So... just what is in our Tanks?

In 2011 River Canal Rescue the nationwide breakdown company for boats attended over 600 instances of fuel related breakdowns, with over 50% of these problems being related specifically to fuel contamination. In previous years contamination could be broken down to two main categories 1)water contamination and 2) diesel bug. However over the last 12 months the cases of unidentified fuel contamination issues has risen dramatically, and the knock on effect has resulted in fundamental components failing in the fuel system.


There is a clear correlation between the increase in diesel issues and the introduction of low sulphur diesel. The biggest down side of this diesel begin its absorption and attraction of water, which is resulting in higher cases of diesel bug and fuel emulsification. However Low sulphur diesel can also cause issues with rubber and components in the fuel system because is contains less lubricants, and eventually this lack of lubrication can result in faster degradation of these components, resulting in seizures, breakages and seal failures. Due to this range of problems most Insurance companies and parts suppliers will no longer cover claims or warrantees where fuel issues are suspected as the cause of the failure, and with an increase in these types of issues it is more important than ever to know... What is in your Tank?


River Canal Rescue has always advocate the use of treatments to combat water in the fuel and diesel bug, and for these problems these offer the best quick fix solutions, even though good maintenance and regular removal of water form you tank will give you the same protection.


However over the last 15 months RCR have seen a rise in contamination issues that are far from the norm, with visible issues causing the diesel to look anything from ‘hot chocolate’ to ‘orange’ to being completely clear, and creating a number of issues throughout the fuel system. 

Typical symptoms are non starting, erratic running, cutting out, but in addition RCR have found fuel pumps experiencing major failures. Injection pumps failures have increase dramatically as the new mixes and bio fuels result in failures of seals, pumps running ‘dry’ and internal rusting which have resulted in an increase of over 34% in these type of failures.


Working with a number of external independent testers and laboratory’s has highlighted the fact that this problem is not unique to the inland waterways. Every industry from ships, to aircraft, tractors to back up generators are experiencing similar issues.

Ian Roos of Fuel QC recently stated that ..... for some time now we have been working on a number of cases where fuel samples are taken from systems where there is frequent filter blocking issues but the samples present clear and bright with no visible contaminants. However on investigation the fuel is found to be filled with crystal.

Ian Roos of Fuel QC recently stated that .....

here is some debate as to the origin because we do not have a definitive test for it.

Companies are all capitalising on the key mistake a lot of people make in assuming the sludge they see, and the problems they have with fuel contamination is microbial. Statistically 95% of the cases we have been getting in the last two months is due to paraffin crystallisation in the fuel. 



Paraffin crystals form inside water droplets; growing bigger and thicker over time, it can appear as a white layer on the tank bottom or the crystals can remains in suspension in the mid-level of the tank, these crystals can be invisible but when they hit a filter they will compact and block up the system. 

There are a lot of explanations as to why new contaminates are being found suspended in fuel and the most likely explanation is that it is a side effect of other elements/contaminants being present, of which water is the most important. Given time to settle water does not normally remain suspended in fuel and therefore this behaviour is most likely caused by additives such as water emulsifiers, which lock the water in to the fuel. And it is these molecules that are the basis for the crystallisation to form.


RCR’s experiences are consistent with these findings, and they now suspect that more and more Paraffin or kerosene is appearing in ordinarily diesel. Additionally the use of different treatments and chemicals being added to fuel are creating a chemical concoction inside fuel tanks.


Over all although diesel bug is still affecting boaters regularly and water contamination is still a big problem, this new issue is as yet undefined and in addition there appears to be so many variations and strains that any coverall ‘treatment’ is unrealistic, no matter what any manufacturer tells you.

However there are things that boaters can do to limit there susceptibility to the current minefield of problems and solutions.

• Use reputable supplier
  
• Use same supplier if possible
  
• Remove water from tank on regular basis
  
• Choose a treatment that works for you and stick to it
  
• Take samples of fuel delivered. Check them before you accept the delivery.
  
• if buying cheap fuel – mix a sample with your current fuel to see if there is a reaction 
  

Diesel bug and bio fuel.

We've recently undertaken quiet a lot of research into the effects of diesel bug and bio fuels. The result has been published in Waterways World, as can be seen below.

Already three marinas have identified (independently) that there is an issue with the bio fuel and fuel set. All three report having several cases of emulsification following fuel set treatment where bio fuel had been added. The marinas have been given advice as to how to sort this problem out but it goes to prove that the problem exists.

Diesel Bug, Water Contamination and Bio Diesel

With the recent introduction of Bio Diesel the confusion surrounding what is best practise and how to deal with situations which are affecting more boaters has lead to RCR provide the following guidance.

Fuel Tank construction in boats

Fuel tanks in boats are usually constructed so that the outlet pipe for the fuel system is located approximately 1-2 inches above the bottom of the tank. The reason for this construction is two fold. 

