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By Wil Andrews
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You are free to use the information in this report in any non-
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Fuel Filtration - Racor
The most trusted name in
information is suitable to his application and takes sole responsibility
fuel filtration - Racor. for any use made of the material.
www.parker.com
A Work In Progress
Lubriquip Pumps & The most common reason for marine diesel engines in general, and
Filters recreational trawler diesel engines in particular, to fail to run is
Lubriquip Pumps Modu-
Flo AL-25, HLJ Filters,
associated with "bad diesel fuel." The things that make the diesel fuel
Maxi-Flo, EO, Maxi- bad generally have nothing to do with the original quality of the fuel.
Monitor The problems come about because of the condition of the fuel we
devcocorp.com/lubriquip
buy and what happens to the fuel when it gets stored, sometimes at
the suppliers' facilities, but most often in our own vessels.
Various Expansion
Joints
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Captn Wil's Fuel Polishing System: Trawlers & Trawlering How To 10/15/2006 08:27 PM
Joints
All types of Bellows and To get anything from this epistle, you must accept the fact that this
Expansion Joints to fit whole thing is a work in progress. The work is to find out how to
your piping systems keep the fuel we burn Just Like New. The progress in this work
www.usbellows.com
comes in fits and starts, and next year I'm sure I'll know more about
the solution to the problem than I know now. Getting the whole
Woma GB Ltd
answer is difficult because while it is of vital concern to us
Manufacturers of Water recreational trawler captains, it is a minor problem when considered
Jetting Equipment up to in light of the events of the nation and world. There is no money
3000 bar dedicated to finding the solution to this problem by either
www.woma.gb.com
government or industry. There are companies selling products
proclaiming that their product will solve the problem, but I am not
Mr. Funnel-simply aware of any formal scientific studies that speak to the causes and
amazing solution of this problem. That leaves it to amateurs like CaptnWil,
Mr. Funnel Separates and others, to see this work in progress to a conclusion for the
water from gas or diesel - recreational boating world. I encourage all of you to make tests and
Ship within 24 hours !
www.fourwinds-ii.com keep records so the whole body of information can be shared by all
of us. We make judgments based on our observations, experiences,
Advertise on this site and faith in advice given by others. It is important that we strive to
be able to change those judgments when the evidence suggests a
change is called for.
In The Beginning
Like most who have experienced bad fuel problems, I first became
aware that such a problem was possible in 1989 when my "newto-
me," four year old trawler engine quit while I was taking her home
from a thousand miles away.
The boat had spent two winters in Chesapeake Bay mostly at the
dock, made the trip down the ICW to the Keys, and I took
possession in Miami. The engine had less than one thousand hours
on it and the fuel tanks were less than half full. With the joy that is
only possible that first day you own a boat, we set out with eight
guests toward North Carolina. Guests came and went along the way,
and thankfully, there were no guests when the engine stopped
underway the first time. Before I finally figured out that the problem
was a clogged fuel filter, and then found the proper element, the
engine stopped eight times. The last time it stopped underway was in
a passage that warns not to anchor because of unexploded ordnance.
For a lot of reasons, that whole voyage is an experience I'll never
forget, but that's another story.
I did not know that this work in progress had really begun until the
engine stopped while underway again in Chesapeake Bay that
summer. It was an uncomfortable feeling to be unable to move in the
middle of the bay with night rising on and the wind coming. By this
time, I understood that the symptom of the problem was a clogged
fuel filter. I recognized that the problem was most likely to occur
when the boat was in a seaway and the fuel got stirred up. That
realization brought terror to my mind when we got caught in a July
storm just off Cape Lookout with 60-knot winds and mountainous
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waves. If the engine had stopped then, those I love the most would
be cast into the breakers of Cape Lookout.
Early Efforts
After going through a Racor element every day for several days, I
decided to get to the bottom of the problem and clean the tanks. The
bottom of each tank had enough black sand-like stuff to fill two five-
gallon buckets each.
What was that stuff? It was the stuff at the bottom of the tank. I have
never had a satisfactory answer about what it was. I am sure there
were ways to find out, but I have only seen speculation and theory
about that stuff. That speculation and theory led to putting an
additive in the fuel to prevent it from forming again which additive
is unimportant.
It is very popular today to think that something you can pour into a
fuel tank will take care of your fuel problems. There is a large body
of experience, including my own, to indicate that any pour-in
solution only treats some of the symptoms, but that's not the real
problem with this procedure The problem is that while the immediate
symptoms may vanish, this cure begins to create its own set of
problems. If you kill the bugs, their dead bodies will cause problems
sometime in the future they just become part of the jelly that wants
to collect at the bottom of the tank, and we know where that leads. If
you emulsify the water in the tank, it still goes through your injection
pump and injectors, and will lead to a whole new set of problems.
