All around the world, steps are being taken to improve the quality of our environment. Prominent among these are the definition, implementation, and attainment of increasingly stringent emissions regulations for all types of engines, including off-highway diesels. These rigorous regulations have driven use of technologies like after-treatment, advanced air systems, and advanced fuel systems. Fuel dispensed off-highway is routinely and significantly dirtier than fuel from on-highway outlets. Furthermore, fuels used in developing countries can be up to 30 times dirtier than the average fuels in North America. Poor fuel cleanliness, coupled with the higher pressures and performance demands of modern fuel systems, create life challenges greater than encountered with cleaner fuels. This can result in costly disruption of operations, loss of productivity, and customer dissatisfaction in the off-highway market. This paper outlines and summarizes the mechanisms creating hard particle-induced wear, the durability challenges for high performance fuel systems operating in dirty fuels, and the specification, design, development, and implementation of an enhanced filtration solution to enable modern fuel systems to function and survive with poor fuel cleanliness. Figure 1 fuel cleanliness challenges [1, 4]

Shafer, Scott

Improvement of the Robustness of the Common Rail System for the Fuel Diversification

2015-01-19679/1/2015

With the diesel emissions and fuel consumption regulations and laws being tightened up, Common Rail System (CRS), capable of accurate and high-pressure diesel fuel injection, has become very popular in the world, and this CRS market is expected to continue to grow in the future. As use of the CRS becomes widespread, CRS is supposed to be used in a wide variety of environment, e.g. bad fuel (for example, much dust [1] and/or water), which increases concerns of CRS reliability. In an attempt to cope with such bad fuel properties, CRS and Fuel collected from the market was investigated. And based on this result, a new test method was worked out to simulate fuel stresses in the market. This test method verified the improved design of CRS with enhanced fuel robustness. This paper describes the new test method and the fuel robustness-enhancing effect of CRS based on the test method.

Niwa, Takahito, Eguchi, Takashi, Yamada, Koichi, Bunne, Satoshi, Omori, Toshihiko, Kato, Takafumi

Fuel Spray Tip Penetration Model for Double Injection Strategy

2015-01-09344/14/2015

In this paper, a semi-empiric fuel spray tip penetration model is proposed. It is applied to single and double injection strategies taking into account the early and far field penetration. The model is based on the momentum flux as initially proposed by [1] for single injection but it is derived from mean mass flow rate herein. Fuel spray interaction with entrainment air is taken into account for the second injection. The proposed model is calibrated and validated using data from 9 experiments conducted with an indirect piezoelectric diesel injector under various injection strategies. The experiments included 1) injection rate measurements using the Bosch method to determine mean mass flow rate during injector opening as well as obtaining injection duration which are both entry parameters to the model; 2) Fuel spray tip penetrations were measured in a pressure vessel using high speed photography for single and double injection strategies. The experimental results were used to calibrate the model's constants and to verify the model's ability to predict spray behavior. Finally, the experimental results for some fuel injection strategies have shown that there is an interaction between the first and second spray and the paper shortly discusses these cases.

Tetrault, Pascal, Plamondon, Etienne, Breuze, Matthieu, Hespel, Camille, Mounaïm-Rousselle, Christine, Seers, Patrice

Diesel Fuel Oxidation Study: A Comparative Study, Part II

2014-01-271710/13/2014

For decades, ENISO12205 test has been used to evaluate the long term storage stability of diesel fuels. Nowadays, new biocomponents especially FAME has increased the need to create faster and more appropriate test method to measure the long term storage stability. Developments in engine technology have also raised the need to create a new method to evaluate the thermal stability of diesel fuels. These new methods should have correlation to field experience. As an example it has been shown that Rancimat (EN15751) and PetroOXY EN16091 have a correlation when fuel contains more than 2% FAME. Rancimat is not applicable for FAME free fuels, so correlation based PetroOXY limit should be limited to fuels containing more than 2 vol% FAME. Study on oxidation stability test methods and their correlation to real life were continued and deepened (part 1: SAE 2013-01-2678). ENISO12205 and PetroOXY EN16091 test methods did not have a correlation according to the earlier studies. Also the tested fuels did not show any signs of oxidation or deterioration during the engine tests, where they were exposed to high temperature and pressure. For further studies, a range of different type of fuels was prepared to see how they differentiate in the stability test conditions. PetroOXY method was applied after the ENISO12205 test in order to evaluate if there is any stability reserve left in the fuels after being exposed to test temperature. Additionally, filterability characteristics of the fuels were studied after ENISO12205 test by using filter blocking tendency test (FBT, IP387). Fuel aging in PSA DW10 engine was studied by taking a sample from the fuel return flow before it entered back to the fuel tank. The fuel had been exposed to high pressure and temperature shortly without passing through a fuel filter after the exposure.