1) Most tanks are metal and therefore over time fuel /water/ air results in corrosion and rust build up, this debris drops to the bottom of the tank and remains there.  

2) The water which is present due to condensation and water ingress in the fuel tank naturally separates out and drops to the bottom of the tank when left to stand. 

In both these cases the outlet pipe position ensures that neither water nor debris is passed though the fuel system providing protection from these types of issues.

The easiest method to identify how much fuel/water is in your tank is to use a clear plastic hose, drop this in to the tank being careful not to disturb the fuel , and when you feel the bottom place your thumb over the end to seal it and withdraw the hose. This should provide you with a sample of the tank and will show the amount of water present, along with an indication of any diesel bug contamination.

We recommend that you :-

1. Dip your tank regularly and where water is present remove it, this can be done simply and cheaply using an oil extractor or electric pump, by pushing the pipe down to the layer of water and extracting water until the diesel comes though. Alternatively visit one of the Marina’s who offer a fuel polishing service. 
2. Regularly check your filler cap seal and replace if worn, cracked or damaged. Also if it has been raining the cap sits lower than the deck so wipe over to remove excess water before opening the cap.
3. If you have a water trap filter, check and empty regularly, so that it is effective.
4. Either leave the tank empty during winterisation and remove any water on your return, or leave the tank full and treated.

The advice above will combat both diesel bug and Bio diesel issues and water contamination removing almost all risks without the need to treat the fuel.

Water in Diesel

All diesels contains some element of water. Water content in diesel makes the diesel murky or cloudy and can be the first indication of an issue.

However when diesel is standing this water separates naturally (around 800ppm 0.08%) and as it is heavier than diesel it eventually drops to the bottom tank. This is why many commercial storage tanks have taps at the bottom to drain off the water.  

Water in fuel is acceptable in small amounts and has been known to improve performance when in quantities of up to 1200ppm (0.12% volume), however there is a risk that too much water (greater than 1500ppm (0.15%) will result in the water lying un-burnt in the combustion chamber and affecting the operation of the pistons, valves, liners,  ect by destroying the lubrication properties of fuel

In addition, too much water in the fuel can cause issues even before this point, as the injectors pressurise the diesel to turn it in to a fine spray, if there is too much water present in diesel then emulsification occurs and the white creamy solution that results will stop you in your tracks.

What is Diesel Bug

Diesel bug is the term given to the enzymes, bacteria etc that live of the water in diesel and affect the diesel properties, and there are over 148 different types identified so far. The first signs of fuel degradation are a fine black dust that is regularly described as soot, a very strong smell of varnish coming from the fuel tank and the fuel turning darker.  

Visible sludge and other lesser known variations of diesel bug that can show as yellow/orange or pale debris floating in the diesel is an indicator of severe or high risk contamination and should be treated as soon as possible.  

Extreme cases see this develop in to a thick black sludge that quickly clogs up the fuel system and stops the engine operating.

Bio Diesel & Low Sulphur Fuels NEW EU Directive

The introduction of the new rules relating to supply of diesel for recreational boats has stipulated that from 2011 it is an offence to sell diesel that contains more than 10mg of sulphur per kilogram of diesel, this effectively makes the fuel virtually ‘sulphur free’.  

Diesel which is low in sulphur can cause issues with rubber and plastic components in the fuel system because is contains less lubricants, and eventually this lack of lubrication can result in faster degradation of these components, resulting in fuel pump and seal failures.

To accomplish the low sulphur content many suppliers have opted to incorporate Bio Diesel, (when biodiesel is blended, fatty acid methyl esters (FAME) are added to the mineral diesel) the recommended maximum is 7% although this will rise to 12% in 2012. The previous level was 5% and the new increase has resulted agricultural users seeing a fast rise in both diesel bug contamination and fuel blockage issues. This has been attributed to the fact that Bio diesel absorbs ‘free’ water, and this is what diesel bug requires to live on, but it can also result in emulsification of the diesel if too much water is absorbed.

Bio diesel only has a shelf life of approx 6months, put it in a marine environment and this half’s and if microbes like diesel bug are present it half’s again, potentially you may only get a few months shelf life!

*100% true bio fuel ie biodiesel produced strictly according to EN14214 standards does not tend to suffer the issues identified above and is a true green alternative which has many other benefits not seen with bio diesel mixtures.

Treatments

The treatments on the market at present have concentrated on two issues, removing water from the diesel and killing diesel bug. There are many different products on the market but these can be split into Biocides and Enzyme based products. Each tackles the issue in different ways. 

With any treatment; it is important to ensure that the product is mixed with the fuel evenly, and therefore treat before filling up, or alternatively give the tank a stir to ensure that the product is effective. If using enzymes it is important not to overdose as this can result in excessive water retention in the diesel.