We'll talk in a little while about the Polishing System Solution, but if
your system qualifies, you can get along just fine without any extra
system.
The older ferryboats have Detroit engines and the newer boats have
Caterpillar engines. There are some facts about the operation that
have special meaning for us in seeing why this operation doesn't
have a fuel problem, but we do:
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the tanks more than a very few weeks. In the summer, the
cycle is not more than one week.
5. The engines are fitted with Racor diesel filters with water
separators and the normal fuel filters that are supplied by the
engine manufacturer just like most recreational trawlers.
Water separators are tended everyday.
The most important thing to understand is that the very high volume
of fuel used and long hours of operation in this installation, magnify
everything about the operation.
If you can guarantee you get clean fuel and guarantee it will be
stored in clean tanks and guarantee it will remain in those tanks no
longer than a week or two, you won't need a Polishing System you
already have the Absolute Solution.
I expect the high circulation rate story came from the fact that Detroit
two-cycle engines use circulated diesel fuel to cool the injectors.
Most four-cycle diesels in the range of sizes used in recreational
trawlers don't cool the injectors with circulated diesel fuel so they
only need to circulate enough fuel to make sure the injection pump
always has a positive head. That is, the lift pump must just pump
enough fuel to guarantee that fuel is always available to the injection
pump at positive pressure.
This low flow rate has a direct bearing on our general problem, but it
also has a specific effect of the action of Racor filter units that have
what is called turbine action. In most installations, the flow rate
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through the filter is far too low to allow the desired turbine action.
They are only mentioned here to let long-time readers know the
reason why.
It is generally agreed that water in the fuel tank causes all sorts of
hell. The experts tell us that algae is born, lives, multiplies, and dies
in the surface between the water and diesel fuel. These critters and
their residue are a major source of trouble. The moral is: no water,
no algae.
Most of the water gets into our tanks by water condensing on the
inside surface of the fuel tank and less often on the surface of the
diesel fuel itself. This occurs every time the temperature of a surface
is below the dew point temperature of the air to which it is exposed.
Without getting too technical, more moist air will have a higher dew
point temperature than less moist air and be more likely to cause
condensation. It is also helpful to note that the condensation always
occurs on the warm side of the surface -- the beer glass sweats on the
outside, and your port lights sweat on the inside in the winter. Thank
God for the first, but lament the latter.
This all means that condensation can only occur in your diesel tank
when the temperature of the surfaces of the tank and/or the diesel
fuel itself is below the dew point of the air INSIDE THE TANK. If
you see condensation on the outside of your tank or on your fuel
lines, there is no condensation going on inside your tank. The
problem can only occur when you don't see such condensation.
Condensation on the surface of the diesel fuel itself is seldom
considered, but is a fact. It works similar to fog at sea.
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conditioner works like the second case. Desiccant filters can also be
made to work like the second case.
There is more junk in fresh diesel fuel pumped from a high volume
supplier than I would ever imagine. That is one of the reasons that
engine manufacturers always put diesel fuel filters on their engines.
We seldom see this crud because most modern fuel filters are spin-
on types with the element hidden from view.
It is one thing to get such dirt into a 20-gallon fuel tank and quite
another to get it into a 300 or 400-gallon fuel tank on a trawler. The
complete fuel turnover rate in the 20-gallon tank guarantees that the
entire contents of the tank will be kept stirred up and the crud will
quickly end up in our fuel filter. In the 400-gallon, on the other hand,
the dirt will just settle to the bottom of the tank like the silt in the
delta of a river. It will build there over time so that it can cause its
worst evil at our most critical moment.
Then there's that black stuff that begins by discoloring the fuel filter,
then discolors the fuel, then makes the fuel black and puts jelly-like
stuff on the fuel filter, and then just shuts down the whole fuel
system.
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Except in rare cases, the factors that make our fuel storage problems
proceed at a very slow pace. It may take months or years for the
problem to become evident, but when it shows its ugly head, it is
"full growed up." It is mean and ugly and spoiling for a fight.
Remember that the first time it happened to me there were ten-
gallons of crud at the bottom of each fuel tank.
Design Considerations
While it now seems obvious, the real objective escaped me for some
time in this venture. The objective is to return and/or keep the fuel
just like new. That's just what the NC Ferry System does by their
high turnover rate. But that statement needs to be refined a little. We
need to determine just where we want to make the fuel just like new.
The answer to that question will determine where our design goes.