Kuronen, Markku Aaro, Hartikka, Tuukka, Kiiski, Ulla

Biodiesel Feedstock and Contaminant Contributions to Diesel Fuel Filter Blocking

2014-01-272310/13/2014

In recent years, the number of complaints and the severity of premature diesel fuel filter plugging have increased dramatically in the U.S. and Europe. These instances are often accompanied by longer start up times, poor drivability, and increased maintenance across different fuel filter applications. The rise in these instances of filter plugging is closely associated with the increasing prevalence of high pressure common rail (HPCR) fuel systems and the growing usage of biodiesel. Smaller pore size restrictions for fuel filters due to tighter clearances in HPCR injectors, coupled with contaminants from biodiesel and carboxylate salts in fuel, have been identified as accelerants of diesel fuel filter plugging. Testing protocols will be reported that can be used to screen contaminant-doped B10 fuels (10% FAME biodiesel in ULSD) to determine their propensity to plug fuel filters. Fuels were evaluated using bench-top filtration testing equipment to determine their filter blocking tendency (FBT) values. Three biodiesel related contaminants were investigated: saturated monoglycerides, sterol glucosides, and carboxylate salts. Test results will show that the specific feedstock of biodiesel - from used cooking oil to coconut oil - can alter the filterability of biodiesel-containing fuels. The same contaminant level may or may not cause filter blocking depending on the biodiesel feedstock. Additionally, the treatment of contaminant-doped fuels with commercially available deposit control additives (DCAs) will be shown to prevent or mitigate diesel fuel filter blocking. Important parameters for test fuel preparation will also be highlighted that could prove useful for internal diesel injector deposit (IDID) engine test development.

Fersner, Alexandra S., Galante-Fox, Julie M.

Monoglyceride Content in Marine Diesel Fuel-A Guide

2014-01-277510/13/2014

Problems with the low-temperature operability performance of biodiesel in blends with petroleum diesel are infrequent, but continue to limit the use of biodiesel during winter months. A troubling aspect of this problem is that in some cases precipitates above the blend Cloud Point (CP) have been detected and have led to plugging of fuel filters and subsequent engine stalling, as well as plugging of fuel dispenser filters. Many researchers found that the saturated monoglyceride content was a main component of the material that was found on plugged fuel filters, as well as traces of Saturated DiGlycerides (SDG), were also present on the plugged fuel filters. This is the reason which forced the organization of standardization to suggest a procedure in order to predict the content of the Saturated MonoGlycerides (SMG) even with uncertainty which can vary from −50% to +50%. The model which was used will be the same as that which was introduced in the Annex C of EN 14214+A1:2013. The model is based on the assumption that saturated fatty esters, saturated fatty acids and saturated monoglycerides are present in the same concentration levels in the FAME. The present work will give a guide with the prediction of the saturate monoglyceride in the distilled marine diesel fuel according to ISO 8217 depending on the operating climate requirements. The target is to provide a guide to understand the difference between the various climate conditions with respect to marine diesels potential cold flow performance.

Kalligeros, Stamatios Spyridon, Zannikos, Fanourios, Lois, Evripidis, Anastopoulos, George

Diesel Fuel Filter Designs for Cold Weather

2014-01-271110/13/2014

Cold weather is a challenge for compression ignition engines. As Diesel fuel creates wax crystals when temperature goes down enough, it comes to plug the fuel filter and the fuel injection system, leading to undesirable effects like loss of power, engine stall after start or even the engine not starting at all. Moreover, it has been shown that FAME Biodiesel has additional negative impacts on vehicle cold flow operability. Despite fuel additives which can support cold conditions, the whole fuel injection system has to be designed to support engine operability in variable environments, meaning also in very cold conditions, with variable fuel qualities. The Diesel Fuel Filter is a key element of the fuel injection system, as it could become to get plugged by wax and deposit formed at cold temperatures. This can generate fuel shortage on the common rail and high pressure fuel injectors. Addressing this filter plugging effect, can be crucial for vehicle operability. In order to understand and quantify the cold fuel flow impact on the Diesel fuel filter, a design of experiment has been set-up and achieved. Various fuels, filter geometries and filter media have been evaluated all together in order to identify the key parameters which impact the cold flow properties. Thanks to that, some design guidelines have been defined. This should permit to adapt filter designs, in accordance with environment constraints, in order to propose the best vehicle operability, even in very cold conditions using worst cold sensitivity Biodiesels.

Arnault, Nicolas, Monsallier, Guy

Influence of Filtering Area and Flow Rate in Fuel Filter Dimensioning

2014-36-02759/30/2014

Research shows that Brazil is among countries of Latin America, Africa and Asia which are considered as bad fuel market [1]. Fuel with poor quality reduces considerably the lifetime of fuel filter installed in vehicles. For this reason, the correct dimensioning of this component is extremely important. In order to improve this development, it is necessary to enlarge the knowledge of the fuel filter. This paper correlates the fuel filter bench test with field results improving the feasibility to use the laboratory data to estimate the fuel filter area and consequently the product lifetime.

da Silva, Danilo Fanton Ribeiro, dos Santos Tavares, Paulo Gabriel, Rossetti, Thiago Aparecido Rehder

Sodium Contamination of Diesel Fuel, its Interaction with Fuel Additives and the Resultant Effects on Filter Plugging and Injector Fouling