Biocides

These are chemically produced products designed to deal with specific issues. They can be used as a one off to treat diesel contamination (diesel bug killer), or dosed to prevent contamination occurring. These include products like M16 Diesel Bug, Grotamar, Yachtcon, Kathon, In general they contain biocide to kill micro bacterial contamination and inhibit further growth of micro bacteria. In some products they include demulsifies to separate out the water from the diesel , and lock in the dead bug ‘bodies’ in the fuel so that they are burnt in the combustions cycle, effectively removing the ‘sludge’. 

Biocides are toxic and therefore should be treated with care and applied strictly according to the supplied instructions. When treating for fuel contamination then it is always advisable to change your filter and remove any water form the tank and water separator. However please ensure that the water is disposed of in accordance to the EU Biocide Directive.

There are many worries relating to bugs building an ‘immunity’ to these biocides, however in reality as all bugs are destroyed rather than treated, the analogy with antibiotics is not applicable.

Enzyme and Natural Emulsifier Products

These products are generally environmentally safe and are based on a combination of manmade enzymes and plant extracts, they tackle the issue by distributing and locking the water in to the fuel so that it can be burnt during the combustion cycle, by removing the water they remove the food for the diesel bug.  If dosed correctly then the maximum water absorption should be in the region of 900ppm (0.09%) for the natural emulsifier products, which is safe; however if overdose this can raise to 2500ppm resulting in diesel turning milky. These include products like FuelSet, Fortron, Soltron and Starbrite. The other group of enzyme based products use Kerosene as a carrier and while this restrict the ability to absorb water kerosene has a much higher wax content. Overdosing with these types of products can lead to change in fuels ability to combust quick enough and cause injector damage.

Some enzyme based products are temperature and UV sensitive and this can cause them deteriorated or stop working effectively if subject to extreme temperature variations and if they are not stored properly.  They are not suitable for treating severe diesel bug contamination and are only effective as a preventative maintenance solution. Overdosing is the biggest risk with these products.

Emulsification of Diesel 

Too much water in the diesel can cause emulsification, this is seen at the filters or more commonly at the injectors as the fuel is put under pressure. Emulsification of diesel at the injectors due to water content has only recently become an issue and RCR in the past 2 months have attended nine boats where 20-40ltrs of bio diesel has been added to the fuel tank, in some cases these vessels have been using regular treatments of enzyme based products.  Initially we were unable to resolve and the first three boats had to have the whole system cleaned and flushed, although in one case the diesel destroyed the seals in the fuel polisher, and resulted in over 200ltrs of fuel being lost!  

To combat this issue we have had to develop a new strategy and after a number of test cases we now use biocide treatments to separate out the water from the diesel whilst in the tank, although because of the complex nature of the mixture this can take up to 48hrs to accomplish. Following this the fuel system is cleaned right though to the return pipes, and the water drained off from the fuel tank to remove the risk of the water being absorbed in the future.

So what treatment should you use:

RCR attends hundreds of contamination issues each year and therefore we have had to ensure that the product we use provides instant results and stops these problems from reoccurring, and for this reason we favour the Biocide treatments.  Enzyme based products are effective and useful when there is only a small amount of water content but too much and you run the risk of not removing it  or overdosing and locking to much water in to the diesel. 

Another reason for favouring the biocide treatment is with the new introduction of Bio diesel and rise in cases of emulsification at the injectors, we believe enzyme products can compound the problem of water absorption.  

RCR use Marine 16 products and recommend the use of Diesel Fuel complete as a regular treatment.  However the most important message to get across is to regularly check your tank for water and if found remove it, doing this will reduce the risk of water contamination and diesel bug irrelevant of which product you choose to use.

Written by 

Stephanie Horton BEng Hons CEng MIET 

 MD of River Canal Rescue

Acknowledgment:- David White of M16, Ian Roos of FuelQC, and background support from David Fletcher NABO chairman, EU Directive, Tony Brooks training notes

Bio Diesel, the real worries – in plain terms.

In the past few years as the new directive regarding the use of red diesel has been in place, the forums and discussion have brought to light many new worries about the fuel we consume and the way we store and use it. One of the biggest issue appears to be the higher potential for water contamination and therefore the development of diesel bug.

Many of you will have suffered from water contamination or diesel bug in its mild or sever form, or at least know of someone that has, it may be that the general perception is that these cases have increased in the past few years, and it is easy to jump to conclusions and conclude that our fuel is becoming more susceptible to these problems.

RCR has been aware and treated water contamination and diesel bug for many years, and worked with Marine 16 to develop a product which would eradicate these problems at source.  We are a great advocate of the products as we know they work providing quick and effective treatment of water contamination and diesel bug blockages.

Marine 16 Diesel Bug Treatment is for sever cases of Diesel Bug, and will clear systems where fuel has turned to jellified slime, clogging the arteries of the engine, all ‘bugs’ are eradicated and dissolved. This product was independently tested by PBO a few years ago and was proven to be one of the best on the market. 

