Negative Impacts of Contaminated Diesel

Negative Impacts of Diesel Contaminated

by Particles According to ISO 4406*

Diesel contaminated by particles represents a significant issue for any operation involving internal combustion engines. ISO 4406 sets standards for classifying particle contamination in oil-based fluids, but its relevance extends to diesel fuel, as the presence of particles can have negative impacts on:

  • Operational efficiency (Higher Fuel Consumption)

  • Energy efficiency and engine power

  • Service life of the injection system, engine, and lubricant

  • Environmental pollution

  • Health impacts on the community

IMPACTS

ON OPERATIONAL EFFICIENCY

ON ENGINE
LIFESPAN

ON THE
ENVIRONMENT

ON
HEALTH

IMPACTS ON
OPERATING EFFICIENCY

INCREASED FUEL CONSUMPTION

Contaminated diesel due to particles can have a direct impact on the operational efficiency of diesel engines. Particles present in the fuel can clog filters, injectors, and other components of the fuel system, resulting in decreased engine performance and increased fuel consumption. This clogging can lead to incomplete combustion, causing soot buildup and reduced engine power. Therefore, particle-contaminated diesel, according to ISO 4406 standards, can lead to a significant decrease in the operational efficiency of diesel vehicles, which in turn results in higher operating and maintenance costs.

THE 4 STEPS OF POWER LOSS

POOR
DOSING

POOR DOSING

Injection systems require ISO 11/8/7 diesel to optimally dose the fuel. Poor injector dosing due to the presence of particles results in power loss and consequently up to 5% higher fuel consumption.

LOSS OF COMPRESSION

LOSS OF COMPRESSION

Particles in the combustion chamber cause premature wear on the cylinders, leading to early compression loss—synonymous with power loss and increased fuel consumption throughout the engine’s service life, by up to 7%.

CONTAMINATED LUBRICANT

CONTAMINATED LUBRICANT

Particle-contaminated lubricant increases friction and temperature, causing up to 2–3% power loss and higher fuel consumption.

PREMATURE DPF SATURATION

PREMATURE DPF SATURATION

Pressure drop in diesel particulate filters (DPFs) causes up to 2% power loss and increased fuel consumption due to combusted particles.

IMPACTS ON
ENGINE LIFESPAN

The presence of particles in diesel fuel can also have direct consequences on engine performance. abrasive particles can cause accelerated wear on components such as cylinders, pistons, and rings, resulting in reduced engine lifespan and increased repair and replacement costs. additionally, particles in diesel can interfere with engine lubrication, leading to greater wear and damage to internal components, and even degrading lubricant additives—reducing oil change intervals. in summary, particle-contaminated diesel, as classified under iso 4406, can significantly decrease the performance and lifespan of diesel engines, affecting the reliability and durability of vehicles and machinery.

Impacts on the
Environment

In addition to impacts on operational efficiency and engine performance, particle-contaminated diesel also has significant environmental consequences. particles present in diesel can contribute to the release of pollutants into the atmosphere, affecting air quality and posing public health risks. incomplete combustion caused by the presence of particles can lead to increased emissions of exhaust gases, including nitrogen oxides (nox) and soot particles, both known for their harmful effects on human health and the environment. therefore, particle-contaminated diesel represents a serious environmental concern, and compliance with the iso 4406 standard is essential to minimize these impacts.

IMPACTS
ON HEALTH

Diesel contaminated with particles poses a serious threat to human health, as the microscopic particles present in this fuel can penetrate deep into the lungs when inhaled. The World Health Organization (WHO) reports that premature deaths caused by particulate matter emitted by engines reach 4.2 million annually. Chronic exposure to the particles found in contaminated diesel can lead to various respiratory issues such as chronic bronchitis, asthma, and even an increased risk of developing lung cancer. Additionally, these particles can travel through the bloodstream and affect other organs, contributing to cardiovascular diseases and nervous system complications.

The most vulnerable groups to these impacts include children, the elderly, and individuals with preexisting respiratory conditions. Therefore, it is crucial to implement strict diesel quality control measures to ensure compliance with the standards set by ISO 4406, in order to protect public health from the harmful effects associated with particle contamination.

COMPLIANCE WITH ISO 4406 STANDARD

The ISO 4406 standard establishes a method for classifying particle contamination in fluids, including diesel fuel. It defines the size and quantity of particles allowed in the fuel, providing a clear guideline to ensure the quality and cleanliness of diesel used in diesel engines. Compliance with this standard is essential to prevent the negative impacts of particle-contaminated diesel, as it sets clear benchmarks for fuel quality and contributes to engine protection, operational efficiency, and environmental preservation.