2013-01-268710/14/2013

Diesel fuel distilled from crude oil should contain no greater than trace amounts of sodium. However, fuel specifications do not include sodium; there is a limit of five parts per million for the amount of sodium plus potassium in fatty acid methyl esters (FAME) used as biodiesel. Sodium compounds are often used as the catalyst for the esterification process for producing FAME and sodium hydroxide is now commonly used in the refining process to produce ultra-low sulphur diesel (ULSD) fuel from crude oil. Good housekeeping should ensure that sodium is not present in the finished fuel. A finished fuel should not only be free of sodium but should also contain a diesel fuel additive package to ensures the fuel meets the quality standards introduced to provide reliable operation, along with the longevity of the fuel supply infrastructure and the diesel engines that ultimately burn this fuel. There has recently been an upsurge in reported field problems due to fouling of the fuel injection system in modern diesel engines. This can take the form of deposits in the fuel filters or within the fuel injectors themselves. Recent work proposed a mechanism whereby sodium contaminated fuel can undergo adverse reactions between the sodium compounds and fuel additives leading to the formation of material that can impede the operation of diesel fuel injectors. This paper presents new work carried out to enhance the understanding of this mechanism and demonstrates that the fate of any sodium contaminant is highly dependent on (i) the fuel additives present in the fuel (ii) the amount of water in the system, (iii) potentially the intensity of fuel/water mixing and (iv) the identity of the sodium salt involved in the reaction. This can lead to sodium accumulating in the water bottoms, forming sodium compounds that go on to plug fuel filters or which may cause injector fouling. The data found may explain the variation in engine test data regarding sodium induced fouling reported in the recent literature.

Barker, Jim, Cook, Stephen, Richards, Paul

Interactions among Fuel Components from Diesel Fuel and Biodiesel

2013-01-259410/14/2013

The European diesel fuel specification limits the biodiesel content to 7 %. It is, however, desirable to increase the amount of renewables in the transport sector; therefore blending with a higher biogenic fuel content is of interest. Blending of fuels can lead to chemical reactions between fuel components and may result in undesired products. In detail, aged biodiesel from unsaturated FAME and fossil diesel fuels can form oligomers and precipitations with a maximum in the range of B10 to B20. Precursors are oligomers that can be separated from the biodiesel or the blends in an amount of up to 20 %. These oligomers are soluble in the fuel, but they seem to have potency for chemical reactions with fuel components or the engine oil. To prevent tentative problems in the fuel filter, the injecting system and the combustion process itself, the formation of oligomers should be disabled in blends. Alcohols have been proven and tested to dissolve precipitations in the fuel. However, flash point problems occur, in case the alcohols have too low boiling points. Some alcohols could be identified to reach the demands of the specification. Additionally, tests regarding the compatibility of materials and engine tests to monitor regulated and non-regulated emissions were carried out. In the result, some blends from biodiesel, diesel fuel and alcohols tend to be appropriate to suppress chemical reactions in the fuel and probably in the engine oil. Further research is necessary to explain the chemical interactions that are responsible for the formation of oligomers and their reaction products. Not only chemical but physical bonds can play important roles and are in the focus of current research.

Krahl, Jürgen, Munack, Axel, Schaper, Kevin, Fey, Barbara, Schmidt, Lasse, Schroeder, Olaf

Fuel Filter - Initial Single-Pass Efficiency Test Method

J1985_201310 (Current)

10/7/2013

This SAE Standard is intended for all sizes of fuel filters, so a variety of test stands may be required depending upon flow rate. The low contamination level, downstream clean-up filter, and short duration of the test, ensures that the particle retention ability of the filter is measured in a single pass as no appreciable loading or regression will occur.

Filter Test Methods Standards Committee

A Representative Testing Methodology for System Influence on Automotive Fuel Filtration

2013-01-08914/8/2013

Filtration of diesel and gasoline fuel in automotive applications is affected by many external and internal parameters, e.g. vibration, temperature, pressure, flow pulsation, and engine start-stop. Current test procedures for automotive fuel filters, proposed by most of the researchers and organizations including Society for Automotive Engineers (SAE) and International Organization for Standardization (ISO), do not apply the previously mentioned real-world-conditions. These operating conditions, which are typical for an automotive fueling system, have a significant effect on fuel filtration and need to be considered for the accurate assessment of the filter. This requires the development of improved testing procedures that will simulate the operating conditions in a fuel system as encountered in the real world. Although researchers have studied this topic in the past, they did not address the analysis of individual and combined effects of all the relevant fuel system parameters, which influence the filter performance. In this paper the effects of these parameters on the performance of diesel fuel filter for passenger cars will be studied using state-of-the-art testing facilities with the capability of simulating several of these system parameters in a laboratory set up.