Marine 16 Fuel Maintenance Treatment  is the product that RCR uses and recommends for repeated dosing to ensure trouble free fuel issues. It treats  Diesel bug, water contamination and also cleans and improves engine efficiency and operation.

Facts

Although a mute fact now, the original discussions regarding the use of white/ red diesel raised a number of issues, the main being that white diesel is more refined and therefore less likely to suffer from the effects of water in fuel, diesel bug, and also runs cleaner therefore reducing coke build up and fouling of heater plugs etc.  Therefore there was an argument that even though paying more for the fuel the quality would be better and therefore the benefits could out way the costs.

However the final decision was taken and boater have been paying a higher premium to receive lower grade fuel to date. However this is all set to change with the new fuel directive, which due to the over riding requirement to have less than 10mg of sulphur per kilogram we will now see the introduction of road diesel to the inland waterways, which should have been a welcome transition.

 Unfortunately as Bio diesel is now being introduced in to road fuel the introduction on the inland waterways because of the storage and use has lead to a number of concerns.  These concerns have been addressed in the new Fuel directive, whish states that, following a survey only 25% of all suppliers will be using bio Diesel mixes, and therefore the perceived risk is minimal. 

The issue regarding how easily it will be to ensure that the diesel supplied is from a non Bio mix will remain and coupled with the 2p to 4p litre price premium could easily be over ridden by price conscious business and individuals. 

N&G Insurers have recommended that cover for failures caused by Bio diesel deteriorating rubber components may be difficult to prove and uphold as not due to wear and tear and therefore ultimately the following advice issued by the directive should be followed to ensure minimal damage.

If a FAME(bio diesel)-free supply cannot be secured then the following precautions are advised: 

Storage on land and onboard

Because of the changes in fuel quality, you will need to exercise increased care in the storage of sulphur free gas oil where this contains biodiesel. The following has been recommended by the UK petroleum industry: 

• Remove all water from tanks and conduct monthly checks to ensure, as far as practical, that they remain free of water. 
• Tanks that don’t already have drain points for removing water are likely to need modification. 
• Examine sight gauges on older fuel storage tanks for signs of leakage and replace any leaking seals. 
• If you are having tanks serviced before you receive the new fuel it would be advisable to replace fuel seals as a one-off precautionary exercise. 
• Replace fuel filters after 2 to 3 deliveries/turnover of the new fuel. 
• Ensure the content of tanks is turned over every 6 months or in any event no less often than every 12 months. 

Equipment 

The majority of equipment and engines supplied in the last 10 years should not have any problems with the fuel but a few precautions are recommended particularly for installations of older engines and equipment. 

• Examine fuel systems following the switch to the new fuel and ensure that any seals or pipes found to be leaking are replaced. 
• If you are having older engines and equipment serviced, replace fuel seals and fuel hoses as a precaution. 
• Replace fuel filters after the first 2 to 3 tank fulls of the new fuel. 
• The current specification for fuel hose to meet the requirements of the Recreational Craft Directive and certified against standard EN ISO 7840 for fire resistant hoses and EN ISO 8469 for non-fire resistant hoses. There is currently concern that these hose specifications have not been approved for use with bio-fuel and this should be checked with the hose supplier. 
• Bio fuel is a very good solvent and may release accumulated sediments in fuel tanks. Although it may not be necessary to clean fuel tanks and fuel lines before using bio-fuel in the lower levels of 7% it would be good practice to monitor filter plugging and keep extra filters to hand. 
• Some metals as well as rubbers and plastics are not recommended for use with bio-fuel particularly at high concentrations. Although not normally a problem at low level concentrations it is know that bio-fuel will ‘pick up’ metal such as copper. 

It is clear that some of this advice is impractical and will be costly and time consuming to the average boater and therefore is unlikely to be implemented by most, so it is likely that at some point we will all experience some of the issues highlighted. 

However Marine 16 have now launched there new improved version of their Fuel Treatment  product; Diesel Fuel Complete Treatment. This new product has been tested extensively and conclusively shows:- 

• Improved cold starting.
• Reduced white smoke on start-up.
• Reduced engine noise.
• Lowered regulated emissions, such as particulates, hydrocarbons and carbon monoxide.
• improves engine lubrications, 
• cleans and, removes carbon deposits, 
• treats and prevents water contamination and diesel bug

Diesel Fuel Complete Treatment  not only treat more fuel 500ml per 500ltrs of fuel , providing you with the same benefits as its predecessor but will also includes additives to deal with some of the issues Bio diesel introduces.  Using the treatment on a regular basis will ensure that water contamination, build up of Diesel bug and deterioration of rubber seals is minimised and therefore offers boaters a practical solution to the new threat of Bio Diesel.