, create the environment in the tank for problems to grow. After extended periods of testing, sometimes years, without having been subjected to an extended full load, operation is interrupted by clogged filters when the lights go out.

Now that you have decided to institute a Fuel Management Plan for your operations, there is work to do. Consider the following as the basis for your Fuel Management Program to further assure that your equipment will run when it is needed most at it’s peak level of performance and repair costs will remain under control:

  • Place in service an AXI Fuel Treatment & Tank Cleaning System appropriate to your operations that are capable of performing a complete tank cleaning and fuel conditioning on each fuel tank in service at least once per year (more often in regions of high humidity). Evaluate what other aspects of fuel monitoring and testing is needed to assure that critical equipment needs, including down-stream equipment, may need to be included in your Fuel Management Plan.

  • Use AXI Broad Spectrum Fuel Catalyst Ultra Concentrate AFC-705 or AFC-710 every six months to enhance the breakdown and removal of sludge, slime, gums, resin, and bio-film from tank walls and baffles that are difficult to access and normal fluid flow does not break loose. Having this unique fuel additive present when fueling downstream equipment also assures that these downstream tanks are being cleaned in the normal course of operations (although separate water removal will be necessary).

  • Periodically (every 30 to 60 days, depending on your climate) use a Fluid Sampler or a hand Fuel Sample Pump to take samples of your fuel from each storage tank and critical equipment fuel tanks for in-house testing for acidity (pH) and use Liqui-Cult Fuel Test Kits to perform testing for microbial contamination. If initial tests indicate fuel problems, utilize laboratory analysis to evaluate the condition of your fuel to assure your fuel supplier is providing fuel that meets the specification of the engine manufacturer you depend on to keep your equipment running.

  • If the quality of your fuel is suspect, consider establishing a quarantine tank to accept new shipments (do not add new shipments of fuel to your stored fuel that has been de-watered and to which you have performed fuel polishing, and is known to meet your Fuel Management protocols).

  • Use Kolor Kut Water Finding Paste at least every 30 to 60-days to monitor the accumulation of water in your storage and equipment fuel tanks due to condensation or from fuel fills. If any amount of water is detected, take steps to remove it.

  • Install Desiccant Breathers on all your fuel storage tanks to help prevent moisture from entering your tanks through the vent as fuel is consumed.

  • Use Water Eliminators in each storage and equipment fuel tank to capture water and remove it before it can cause problems with engine operations or seasonally prevent water from freezing in fuel lines?

With only moderate effort, you can be assured that your diesel fuel will provide optimal performance and enjoy the expected life of your engine’s fuel filters, fuel system components, and your substantial investment in the diesel engine.