Khadilkar, Sumit, Soliman, Ahmed, Schuetzbach, Peter, Kustic, Marko

The Impact Upon Durability of Heavy-Duty Diesel Engine Using 5 Percentage Biodiesel

2013-01-16864/8/2013

Due to the increasing price of crude oil, biofuel as an alternative of fossil fuels is sought to be a global-wide solution to reduce the emission of greenhouse gas. In order to compare the influence on engine which meet euro IV emission standard by using pure fossil diesel, 2% and 5% biodiesel. A long-term operation with blended 2% and 5% biodiesel by standard engine test had been evaluated in this study. The results could be referred to the consideration of marketing promotion strategy as well as government policy in Taiwan. Both B2-B5 diesel fuel (2 and 5 vol% biodiesel) and diesel fuel were employed to the same engines for testing purpose to compare the influence. The engines were equipped with an electronically controlled common-rail fuel injection system. After 500 hours full load durability operation, the key components of the engines were analyzed and characterized by a series of inspections to identify the degree of decay and wear behavior. In addition, the engine performance which by the test procedure for SAE J1995 and emission measured which by the test procedure for FTP transient cycle were also determined at each maintenance stage. In this study, oil characteristics after durability test had also been evaluated. The results indicated that the engine components including piston rings, cylinder liners and needle valves of injector were less difference in dimensions comparison before and after durability tests. The fuel supply system of the diesel engine consists of a fuel tank, fuel pipes, fuel filters, and a low pressure pump had also been evaluated. According to microscopic characterization and engine oil analyses, the wear loss of the key components was insignificant and tribological performance of the B5 biodiesel was slightly better than that of diesel fuel. It was found that the performance and emissions were varied under ±3% when diesel engine was fueled with B5 biodiesel.

Ku, Yong-Yuan, Lin, Ko Wei, Chen, Ya-Lun, Liao, Ching-Fu

FAME Filterability: Understanding and Solutions

2012-01-15899/10/2012

The introduction of fatty acid methyl ester (FAME) into the diesel pool has led to an increase in the incidence of diesel fuel filter blocking. In contrast to conventional diesel, filter blocking events can occur above a fuel's Cloud Point (CP). It has been shown that this phenomenon is due to trace levels of impurities carried over from the original oil source into the final fuel. The two species identified as being the main cause of the filtration problems are saturated monoglycerides (sMG) and sterol glucosides (SG). Reported in this paper is an extensive study completed to understand the impact that these impurities have on the filterability of FAME and FAME containing fuels. This has been investigated using laboratory based filterability tests that incorporate a specific cold soak and the critical contaminant levels causing failure have been determined. In addition to this, the appearance of the crystals formed and their coverage of the fuel filter surface have been studied using scanning electron microscopy (SEM). These two techniques have also been used to identify and select additive technology that can positively impact filterability when sMG and SG precipitate from either FAME or fossil fuel containing a portion of FAME.

Camerlynck, Stephanie, Chandler, John, Hornby, Ben, van Zuylen, Isabel

Diesel Vehicle Cold Operability: Design of Fuel System Essential Besides Fuel Properties

2012-01-15929/10/2012

Cold operability is estimated by fuel's cold filter plugging point (CFPP). However, correlation of CFPP with diesel vehicle performance originates from a period when simple in-line or distributor fuel injection systems were applied and fuels did not contain biocomponents. Today, common rail fuel injection systems are used and there seem to be remarkable differences in their design between vehicle models. Seven cars were tested in a climate chamber. The best cars operated down to 8°C below fuel's CFPP but the worst get into problems 5°C above CFPP with the same fuel. It is challenging to define what CFPP is needed in order to guarantee trouble-free winter performance because there are big differences between car models. It is fundamental to get the fuel temperature of a vehicle's fuel filter above the fuel's cloud point during driving, and this depends on fuel system design factors, such as location and size of fuel filter and fuel heater if it is used. Oil companies prefer diesel fuels which do not have unnecessary good cold properties because better cold properties reduce the diesel fuel yield at refineries at a time when there is shortage of diesel fuels in Europe. Light middle distillate fractions suitable for winter grades are needed also for aviation kerosene production. Cold operability problems related to biocomponents can be avoided by using isomerized HVO. Trouble-free operation in cold conditions is important for all stakeholders: oil companies, automotive companies and vehicle owners. Further exchange of information and cooperation between oil, automotive and fuel additive companies would be valuable as well as more vehicle testing.

Mikkonen, Seppo, Kiiski, Ulla, Saikkonen, Pirjo, Sorvari, Jari

A Novel Technique for Investigating the Characteristics and History of Deposits Formed Within High Pressure Fuel Injection Equipment

