(You may also use these links to enter the Shopping Cart to place an order or to determine shipping cost)
MTC-500 -- 8 GPM Cart Mounted Fuel Polishing - 110V-60Hz or 230V-50Hz
Your Price: $7102.00
MTC-1000-LX -- 16 GPM Cart Mounted Fuel Polishing - 110V-60Hz or 220V-50Hz
Your Price: $8501.00
MTC-3000 -- 25 GPM Cart Mounted Fuel Polishing - 110V-60Hz or 230V-50Hz
Your Price: $10976.00
(You may also use these links to enter the Shopping Cart to place an order or to determine shipping cost)
DM 10 Digital Flow Meter (1/2" Ports, Total & Flow Rate) 1-10 GPM
Your Price: $823.00
DM 30 Digital Flow Meter (1" Ports, Total Only) 3-30 GPM
Your Price: $309.00
MTC-H20 Water Sensor and Alarm
Your Price: $271.00
MTC ASB - Spill Prevention Berm
Your Price: $465.00
MTC MG-01 Motor Guard For MTC Pump
Your Price: $154.00
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AFC-705 Diesel Fuel Catalyst -- 8-oz. Bottle
Your Price: $32.00
AFC-705 Diesel Fuel Catalyst -- 1-Gallon
Your Price: $209.00
AFC-710 Diesel Fuel Catalyst -- 8-oz. Bottle
Your Price: $31.00
AFC-710 Diesel Fuel Catalyst -- 1-Gallon
Your Price: $204.00
TS4-SS Tank Fluid Sampler, Stainless Steel - 4 oz.
Your Price: $383.00
TS8-SS Tank Fluid Sampler, Stainless Steel - 8 oz.
Your Price: $432.00
TS16-SS Tank Fluid Sampler, Stainless Steel - 16 oz.
Your Price: $508.00
FT-100 Liqui-Cult Fuel Test Kit - Box of 10 bottles
Your Price: $142.50
Replacement Filters Elements
WB-3 - Fine Filter plus Water Block Spin-On Filter - 3 micron
Your Price: $49.00
WB-10 - Fine Filter plus Water Block Spin-On Filter - 10 Micron
Your Price: $46.00
FF-1 - Fine Filter Spin-On Filter (Bio Diesel Compatible) - 1 Micron
Your Price: $80.00
FF-3 - Fine Filter Spin-On Filter - 3 micron
Your Price: $41.00
FFZ-3 - Fine Filter Spin-On "X-Glass" - 3-Micron Absolute
Your Price: $49.00
FF-10 - Fine Filter Spin-On Filter - 10 micron
Your Price: $32.00
FF-25 - Fine Filter Spin-On Filter - 25 micron
Your Price: $32.00
FW-10 - Filter Pliers for Changing Spin-on Filters
Your Price: $55.00
FF-BP - By-pass Spin-on Filter - Void Canister with No Media
Your Price: $22.00
SH 1.0 - 1" Clear Vacuum (Suction) Hose - $/FT
Your Price: $12.00
SH 1.5 - 1 1/2" Clear Vacuum (Suction) Hose - $/FT
Your Price: $19.00
SH 2.0 - 2" Clear Vacuum (Suction) Hose - $/FT
Your Price: $30.00
SH 3.0 - 3" Clear Vacuum (Suction) Hose - $/FT
Your Price: $61.00
DH 0.375 - 3/8" Flexible Pressure (Discharge) Hose - $/FT
Your Price: $4.00
DH 0.75 - 3/4" Flexible Pressure (Discharge) Hose - 25 ft.
Your Price: $14.00
DH 1.0 - 1" Flexible Pressure (Discharge) Hose - 25 ft.
Your Price: $18.00
DH 1.25 - 1 1/4" Flexible Pressure (Discharge) Hose - $/FT
Your Price: $26.00
DH 2.0 - 2" Flexible Pressure (Discharge) Hose - $/FT
Your Price: $31.00
DH 2.5 - 2 1/2" Flexible Pressure (Discharge) Hose - $/FT
Your Price: $37.00
AXI (formerly ALGAE-X®) Mobil Tank Cleaning Systems are designed to efficiently and safely clean and restore fuel to a pristine condition. Vital to the fuel polishing process, these systems incorporate a multi-stage filtration process that reconditions, stabilizes and decontaminates diesel fuel, bio-fuels, light oils, and hydraulic fluids. All MTC systems are specifically designed for tanks with contaminated fuel that require the removal of water, sediment, and sludge accumulation.