The common system with one secondary and one primary fuel filter
tries to keep the fuel that enters the injection pump just like new and
the only effect on the remaining fuel is the returned clean fuel. Once
we understand that most of our engines return very little fuel to the
tank it becomes obvious that this system has little or no effect on the
fuel in our tank. The fuel in the tank keeps getting less and less just
like new, and filter replacement intervals decrease.
Depth type filters provide better filtration than edge type filters and
are available with much larger capacities than edge type filters. Like
most on this list, I was introduced to depth type filters very late in
the game. I did not even know of their existence until after I initially
solved my fuel problem with a polishing system using a Racor edge
type filter.
Gulf Coast Filters (GCF) manufactures the depth type filters I have
experience with, but there are many other manufacturers of such
filters. I have every reason to expect that those filters perform well.
The basic concept of the depth type filter is that the fuel passes
through a lot of filter media. For example, the fuel travels from one
end of a roll of paper towels to the other as it passes through a GCF
F-1 fuel filter thus the depth. It is that eleven plus-inches of contact
with the filter media that makes this filter so efficient. It is its huge
volume, when compared to the volume of a Racor-500 or 900 that
gives it such an impressive capacity.
Depth type filters are not required for the diesel polishing system,
but they will increase the efficiency of the system and reduce the
maintenance. I will describe the application of these filters as we go
along, but you can just substitute any other quality filter you desire.
The System
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The system has evolved over the almost two-years that I have been
investigating this problem. That evolution has come about as I have
learned more about the subject from my own observations and the
experiences of others.
Components
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3. Gulf Coast Filter O-1 Jr. If you can't make the F-1 fit,
you can use a Jr. It was originally designed as a small
bypass oil filter, but can serve very well as a fuel filter.
This unit uses a roll of toilet paper as the element and can
be fitted most anywhere in any position. Its drawbacks are
that it has less capacity than the F-1 and does not have a
water separator. If you use this filter, you must make sure
a water separator is in the system.
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the risk of emptying the fuel tank into the bilge. Do Not! I
say, Do Not use the Racor gauge that replaces the T-
handle. It cannot be fitted with a shutoff valve.
You will notice that the GCF F-1 and O-1 JR. are piped in series
with a Racor in "Polishing System With Gulf Coast Filter." This is
possible because the F-1 and JR will filter particles much smaller
than the Racor and the Racor will remain clean almost forever. If the
F-1 gets clogged up, you may safely bypass it with its bypass valves
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and just use the Racor until you are in a place to replace the GCF
element. In like manner, if the Racor gets clogged up you can just
bypass it and operate on the GCF alone until the Racor element is
changed
In "Polishing System With Racor Filters," the Racor filters are piped
in parallel because they have the same filtering efficiency.
System Operation
This will mean that you are polishing the fuel any time you are
underway. If you are on a cruise that means you may not need to
operate the polishing system on its weekly schedule. You can just
operate on the weekly schedule when the boat is idle.
In any event, you should pump enough to turn the fuel over at least
three times per week. More is better than less.
Check Valve
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The system is designed so that the Walbro just keeps a positive head
on the engine lift pump while underway and bypass most of the fuel
around the engine. If the Walbro were to fail while underway, the
engine lift pump would try to draw fuel from the engine return line
and the engine would stop running because of air in that line. The
check valve will prevent that problem. The two-way valve in the
same line can be used to close the return as well, but the check valve
just makes it more convenient.
Three-Way Valve
The three-way valve is provided for those who do not want to run the
Walbro underway. In that situation, turn the three-way valve to the
proper position and adjust the two-way valve in the line that has the
check valve.
Fuel Circuit
Any other procedure may lead to a fuel spill. That means making
sure the valves at the fuel tanks are always set properly.
Day Tanks
Day tanks have become a popular topic of late, and a few words are
necessary about them in connection with a fuel polishing system.
It is important to remember that the clean and dry fuel in the day
tank will be exposed to the same conditions that cause the fuel in the
main storage tank to become bad. Given enough time, the fuel in the
day tank will get to the same condition as the fuel in the main tank.
A filter and a water separator are still required on the outlet of the
day tank.
Wiring
All of the usual safety wiring practices should be followed and the
pump should be protected with a 5-amp fuse or circuit breaker. It
will be convenient to locate the switch or timer close to the helm.
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Used Gulf Coast Filter F-1 element and Racor 500 2-micron element: F-1 element shown
after 500 hours with clean fuel. Racor element cutaway showing pleating of element.
When you see the signature Captn Wil, you better be ready to toss
preconceived notions and advertising claims out the porthole
Much of the equipment testing and system development undertaken by Wil Andrews was
accomplished aboard his beloved AfterSail, a Krogen 42 Pilothouse.
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