2012-01-16859/10/2012

The recent developments in diesel fuel injection equipment coupled with the moves in the US to using ULSD and biodiesel blends has seen an increase in the number of reports from both engine manufacturers and fleet operators regarding fuel system deposit formation issues. These deposits not only form on and within the fuel injectors but they also form elsewhere in the fuel system, due to fuel recirculation. These will eventually accumulate in the fuel filters. Historically, diesel fuel system deposits have been attributed to contamination of the fuel or the degradation of the fuel with age. Such age related degradation has been attributed to oxidation of the fuel via well documented pathways, although the initiation of this process is still poorly understood. Papers at recent SAE meetings in Florence, San Antonio, Rio de Janeiro, San Diego and Kyoto have addressed many of these causes. However, in recent cases the deposits internal to the fuel injector have become prevalent and characterisation of the deposits on the injector needle has become an industry priority. The deposits are different from those traditionally encountered, with inorganic and carbon components being found. This paper will describe for the first time the application of Time-of-Flight Secondary Ion Mass spectrometry (ToF-SIMS), for the analysis of these deposits. This technique involves: surface spectroscopy; static SIMS, the application of very low primary ion dose densities yielding quasi nondestructive surface analysis. Combined with surface imaging which involves the rastering of a finely focussed ion beam over the surface yielding mass resolved secondary ion images; chemical maps, and depth profiling. Every pixel of a ToF-SIMS map represents a full mass spectrum. The technique also allows dynamic SIMS; and 3D Rendering. Where the application of high primary ion dose densities to the sample yields, successive removal of top surface layers and from the resultant mass spectra elemental in-depth distribution. Thus for the first time both the surface and the inner layers of a deposit may be characterised in three dimensions. This paper also discusses the insights that such analysis can bring to the constitution, origin, and build-up history of these deposits and could provide a basis for the development of strategies to minimise such deposit formation.

Barker, Jim, Snape, Colin, Scurr, David

The Influence of Biodiesel Fuel Quality on Modern Diesel Vehicle Performance

2012-01-08584/16/2012

Vehicle manufacturers have developed new vehicle and diesel engine technologies compatible with B6-B20 biodiesel blends meeting ASTM D7467, “Standard Specification for Diesel Fuel Oil, Biodiesel Blend (B6 to B20).” However, recent U.S. market place fuel surveys have shown that many retail biodiesel samples are out of specification. A vehicle designed to use biodiesel blends is likely to encounter occasional use of poor quality biodiesel fuel; and therefore understanding the effects of bad marketplace biodiesel fuels on engine and fuel system performance is critical to develop durable automotive technologies. The results presented herein are from vehicle evaluation studies with both on-specification and off-specification bio-based fuels. These studies focused on the performance of fuel injection equipment, engine, engine oil, emissions and emissions system durability. Evaluations were conducted on B-20 (20 volume% blend of biodiesel in ultra low sulfur diesel fuel, (ULSD), biodiesel (B100) and a 50 volume% blend of vegetable oil and ULSD. The study results showed that in general B20 fuels meeting the ASTM D7467 specification did not cause any operational issues but vehicles operated on off-specification biodiesel fuels experienced operational issues including internal injector deposits, combustion chamber deposits, sticking of piston rings and fuel filter clogging.

Lopes, Shailesh Martin, Cushing, Timothy

Performance Evaluation and Components Behavior of Light Duty Diesel Engine after 300 Hours Test Fuelled with Pure Biodiesel: Effects on Reliability and Durability

2012-01-08654/16/2012

Pure biodiesel is non-toxic, biodegradable and greenhouse gas neutral alternative fuel with potential successful future but reduced quantitative information is available about the impact of biodiesel on engine durability and long period usage effects. In this study, a commercial light duty Diesel engine installed on an engine test bench has been operated fuelled with pure biodiesel (B100 referred to the EN-14214 standard) during a period test of 300 hours in order to analyze engine performance and components behavior. A engine characterization has been completed using conventional diesel fuel (EN 590). Then, following a specific defined operation cycle and fuelled with pure biodiesel, a study over different engine components such as: engine oil, fuel filters, Diesel Particulate Filter (DPF), so on, has been done in order to obtain possible negative effects and modifications required over maintenance policies applied to them. Furthermore, in order to increase the severity of the test performed, problems related with excessive blowby have been provoked. Finally, engine and fuel system components were disassembled, inspected, and evaluated to compare main characteristics after long time test.

Bermudez, Vicente, Tormos, Bernardo, Garcia, Antonio, Linares, Waldemar

Research on Clogging Mechanism of Multilayered Fuel Filters and Extension of Filter Life Span in Ethanol Blended Fuel

2011-32-057011/8/2011

Recently, the use of ethanol blended fuel is growing worldwide. Therefore, there is increasing needs for addressing issues relating to ethanol blended fuel use in gasoline engine fuel supply systems. In this paper, we focused on one of such issues, which is the reduced life of a multi-layered fuel filter used at inlet side of a fuel pump when it is used with ethanol blended fuel. In this study, we clarified that ethanol blended fuel tends to disperse dust particles contained in fuel to a greater extent than gasoline, and that it has a mechanism to accelerate clogging by concentrating the clogging only on the finest layer of the multi-layered filter. Also, in the process of clarifying this principle, we confirmed that dust particles dispersed by ethanol are coagulated when passing through the filter layers. Based on this, we developed a filter structure that increases dust particle capturing capability by combining dust particles into larger size before reaching the filter, thereby doubling the effective life of the filter for ethanol blended fuel.

Ito, Atsushi, Ishii, Tsubasa, Ando, Hideaki, Umebayashi, Fujio, Kinoshita, Keita

Fuel Warmer - Diesel Engines

J1422_201110 (Current)10/27/2011

This SAE Information Report establishes performance requirements for devices used to warm diesel fuel before entering the fuel filter(s).