AXI’s Mobile Fuel Polishing Systems are built with industrial quality components, mounted on both a heavy duty aluminum cart (MTC Series) and/or carbon steel skid (MTC-HC Series) with capacities up to 150 GPM. All MTC and MTC HC systems feature multi-stage water removal, particulate filtration, fuel conditioning, a compact industrial design locking cam and groove connections, built-in spill containment tray, and bypass loop capability. MTC HC systems also offer multiple sampling ports, large contamination holding capacity, robust compact industrial design, liquid-filled vacuum and pressure gauges, AXI Watect water sensor, and PLC filtration system controller.
The fuel polishing process conditions and stabilizes diesel and bio-fuels, eliminates microbial contamination, and ensures fuel remains clean and dry. These MTC systems are designed to offer the maximum in flexibility and mobility, and, as a critical part of a Fuel Management Program, will 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 MTC System (optional on the MTC-X), 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 MTC Systems feature:
Multi-stage Water Removal, Particulate Filtration, and Fuel Conditioning
Compact Industrial Design
Locking Cam and Groove Connections
Built In Spill Containment Tray
Primary and Secondary Filtration with By-pass Loop Capability
Self-Priming Rotary Vane Pumps with Integrated Adjustable Bypass Valve
An MTC Series Fuel Polishing System is the central component of a Fuel Management Plan that involves the maintenance of numerous fuel tank or providing fuel polishing services to your customers over a wide region. 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.
The Mobile Tank Cleaning (MTC) Series Fuel Conditioning and Tank Cleaning Systems are cart mounted mobile Fuel Polishing Systems that are available in three configurations: the MTC 500, an 8 gallon per minute unit, the MTC 1000-LX, a 15 gallon per minute unit, and the MTC 3000, a 26 gallon per minute unit. These Fuel Polishing Systems recondition, stabilize and decontaminate Diesel Fuel, Bio-Diesel and light Hydraulic Fluids. They efficiently removes sludge, water and sediments that naturally accumulate in tanks. The MTC system excels in low operating cost and compact design, and cleans tanks and restores fuels and oils to their "Clear & Bright" condition. They eliminates fuel "algae" issues, clogged filters, excessive exhaust smoke, and tank sludge, providing Optimal Fuel Quality for Peak Engine Performance and Reliability.
Generally the fuel conditioning and tank cleaning process involves circulating the contents of a fuel tank of fuel three times. If the goal is to complete a tank cleaning job within one eight hour shift, not including preparation and cleanup time, the MTC 500 can accomplish this on tanks up to 1,280 gallons (4,800 liters), the MTC 1000 LX can on tanks up to 2,400 gallons (9,000 liters), and the MTC 3000 can on tanks up to 4,200 gallons (16,000 liters). The MTC Systems are our mid-range systems from a flow capacity standpoint, and all three are available in 110V 60Hz 15A or 230V 50Hz 15A AC power.
The AXI Mobile Tank Cleaning Systems are ideal for any individual or enterprise that has multiple tanks that require periodic cleaning to assure that fuel being consumed by equipment is in optimal condition. This could be a construction, trucking, fuel supply or filling station, or agricultural operation, mining or quarry operation, railroad, or a municipality with fire, police, EMS, water or sewer treatment plants, and waste disposal facilities that all require periodic service. It is also ideal for an independent maintenance service provider, such as maintaining marine vessels, backup or emergency power generators for offices, plants, data centers, or similar enterprises, cell tower generators, or other enterprises where the service provider can offer fuel and tank service assuring that fuel in storage is kept in optimal condition and fuel tanks are clean and free of water and other contamination.
Mobile Tank Cleaning Systems are classified by the system’s capability to treat a single tank in eight hours. It is recommended that you treat each tank when it is full (why clean only the bottom half of the tank?), and the entire contents of the fuel storage tank should be circulated three times to achieve the diesel fuel cleanliness rating recommended by engine manufacturers. (Note: the first time a tank that has been in use for more than five years is cleaned, you should circulate the contents five times, and then three times each cleaning thereafter as determined by your Fuel Management Plan (see below), part of a preventative maintenance program).
Based on the range of tank sizes that you will likely be treating, choosing the right Mobile Tank Cleaning System for your application is a function of the amount of time (man-hours) you can dedicate to each tank cleaning. Ensuring low ongoing costs is critical, as is efficient use of personnel. As an example, let’s assume you have numerous tanks in the 500 to 1,000 gallon range, and two or three that are 2,000 gallons. An MTC-500, operating at 8 gallons per minute (480 gallons per hour) can perform a complete treatment of 3,000 gallons (a 1,000 gallon tank circulated three times) in 6.25 hours. This allows 1.75 hours of an 8 hour workday for mobilizing to the tank, setup, treatment, packing up the equipment and transit back to the base location. The several 2,000 gallon tank treatments will require a two day treatment involving 12.5 hours of operation (6,000 gallons / 480 gallons per hour). This may be acceptable, but if you have more larger tanks, than a system capable of higher rates of treatment is likely more cost effective over time.
