focus on training section: unit 3 diesel fuel injection training … · 2015-10-29 · section...

SECTION OVERVIEW

Rev. 9/15

Focus on Training Section: Unit 3

Diesel Fuel Injection Training Program

Model Type: All Pump Types

Section: Unit 3 Fuel and Filtration

1. Title Page Unit learning objectives Understand the properties of common types of

fuels Understand the principals of filtration Be able to make recommendations regarding

fuel storage and filtration Notes:

2. Typical Fuel System Be able to note the components of a typical fuel system Fuel Tank Pre-Filter or Primary Filter Lift Pump Final Filter or Secondary Filter Fuel Injection Pump Notes:

3. Fuel Tank Understand the importance of fuel quality Be able to explain the purpose of the tank filter Note filler cap problems Notes:

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4. Water in Tank Contamina-tion

Algae formation at interface between water and fuel Notes:

5. Fuels Know the fuels to be covered and be able to note usage

6. Typical Fuel Properties Fuel properties Notes:

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7. Heat Content A measure of a fuel’s heating ability expressed in BTU’s or Calories

BTU: A British Thermal Unit is the amount of heat required to raise the temperature of one pound of water by 1 degree F

Calorie: The amount of heat required to raise the temperature of one gram of water by one degree C. Expressed as kilogram/calories. 3.968 kg/c = 1 BTU

Notes:

8. Heat Content Heat content of various fuels Notes:

9. Flash Point The temperature at which a fuel’s vapors will ignite (flash) when exposed to a flame Notes:

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10. Flash Point Flash points of the various types of fuel Notes:

11. Spontaneous Ignition Tem-perature

The temperature at which a fuel will ignite and burn in an engine under conditions conductive to ignition without the presence of a flame or spark Notes:

12. Spontaneous Ignition Temperature

Spontaneous ignition points of the various fuels Notes:

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13. Fuel Viscosity A measure of a fluid’s resistance to flow at a given temperature. Describe the effect on lubrication, leakage and flow Notes:

14. Kerosene Be able to describe temperature effect and note steepness of curve. Note actual viscosity at operating temperature Notes:

15. Diesel Fuel #2 Be able to describe temperature effect and note actual viscosity at operating temperature Notes:

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16. Cloud Point The temperature level of a paraffin based fuel at which the wax crystallizes and precipitates out of the fuel Notes:

17. Cloud Point Cloud point of the various fuels Note that the cloud point is a function of paraffin

content Gasoline and JP4 are napthene based fuels Notes:

18. Pour Point The temperature at which a liquid thickens to the point where it will not readily flow Notes:

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19. Pour Point Pour point of the various fuels Note that the pour point is generally 10 degrees

below its cloud point Notes:

20. Fuel Weight Measured in pounds per gallon or in specific gravity (density) of the fluid

Specific Gravity is a measure of a liquid’s weight in comparison to water, which is given a value of 1.0

Note the change in weight and heat content at different temperatures. As the fuel warms up the volume increases, thus lowering the Specific Gravity (density)

Notes:

21. Octane / Cetane Octane: A method of rating a gasoline’s resistance to ignition. The higher the Octane rating, the lower the tendency to detonate (knock). Converse relationship to a Cetane rating

Cetane: A method of rating a diesel fuel’s susceptibility to ignition. The lower the Cetane rating, the more difficult it is to ignite. Converse relationship to an Octane rating

Notes:

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22. Octane / Cetane Octane / Cetane ratings of the various fuels Notes:

23. Pre-Filter / Water Separation

Understand the reason for the location and the normal micron size Notes:

24. Water in Fuel Know the causes and sources of water contamination

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25. Fuel Quality Issues Be able to identify visual differences between clean, water contaminated and oxidized / dirty fuel

Be able to describe the differences between dissolved, emulsified and free water

26. Water Contaminated Pump

Understand the cause and effect of water contamination Notes:

27. Water Damaged Compo-nents

Note water damage in 24 hours Notes:

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28. Water Contaminated Pump

This pump operated for 1500 hours on a durability test with 2% water added to the diesel fuel. Upon initial inspection, there is very little evidence of any water contamination or damage Notes:

29. Regulating Pistons Upon closer inspection we can see the damage that water can cause. The piston on the right operated with #2 diesel fuel, the piston on the left operated with diesel fuel with 2% water added

Note the galling and discoloration on the piston run with water. This type of galling may lead to the piston sticking

Notes:

30. Transfer Pump Blades Transfer pump blades run with 2% water. Scuffing and wear to the ends and sides of the blades is apparent Notes:

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31. Metering Valve Pitting and corrosion cause by the presence of water. This valve may eventually stick in its bore causing stalling Notes:

32. Leaf Springs The leaf spring on the right is in good condition while the one on the left failed due to fretting corrosion Notes:

33. Lift Pump Location Be able to describe the position in the system and explain the benefits of a controlled supply pressure and the effect on the system Notes:

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34. Fuel Heater Location Understand why the heater is positioned immediately prior to the filter Notes:

35. Fuel Heater Location A side load heater is used when a hand primer or an electric boost pump is installed Notes:

36. Waxed Filter Be able to describe the waxing process and the effect of temperature changes Notes:

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37. Fuel Heater Location Understand why the heater is positioned immediately prior to the filter Notes:

38. Fuel Filter Be able to explain the importance of a final filter. Note it’s position in relation to the injection pump Notes:

39. Worn Rotor Note the effects of contaminates on pump components Notes:

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44. Micron Size Be able to describe filter ratings Note that 10 microns used to be the critical size 2 to 5 micron rated filters have become the norm

for today’s injection equipment Notes:

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46. Basic Diesel Fuel Filtration What you and your customers need to know about fuels, proper fuel handling and filtration for protection of their fuel injection equipment Notes:

47. Terminology Understand Primary Filters Secondary Filters Notes:

48. Terminology Understand Water Separators Coalescers Sediment Bowl Notes:

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49. Filter Sizing and Capacity Understand Fuel Flow vs. Fuel Consumption Porting and line size determines fuel flow

capacity Notes:

50. Filter Sizing and Capacity Understand Increases in filter media quantity increases filter

life Use of a pre-filter increases final filter life What are the effects on pump/engine

performance when run with a choked filter Notes:

51. Recommendations Recommendations to be passed on to the equipment owner/operator Notes:

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52. Recommendations Recommendations to be passed on to the equipment owner/operator Notes:

53. Recommendations in Fuel Handling and Storage

Recommendations to be passed on to the equipment owner/operator Notes:

54. Chemical Improvement of Fuel Quality

Understand Cetane Waxing/choking Lubricity Fuel Stability Corrosion Protection Recommendations to be passed on to the equipment owner/operator Notes:

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55. Ultra Low Sulfur Diesel Fuel

Introduced to the US market in October, 2007 Sulfur content reduced to 15 PPM max. Notes:

56. Fuel Lubricity Lubricity describes the ability of a fluid to minimize friction between, and damage to, surfaces in relative motion under loaded conditions Notes:

57. Low Lubricity Diesel Fuel

Parts condition is the only true measure of a fuel’s lubricity (Reference S.L. 288) Notes:

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61. Taking Care of Your Customers

Take care of your customers with good sound advice and recommendations Notes:

focus on training section: unit 3 diesel fuel injection training … · 2015-10-29 · section...

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