Common Tests Technical Steering Committee

Flex Fuel Filter with Higher Dust Holding Capacity

2011-36-021310/4/2011

The flex-fuel engine technology evolution and bio fuels increasingly market presence brings new challenges on components development requirements. One of the affected products is the fuel filter, where downsizing, dust holding capacity and filtration efficiency are the improvement goals. In order to attend these market demands, MAHLE has developed a new flex-fuel filter generation. This new product is able to double the dust holding capacity while maintaining the filtration efficiency. In addition, new product dimensions, like body diameter and distance between inlet and outlet, are the same found in current solutions. In this way, it can be used in many vehicles with none or few modifications at interface components. First optimization was done through changes in filter housing design and fuel system line connectors. Second optimization was single layer cellulose media improvement to multilayer concept. Comparative tests between this new flex-fuel filter generation and current solution was done to confirm performance improvement.

Yoshino, Fernando Jun, Marques, Gisela Ablas, Fritz, Luiz Carlos, de Aquiar, Bruno, Moreira, Fabio

Investigation of the Gel Formation and Filter Solutions in the Fuel System for Flex-Fuel Vehicles

2011-36-021710/4/2011

At flex fuel technology introduction in the Brazilian market, new technical issues came-up due to ethanol chemical reaction with component materials developed only for gasoline aging. One of these items was the gel formation at fuel system. This gel flows through the fuel systems and clogs the fuel filters. And, as final result, the fuel pump is lost due to overpressure working condition. To implement solutions against this way of failure, it was necessary to understand gel formation mechanism in laboratory level. In this investigation, many boundary conditions were changed and analyzed in order to identify contribution of each factor during gel formation process. As result, it was possible to implement a laboratory gel formation test for fuel filters, not depending any more from field tests and allowing test repeatability to develop an improved fuel filter.

Cordeiro, Sandra Matos, Yoshino, Fernando Jun

A Novel Technique for Investigating the Nature and Origins of Deposits Formed in High Pressure Fuel Injection Equipment

2009-01-263711/2/2009

Recent developments in diesel fuel injection equipment coupled with moves to using ULSD and biodiesel blends has seen an increase in the number of reports, from both engine manufacturers and fleet operators, regarding fuel system deposit issues. Preliminary work performed to characterise these deposits showed them to be complicated mixtures, predominantly carbon like but also containing other possible carbon precursor materials. This paper describes the application of the combination of hydropyrolysis, gas chromatography and mass spectrometry to the analysis of these deposits. It also discusses the insights that such analysis can bring to the constitution and origin of these deposits.

Barker, Jim, Richards, Paul, Snape, Colin, Meredith, Will

Procedure for Determining the Allowable Particle Contamination for Diesel Fuel Injection Equipment (FIE)

2009-01-08704/20/2009

Increasing injection pressures together with Diesel fuel lubricated Common Rail pumps replacing oil lubricated systems demand a more sophisticated investigation of robustness and durability against particle contamination of fuel. The established way of requiring filtration efficiency levels per lab standard is not significant enough if we look at variable factors like vibration of the fuel filter and viscosity of the fuel. Because these and other factors tremendously influence filtration efficiency, future Diesel FIE cleanliness requirements will need to define an allowable contamination limit downstream of the filter. More precisely, this is not a scalar limit but a contamination collective that considers the varying vehicle filtration and operating environment. This paper describes a procedure for defining allowable contamination limits of the FIE components. The procedure includes sensitivity, robustness and “key life” tests. The latter one is similar to a S-N curve (Woehler curve) and is the basis for the damage accumulation model of particle contamination.

von Stockhausen, Alexander, Mangold, Martin P., Eppinger, Dieter, Livingston, Thomas C.

Personal Watercraft Fuel Systems

J2046_200808 (Historical)

8/5/2008

This SAE Standard applies to permanently installed gasoline fuel systems in personal watercraft as defined in 2.2, except fuel systems on outboard engines.

Personal Watercraft Committee

Removal of Water Drops from Viscor 1487 Oil

2007-01-14274/16/2007

Water-in-oil emulsion separations are of importance to petrochemical industries. Water molecules of less than 100μ diameter are present as secondary emulsions. The presence of water reduces the efficiency of the fuel combustion, the water droplets can plug small orifices, and the water can dissolve polar compounds from the fuel and form corrosive materials such as sulfuric acid which can damage engine parts. Thus, fuel filtration extends the life of engine. Coalescence filters are efficient and effectual for the removal of secondary emulsions. The aim of this work is to eliminate these water molecules by development of filters to suit this application. The approach to this work is to apply surface modifiers to change surface wetting characteristics. In this approach, solid surface wettability of the dispersed liquid is varied to determine its effect on coalescence phenomena and filter performance. To construct depth filter media with specified coatings the fibers may be coated prior to forming the media, or the media may first be constructed and the coating applied to the media. Filters are to be tested in a liquid-liquid coalescence experiment .The difference in wettability of the filters studied using modified Washburn's equation is presented here. Recommendations for future work are proposed.

Moorthy, K., Newby, B., Chase, G.G.