Smaller storage tanks tend to have smaller access ports, precluding the use of higher flow Mobile Tank Cleaning Systems that utilize larger diameter hoses for suction and return lines. As an example, if you will be cleaning tanks that have a three inch filler cap as the only access, the maximum outside hose diameter would be one and one-half inches (1 1/2 inch) for each hose. Check tanks for anti-siphon devices as these may prevent access for tank cleaning purposes. If you have only a few small tanks, but otherwise require a high flow system, consider tank modifications that provide a larger access point.
AXI MTC Systems are built with industrial quality components mounted on a heavy-duty aluminum frame and mounted on an aluminum two-wheel cart. These MTCs feature brass plumbing and quick disconnect fittings. A clear suction hose show fuel flow and clarity. The large drip tray is designed to prevent spillage. Fuel can be polished without using any consumables by connecting the discharge hose to the quick disconnect, bypassing the filter. A pressure gauge is installed on the spin-on filter head to ensure optimal filter usage. All MTC models also come with a liquid-filled stainless-steel vacuum gauge.
The MTC System processes fuel or oil by pumping it from the tank through the intake hose to the intake port, through the Primary Centrifugal Fuel-Water Separator and Purifier, the AXI Magnetic Fuel Conditioner. The fuel flow may be directed back to the tank in the Second Phase of the fuel conditioning and tank cleaning process, or directed to flow through the secondary spin on filter for further decontamination of particulates or emulsified water. The entire process of cleaning the fuel tank and conditioning the fuel is explained in more detail further below on this page at "General Tank Cleaning Procedures".
The principal components are a continuous-duty self priming rotary vane pump, a FP Series Fuel/Water Separator and Purifier, the AXI Fuel Conditioner, and a Secondary Spin-on Filter equipped with a Pressure Gauge for monitoring filter element changes, utilizing either various fine particulate removal or water block filter elements, and an AXI Fuel Conditioner.
The fuel flow first enters the AXI Fuel Conditioner after exiting the Primary Filter. 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.
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.
The MTC 500 System utilizes an AXI FP-15 Water Separator-Purifier, and the MTC 1000-LX and 3000 Systems utilize the AXI FP-40 Water Separator-Purifier. The FP Series Fuel/Water Separator and Purifier utilizes the principle of centrifugal force to split water, fuel sludge, and particles of dirt from fuels, and separate them so that the waste can be isolated and drained out without the use of filter elements that must be purchased, inventoried and consumed. The heavier fluid (water), sludge and particulates are heavier than diesel fuel (water, sludge and particulates have a specific gravity greater than diesel fuel). When spun around inside the cylinder, guided by baffles inside the cylinder, these materials are forced to the outside wall of the cylinder and then drops down along the outside wall of the cylinder to collect at the bottom of the cylinder for removal by opening a valve and depositing these contaminants into a container for proper disposal.
An optional water sensor and alert module may be added to the FP Water Separator-Purifier that utilizes a 9 volt powered audible and visual alarm to advise when the FP Series unit requires draining.
In each of the MTC 500, 1000-LX, and the 3000 Systems, the Secondary Filter is a spin-on filter for fine filtration down to 1 micron or for a Water Block coalescing filter down to 3 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 MTC Systems. 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 MTC Systems".
The 3 micron Water Block filter is usually the preferred filter for ongoing preventative maintenance. 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. It is better to have the engine manufacturer’s filter be the last line of defense against contamination in stead of it being the only defense.
The AXI Pre-Filter System, and optional add-on to any MTC 500, 1000 LX, or 3000 Cart Mounted System, is a large-capacity, heavy duty pre-filter bag filter system that will remove major sludge, debris and water from the fuel by trapping extraordinary amounts of sludge, rust, scale, and other contaminants upstream before they access the MTC Mobile Tank Cleaning unit. Utilizing an AXI Pre-Filter provides a substantial reduction in the cost of consumables during a tank cleaning operation because pre-filter bags are inexpensive compared to fine filtration elements that are typically used in the later phases of the tank cleaning process and they can often be emptied and re-used during the early phase when more sludge is being encountered. Including the Pre-Filter System when cleaning particularly contaminated tanks, especially when a tank cleaning service tends to perform cleaning on a volume of tanks that have never been cleaned previously, also adds an additional level of protection for the pump, removing more debris and contaminants that could eventually cause wear on the vanes of the pump.