Recommendations and Conclusions

To mitigate the negative impacts of particle-contaminated diesel according to ISO 4406, careful attention must be given to the quality of the diesel fuel used in engines, along with the proper selection of ultrafiltration systems that meet high-efficiency standards such as THETA 4 > 4000 (in a single pass) and BETA 4 > 4000 (in recirculation). Additionally, when selecting filtration systems, it is essential to include filters that comply with SAE J1488 standards to effectively mitigate the presence of water in oil-based fluids.

It is recommended to perform regular diesel quality testing in accordance with ISO 4406 to ensure compliance with cleanliness and purity standards. Moreover, maintaining a preventive maintenance program—including the inspection and replacement of filters and fuel system components—is critical to avoiding particle contamination. The use of advanced fuel filtration and purification technologies can also play a significant role in preventing particle contamination and protecting diesel engines.

In conclusion, diesel contaminated by particles as defined by ISO 4406 represents a serious threat to operational efficiency, engine performance, and the environment. Adhering to the standards established by ISO 4406 is essential for minimizing these impacts and ensuring optimal performance of diesel engines. By adopting effective maintenance and quality control practices, it is possible to mitigate the negative impacts of contaminated diesel and promote reliable, sustainable performance in diesel engines across various industrial sectors.

OEMs have established ISO 18/16/13 as the MAXIMUM LIMIT and ISO 11/8/7 as the OPTIMAL standard, while in Latin America, the average diesel fuel consumed has a cleanliness level of ISO 22/20/17—between 1,000 and 2,000 times more contaminated than the established optimal level.

Invisible Enemies in the Air

Particles and Moisture in Oily Fluid Storage Tanks

(Diesel, Engine Oil, and Hydraulic Oil)

Storage tanks for oily fluids (fuel, lubricating oil, and hydraulic oil) are essential to ensure the continuous and efficient operation of a wide range of industrial equipment, heavy machinery, vehicles, and power systems. However, these tanks are vulnerable to the presence of invisible contaminants such as particles and moisture, which can compromise the quality of the stored fluid, reduce equipment lifespan, and increase operating costs. Lack of control over these contaminants often leads to premature failures, hydraulic system breakdowns, and environmental issues.

This white paper explores how breathers are a key tool for protecting storage tanks and stored fluids against invisible enemies present in the air, offering an effective strategy to preserve the integrity of fuel and hydraulic oil while enhancing the reliability and operational efficiency of facilities.

1. PARTICLES AND MOISTURE

2. The Role of Breathers

3. Applications of Breathers

4. Selecting the Right Breather

1

PARTICLES AND
MOISTURE

Invisible Enemies in the Air

PARTICLES

In any industrial or storage environment, the air is filled with microscopic particles that can enter tanks during filling and emptying cycles. These particles may include:

  • Dust and dirt: Originating from the environment or during fuel transportation.

  • Metallic particles: Resulting from normal equipment wear or corrosion.

  • Biological contaminants: Such as fungal spores or bacteria, which can thrive in humid environments.

These particles can mix with fuel or oil, clog filters, damage system components, and reduce efficiency. In hydraulic systems, particles can damage seals and precision components.

 

MOISTURE

Water in storage tanks is another invisible contaminant that can enter the system in various ways:

  • Condensation: Warm, humid air entering the tank cools down and forms water droplets.

  • Water infiltration: During rain or high humidity, water may enter through tank openings.

  • Contamination from external sources: Such as seal failures in valves or connections.

 

Water in fuel or hydraulic oil can have disastrous consequences:

  • Corrosion of metal components in the tank and connected systems.

  • Formation of emulsifiers that affect lubrication, reducing the effectiveness of hydraulic oil and fuel.

  • Reduced effectiveness of additives in the fuel, impacting its performance and quality.

2

The Role of
Breathers

Protection Against Invisible Enemies

Breathers are filtration and dehumidification devices placed on tank openings to prevent airborne contaminants from entering. These vents serve a dual purpose: filtering particles from incoming air and absorbing moisture, thereby protecting the tank’s contents and any connected systems.

How Breathers Work

  • Particle Filtration: Breathers are equipped with high-efficiency air filters that trap fine particles such as dust and dirt before they can enter the tank. FMS breathers feature a 2-micron particle filter on the top, ensuring that the air entering the tank is completely clean.

  • Moisture Control: FMS breathers include dehydrators or specially sized absorbents such as silica gel, which retain 80–85% of the air’s moisture. Additionally, they contain molecular sieve material that absorbs the remaining 20–15% of moisture in the air before it enters the tank. This prevents internal condensation and helps maintain the integrity of the stored fluid.