Ecological Spin on filter for compact engines Marcos Vanussi

2006-01-287011/21/2006

In the last 50 years, the evolution of many products was determined by innovation and technology, transforming the society itself. Notebook, cell phone, iPod and vehicles are good examples of this trend. At Brazil's 2005 SAE Congress, it was foreseen that in the next 10 years, the automotive industry will bring higher innovation than in the last 30 years. To survive, the auto parts industry has to invest in new product solutions. New concepts; design and solution for current auto parts should be implemented in order to follow the fast process in the automotive industries.

Vanussi, Marcos, Fritz, Luiz Carlos

Influence of FAME Blends in Diesel Fuel on Driveability Performance of Diesel Vehicles at Low Temperatures

2006-01-330610/16/2006

In this study influence of fatty acid methyl ester (FAME) blends in petroleum based diesel fuel on cold performance was investigated. First, influences on pour point (PP), cold filter plugging point (CFPP) and cloud point (CP) were evaluated for palm oil methyl ester (PME) and rape-seed oil methyl ester (RME) blends. RME-blended fuels showed similar properties to those of the base fuel. Thus, for vehicle tests, low temperature performance was examined with PME-blended fuels only. Startability and driveability were evaluated at varying temperatures using two vehicles (one old model and one new model). The results indicated that at low temperatures PME blends would deteriorate driveability performance.

Kono, Naoki, Fukumoto, Junichi, Iizuka, Masashi, Takeda, Hiroshi

Fuel Filter - Initial Single-Pass Efficiency Test Method

J1985_200608 (Historical)8/9/2006

This SAE Standard is intended for all sizes of fuel filters, so a variety of test stands may be required depending upon flow rate. The low contamination level, downstream clean-up filter, and short duration of the test ensures that the particle retention ability of the filter is measured in a single pass as no appreciable loading or regression will occur.

Filter Test Methods Standards Committee

Shake and bake: a recipe for testing

OFHAPR06_024/1/2006

Vehicles, components endure much in-lab abuse before they enter the commercial-vehicle market. Off-highway equipment has to survive some of the roughest conditions in the world, and many vehicles have lifetimes that make passenger cars seem as transitory as cell phones. To meet these requirements, manufacturers spend plenty of time testing components and systems in a range of simulated environments. A growing number of tests are now being performed in the virtual world, saving the expense of building models. Once prototypes are produced, they undergo extensive testing in real-world tests that simulate the harshest conditions equipment will face. These tests occur at elevated temperatures and often have constant vibrations, leading many to dub this the shake-and-bake portion of development.

Costlow, Terry

Impact of Low Quality Fuel in Fuel Injectors

2005-01-400711/22/2005

The use of oxygenated fuels in Brazil required the OEM to develop local testing methods to check the abilities of injector components and materials to withstand the aggressive characteristics of the fuel found in the field. This paper complements paper SAE 962350 and documents the engineering work that was performed to identify the root cause of the field problems related to the single point injectors, the testing procedure developed and the actions taken to minimize the field issues.

Chiarelli, Paulo Maurício, Moles, Claudio Wilson, Coelho, Eugenio Paccelli Dantas, Chrispim, Leandro, dos Santos, Marco Antonio Correia, Barwick, Matthew, de Urquidi, Ricardo

Development of a 4-Stroke Small-Displacement Scooter with Discharge Pump Type Fuel Injection System

2005-32-008510/12/2005

This paper describes the development of a new fuel supply system for small-displacement motorcycles which achieved better functions for environmental protection such as reduced exhaust emissions and improved fuel economy and was installed on a new 4-stroke 50 cm3 model scooter. The new fuel supply system, in which the fuel injection is controlled electronically, is called the discharge pump (DCP) system. Previously, electronically-controlled fuel injection systems were normally used for large-displacement models due to high cost, but the newly developed. DCP system makes it practical to use electronically-controlled fuel injection systems for small-displacement models whose production cost must be kept low. In addition to the same ECM and sensors as used in the conventional electronically-controlled fuel injection systems, the DCP system has the fuel pump, regulator, and injector combined in a single unit as the DCP, and the gravity-flow normal-pressure fuel piping system (with the fuel tank installed above the DCP). This new arrangement enables the system to be manufactured at lower cost while maintaining the same high mechanical performance as the conventional electronically-controlled fuel injection systems. Furthermore, compared with conventional systems, the new system demonstrates excellent performance such as improved startability, all-weather adaptability, and fuel economy, all of which can be achieved by monitoring engine conditions with various sensors and controlling fuel injection with high accuracy.

ISHIBE, Eiichi, TORII, Kenji, KASAI, Tsuyoshi

Presentation of a Standard Dust Capacity Test Method for Gasoline Vehicle Fuel Delivery Modules

2005-01-14954/11/2005

The vehicle fuel delivery module must perform without failure while under the ingested dust contamination conditions in the vehicle fuel system. Calculations for the required dust capacity of a vehicle fuel system are based on the total amount of contamination expected in the fuel tank during the life of the vehicle. The amount of dust that the fuel delivery module can ingest before degrading the performance of the vehicle determines the “Life” of the fuel delivery system. Current testing of the vehicle fuel delivery module requires individual dust capacity testing on each of the filters in the system. This does not account for the dynamics of the filters in series or the affects of the fuel delivery module design. This demands the creation of a standard test method to test the dust capacity of the complete fuel delivery module. This paper presents the calculations for obtaining the required dust capacity for the vehicle system and introduces a standard test method for conducting dust capacity testing on a complete fuel delivery module. The dust capacity test is a bench test to evaluate the performance of the fuel delivery module as it is exposed to test dust at standard conditions. The considerations required in development and a review of the standard test method is presented.