Utilizing the pre-filter on tanks that have never been cleaned shortens the dialysis process as the pre-filter will also remove water, providing two water removal devices and allowing the Primary Filtration centrifuge on the MTC system to pick up only that water that may get past the Pre-Filter unit.
The PF-10, available individually or mounted on a heavy duty 2-wheel cart, is recommended for the MTC 500 and MTC 1000 LX Systems, and the PF-30, also available individually or mounted on a heavy duty 2-wheel cart, is recommended for the MTC-3000 System. A hose-kit to connect the pre-filter to the MTC System is included with the Pre-Filter option, consisting of a six foot reinforced clear hose, including cam and groove fittings for making the connection. Also included are ball valves for both the suction and discharge side of the Pre-Filter, vacuum gauge for determining when the filter bag requires operator attention, and drain valve for removing water and other debris from the bottom of the pre-filter.
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.
The MTC has two different operating modes (Bypass Mode and Fine Filtration Mode), providing the operator flexibility and time efficiency.
In Bypass Mode, bulk water and sludge are removed from the tank into a separate container for disposal. The fuel bypasses the fine filters, removing free water, sludge, and particulate, as small as 1 micron, from the tank. During this step, the system is not in a re-circulating mode. The fuel enters through the Inlet Port and exits through Discharge Port 1 into a separate waste container. Water and sludge are directly removed from the tank and collected in an appropriate container for disposal. Next step, while still in bypass mode, put the hose that was in a separate container back into the main ank to create a kidney loop. This process will further save and extend the life of the spin-on filters, and remove the worst of contaminants, before polishing with fine filters to meet the required cleanliness.
In Fine Filtration Mode, the MTC system is continuously restoring, reconditioning, and returning the fuel back to the tank. Fine Filtration mode will continuously remove free water and particles as small as 1 micron, utilizing high efficiency spin-on filters.
We always recommend keeping a “before” and “after” bottom tank sample for "show & tell" purposes to demonstrate the improvement of fuel color, clarity, and opacity.
Hoses: The intake/suction hose is a clear, see-through reinforced vacuum hose. The return hose is black or blue/black, non-marking, high quality, discharge fuel hose. Both hoses are equipped with quick disconnects or Cam & Groove couplings.
Note: Never restrict the flow on the suction side of an MTC; e.g. by using a smaller ID hose or pipe or attaching the suction hose to a fitting on the tank that has a smaller ID than the hose. This will lead to excessive pump load, noise and ultimately damage the pump.
AXI recommends 3 phases to successfully polish a fuel tank. This will ensure all water is removed from the fuel, particulate is removed, and the fuel is in an optimal condition. The goal of Phase One is to remove any free water and sludge on the bottom of the tank without mixing the water into an emulsified state within the fuel.Start the pump motor and be ready to immediately stop it. The vane pump will start pumping as long as the system is primed and the suction lift is not excessive. The flow of fuel can be observed in the see-through suction hose. Watch for a steady flow of fuel into the container.
After removing the bulk of the sludge and water from the tank into a separate container for disposal and draining the separator, the return hose is now inserted into the tank. The goal of Phase Two is to remove any additional free water within the tank and also remove any large contaminants and sludge. This phase will clean the fuel and should be a precursor to using the more expensive spin-on filters. It should be noted that meeting required cleanliness codes is typically not possible with pre-filtering alone. Phase Two is used to extend the life of the spin-on filters, and remove the worst of the contaminants, before polishing with fine filters to meet the required cleanliness.
Depending on the amount of contaminant in the tank, we recommend you stop the pump shortly after priming and check for free water and sludge by draining the water separator. It may be necessary to depress the air purge valve on top of the separator after opening the drain valve.
Repeating this process and observing the fuel flow will indicate how long the pump should run before it is necessary to drain the separator.
Phase Three is the most important phase in meeting specific cleanliness codes. Unlike the pre-filter, the spin-on filters typically use absolute rated media. Absolute filters have a very high efficiency and will ensure that fuel leaving the system is clean to specification and has a low water content. Like previously mentioned, pre-filtering should be performed to remove any large particulate, water, and sludge. Pre-filtering will extend the life of the spin-on filters.
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.
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.
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.
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 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.
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.
Use a Portable Particle Counter to test each incoming load of fuel to assure that the cleanliness of fuel provided by your supplier meets the specifications established by the manufacturers of the engines that power your equipment. Your engine warranty depends on it!
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.