Benefits of Breathers

  1. Corrosion Prevention: By keeping moisture out of the tank, breathers help prevent corrosion of the tank walls and the metallic components of connected systems.

  2. Improved Fluid Quality: By filtering out particles and reducing moisture, breathers preserve the purity of diesel or hydraulic oil, ensuring optimal performance.

  3. Extended Equipment Life: Clean, dry fluid reduces wear on pumps, motors, and valves, increasing equipment reliability and service life.

  4. Reduced Operating Costs: High-efficiency breathers help cut maintenance costs by preventing premature failures and reducing the need for frequent fluid and component replacement.

INLET

X = Replacement Cartridge
Y = Housing with Connector
(with splash protection)

OUTLET

Outlet
(90° Rotated View)

3

Applications
of Breathers

Fuel Storage
Tanks

Breathers in fuel storage tanks prevent oxidation and the formation of gums and deposits that can damage engines and equipment. This is essential in industrial facilities, gas stations, tanker trucks, and power systems operating with high-quality fuels.

Hydraulic Oil
Tanks

Breathers for hydraulic oil tanks protect the oil from contaminants, ensuring efficient lubrication and protecting hydraulic pumps and other high-precision components. This is crucial for heavy machinery, agricultural equipment, industrial control systems, and any application relying on high-pressure hydraulic systems.

4

Selecting the
Right Breather

Not all breathers are the same. It is crucial to select the right breather according to the type of tank and operating conditions. Some key factors to consider are:

  • Filtration capacity: Ensure the breather has the capacity to filter the particles present in your specific environment.
  • Moisture control: Choose a breather with a high-capacity desiccant if your environment has high humidity or temperature fluctuations.
  • Durability and resistance: Breathable must withstand extreme conditions such as high temperatures and corrosive environments.
  • Size and ease of installation: The breather must be compatible with your tank’s design and easy to install.

Conclusion

Invisible enemies such as particles and moisture pose constant threats to fuel and hydraulic oil storage tanks. Particle filtration and moisture control through proper breathers are essential measures to protect the quality of oily fluids (fuel, lubricating oil, and hydraulic oil), extend equipment lifespan, and reduce operating costs.

Is Your Tank Protected from Invisible Enemies?

Ensure the integrity of your fuel and hydraulic oil with a high-quality breather. Contact us today for more information on how our specialized breathers can enhance the reliability and efficiency of your operations.
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FILTRATION IN HYDRAULIC SYSTEMS ACCORDING TO THE FMS METHODOLOGY

Filtration in hydraulic systems is an essential component to ensure the system’s efficiency, durability, and reliability. Hydraulic systems, which operate under high pressure and with moving fluids, are prone to the accumulation of contaminants such as metal particles, dust, water, and other pollutants. These elements can cause premature wear of components, reduce energy efficiency, and compromise system safety.

The FMS International approach to filtration management in hydraulic systems is based on four fundamental pillars: parameter definition, clean start, effective monitoring, and staying clean. These principles ensure that the hydraulic system operates optimally throughout its service life.

1. Parameters

Most hydraulic systems (85%) fail due to contamination issues, and lubricants often require premature replacement for the same reason. For this reason, ISO 4406 parameters have been defined for hydraulic system components.

2. Clean Start

New lubricants often fail to meet ISO cleanliness standards and should enter the equipment with a code no higher than 16/14/12. However, achieving this goal requires dealing with low temperatures (viscosity) when filtering new oil.

3. Effective monitoring

Monitoring practices are often NOT the most effective, as sampling methodologies can alter results, and even more critically, there may be no predictive solutions in place to help mitigate results that fall outside the optimal ISO parameters specified by OEMs.

4. Staying clean

Oil dialysis has proven to be ineffective in many cases, as filtration systems are often not properly sized, or the equipment falls out of specification in a short time without effective monitoring to determine the appropriate interval for each dialysis.

1

Definition of
parameters

The first phase of the filtration process is the definition of parameters. Before installing any filtration system, it is crucial to define which contaminants could affect the system’s performance and what levels of cleanliness are required. Key parameters include:

  • PARTICLE SIZE: determine the range of particle sizes that can enter the system and must be removed. hydraulic systems typically need to filter particles ranging from micrometers to millimeters, depending on the sensitivity of the components.
  • HYDRAULIC FLUID CONTAMINATION LEVEL ACCORDING TO ISO 4406: The ISO 4406 standard provides a classification system for the contamination level of hydraulic fluids, based on the number of particles present in the fluid. The standard divides particles into three sizes:

VISUAL COMPARISON OF CLEANLINESS IN ISO 4406 CODES

According to this standard, hydraulic fluids are classified into different contamination levels depending on the number of particles present in each of these categories. This classification allows specifying the required cleanliness level for each hydraulic system, optimizing the selection of the filter type and the maintenance frequency.