Graber, Julie A.

Non-Linear Finite Element Analysis of a Fuel Filter System

2002-01-312111/18/2002

A fuel filter system essentially consists of a center tube, which is screwed on to a head and rests against a bowl. A thin circular plate, called end-cap, slides inside the bowl with spline teeth. The fuel filter material is inside the bowl and rests on the end-cap. When the bowl is tightened an input torque is transferred to the center tube and on to the head. It is required to estimate the stresses of the various components when a maximum tightening torque is applied to the bowl. A non-linear large deflection contact analysis of the fuel filter system needs to be performed. A number of contacts between the different deformable bodies, i.e. head and bowl, end-cap and center tube, etc. are resolved for equilibrium.

Krishna, Murali M. R., Lee, Brian

The Influence of Fuel Filter Design on the Low Temperature Performance of Light Duty Diesel Vehicles

2002-01-17015/6/2002

Tests have been carried out to determine how the fuel filter design affects low temperature performance of light duty diesel vehicles in the Korean market. Representative fuel filters have been collected to investigate their characteristics in terms of the effective pore size and the filtration area, which have been assessed against the low temperature test results from both fuel flow rig and cold chamber chassis dynamometer operations. The results show that both the effective pore size and the filtration area are critical in determining the low temperature performance of vehicles tested. It has been found that for trouble-free operation of the vehicles at temperatures down to -20 °C, it is desirable the effective pore size of the fuel filter is larger than 35 micrometers and the filtration area larger than 3,500 cm2.

Sheen, D.-H., Yang, D.-J., Kim, S.-H., Kim, H.-S.

J2406_200203 (Historical)

3/13/2002

Truck and Bus Powertrain Committee

Increasing Diesel Fuel Filter Life Through the Use of Fuel Additives

2000-01-288910/16/2000

Inconsistent fuel filter life is a problem that continues to plague most heavy-duty diesel fleets. It has been proven that fuel filter life can be strongly influenced by the thermal and oxidative stability of diesel fuel that is being filtered. Filters consistently exposed to diesel fuels that produce a tar-like substance in abundance upon heating (sometimes termed “asphaltenes”) will plug far more rapidly than filters exposed to diesel fuel that does not easily form these tar-like substances. Fuel additives have long been used to maintain fuel system cleanliness and to improve diesel fuel stability. It follows logically that such additives could have a positive impact on fuel filter life by maintaining the cleanliness of the fuel filtration media. This paper reviews the laboratory evaluations and field tests that were run to compare fuel filter life in both the presence and absence of diesel fuel additives. Both laboratory and field results show a substantial fuel filter life improvement with the consistent addition of a proprietary additive to diesel fuel systems.

Martin, Harold R., Blythe, Glen H.

Micromachined Flow Sensor for Fuel Injection

2000-01-13653/6/2000

This paper presents the structure, operation principle, and fabrication process of a novel type of flow-velocity sensor. Like the well known classical Pitot (Prandtl) tube, it realizes flow velocity detection by measurement of the pressure difference between stagnant fluid pressure in front of the sensor and static pressure in the flow around the sensor. This difference results in a deflection of a diaphragm suspended boss, that serves as the counter electrode of an integrated capacitor which is directly exposed to the fluid to be measured. Experimental results in the wind tunnel and in the gasoline direct injection experimental set-up confirm the sensor's operation principle and show good time response.

Kanai, Yoshitaka, Mizuno, Jun, Nottmeyer, Kay, Kobayashi, Takashi

Properties of Precoated Galvannealed Steel Sheets for Lead-Free Automotive Fuel Tank Use

2000-01-03073/6/2000

The goal of this study was to identify a pre-coated steel sheet that will satisfy press formability, seam weldability, spot weldability, brazing property, external corrosion resistance and internal fuel resistance. We established an experimental method for anti-fuel resistance measurement by applying synthetic spoiled gasoline by investigating the composition of spoiled gasoline and corrosion products in the fuel tank, which was collected in North America after 160,000 kilometers' running. Newly developed lead-free pre-coated steel sheet shows excellent anti-fuel corrosion resistance in comparison with that of usual terne coated steel sheet according to this method.

Ogata, Hiroyuki, Suzuki, Sachiko, Umino, Shigeru, Mochizuki, Kazuo

Considerations on Ice Formation in Aircraft Fuel Systems

AIR790B (Historical)

10/1/1999

This document suggests and summarizes points that should be considered with respect to the formation of ice in aircraft fuel systems. These summaries represent a cross-section of the opinions of fuel system designers and users.

AE-5A Aerospace Fuel, Inerting and Lubrication Sys Committee

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