  • VISCOSITY OF THE FLUID: Hydraulic systems operate with a variety of fluids that vary in viscosity. The viscosity of the fluid affects the filter’s ability to efficiently remove particles.
  • SYSTEM FLOW: The fluid flow rate in the system must be considered when selecting the type and size of the filter. Very high flow may require larger filters or multiple filters in parallel to avoid clogging.

2

CLEAN
START

The Clean Start principle refers to the implementation of measures to ensure that the system is free from contaminants from the start of its operation. This phase is essential to ensure that contaminants do not enter the system during installation or startup.

SOME KEY ASPECTS OF “CLEAN START” INCLUDE:

  • PRE-CLEANING OF COMPONENTS: Ensuring that all hydraulic components (pipes, valves, pumps, etc.) are free of particles and dirt before system installation. It is recommended to use cleaning procedures such as washing with specialized cleaning fluids or compressed air.
  • USE OF FILTERS IN THE START-UP PHASE: Installing temporary filters to capture any particles that may detach during installation. These filters should have a low clogging capacity to avoid interfering with the system’s startup.
  • HYDRAULIC FLUID QUALITY: Ensuring that the hydraulic fluid used from the beginning is of high quality and suitable for the system’s specifications, free from previous contaminants.

3

Effective
monitoring

Effective monitoring is key to ensuring that the hydraulic system maintains an adequate level of cleanliness during its operation. Filtration is not a static process; it requires constant monitoring to ensure that the filters are functioning properly.

SOME EFFECTIVE MONITORING METHODS INCLUDE:

  • DIFFERENTIAL PRESSURE MONITORING: Monitoring pressure through the differential between the filter’s inlet and outlet is a key indicator of its performance. An increase in differential pressure may indicate that the filter is clogged and needs to be replaced or cleaned.
  • FLUID ANALYSIS: Performing periodic analysis of the hydraulic fluid to detect the presence of contaminants such as metal particles or water. This analysis can be conducted through laboratory tests or by using inline particle sensors.
  • PERIODIC ISO4406 CODE MEASUREMENTS: Integrating laser particle counters into the system to provide real-time data on the concentration of particles in the fluid. These counters help identify issues before they cause significant damage and, most importantly, evaluate whether the bypass filter is performing its intended function.
  • REMOTE MONITORING: Implementing remote monitoring systems that allow operators to check the system’s status from distant locations. This is useful for equipment in hard-to-reach areas or when constant supervision is required.

4

Staying
clean

The final principle of the FMS International methodology is Staying Clean, which refers to the regular maintenance of the filtration system to ensure its efficient operation over time. This involves the installation of high-efficiency filters, which must be capable of controlling particles more effectively in the system, always preceded by proper dialysis with ISO 4406 certification.

THE OPTIONS AVAILABLE TO ENSURE HIGH-EFFICIENCY FILTRATION INCLUDE:

  • HIGH-EFFICIENCY BYPASS FILTER (does not require modifying the original machine setup).
  • HIGH-EFFICIENCY SUCTION AND PRESSURE FILTER (requires changing the current machine setup).
  • HIGH-EFFICIENCY RETURN FILTER (when possible, without the need to modify the original machine setup).

NOTE: There are stationary units that can use a recirculator to improve the filtration system’s performance.

SOME KEY POINTS FOR “STAYING CLEAN” INCLUDE:

  • REGULAR PREVENTIVE MAINTENANCE: Establish a preventive maintenance program that includes periodic cleaning or replacement of filters, checking the fluid condition, and verifying the monitoring system.
  • FILTER REPLACEMENT: Filters should be replaced according to the manufacturer’s recommendations or when monitoring indicates that the filter’s capacity has been exceeded.
  • CONTROL OF EXTERNAL CONTAMINATION: Reduce the entry of external contaminants into the system through measures such as properly sealing system inlets, controlling air quality with specialized breathers that prevent the ingress of particles and moisture.
  • STAFF TRAINING: Ensure that all personnel involved in the maintenance of hydraulic systems are trained in best practices to keep systems clean, from handling filters to properly installing components.

CONCLUSION

Filtration in hydraulic systems is essential to ensure the longevity, efficiency, and safety of equipment. By applying the FMS International methodology, which focuses on Parameter Definition, Clean Start, Effective Monitoring, and Staying Clean, the performance of hydraulic systems can be significantly improved, and operational costs resulting from failures and expensive repairs can be reduced. The implementation of these practices not only prevents damage from contaminants but also optimizes system performance throughout its service life.

CASE STUDY

Nicaraguan Brewing Company (CCN)
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