3. In part, or in whole, failure is inevitable when any of these are present
FUEL CONTAMINATION
7,$&)#
9$#*%&'"&#)*&23"#&1$2$6'(6&83(#$2'($(#&
+3,(1&0'#)'(&1'*"*-&+,*-<&$(1&'"&$&>%'2$%;&
8$#$-;"#&$11'43($-&+,*-&:%*$.130(!&
8+3)0-+,*#9)0:$%#
/)*%*&'"&3(*&"'2>-*&%,-*&0)*(&'#&832*"&
2'8%3:'$-&6%30#)&'(&1'*"*-&+,*-&A&'#&8$((3#&*B'"#&
0'#)3,#&#)*&>%*"*(8*&3+&0$#*%!&&
;*<'=&#
C-,16*&'"&#;>'8$--;&$&832:'($43(&3+&1'=*%*(#&
>$%48,-$#*<&'(8-,1'(6&2'8%3:'$-&6%30#)<&
3%6$('8&$(1&'(3%6$('8&0$"#*&832>3,(1"<&
0$B*"<&$(1&3#)*%&83(#$2'($(#"!&
>2/%,*$&"&2#
D-#)3,6)&$">)$-#*(*"&$%*&-*""&#)$(&EF2&'(&"'G*&'(&
#)*'%&($#,%$-&"#$#*<&#)*;&)$5*&$&#*(1*(8;&
$66-32*%$#*<&+3%2'(6&8-,"#*%"&$%3,(1&HIIAEIIF2&
#)$#&8$,"*&>%*2$#,%*&+,*-&J-#*%&:-38.$6*!&&
7,?#
D--&1'*"*-&+,*-"&83(#$'(&0$B<&$(1&0'--&83(#%':,#*&
#3&>%*2$#,%*&J-#*%&:-38.$6*!&&/)*"*&0$B*"&0'--&
8%;"#$--'G*&'+&#)*&#*2>*%$#,%*&1%3>"&$&
8*%#$'(&>3'(#&.(30(&$"&#)*&KL-3,1&M3'(#!N&&
@,)A3<*,$&2BC+)$#
C3-'1&>$%48-*"<&",8)&$"&1'%#&$(1&1,"#<&8$,"*&
1$2$6*&+,*-&";"#*2&832>3(*(#"&#)%3,6)&
1'%*8#&:31;&$:%$"'5*&0*$%&$(1&*%3"'3(!&
D,+*<)&#;$,)$2#E&)&#
5. Compounding and complex factors that are detrimental to the bottom line
The COSTs BEHIND DIRTY FUEL
Repair Costs
/)3,6)&2$(;&3%6$('G$43("&>-$(&3(&%*6,-$%&
2$'(#*($(8*<&%*>$'%&+%*?,*(8'*"&$%*&6%*$#*%&0)*(&
1'%#;&+,*-&%,("&#)%3,6)&$(&*(6'(*<&1,*&#)*&
(*6$45*&*=*8#"&3+&30"$,5+",A0"6&
Parts Costs
D-#)3,6)&1'*"*-&*(6'(*"&)$5*&)$1&"'6('J8$(#&
#*8)(3-36'8$-&$15$(8*"<&+,*-&)$"&"#$;*1&
>%'2$%'-;&#)*&"$2*<&-*$1'(6&'(8%*$"*1&>$%#&
1*6%$1$43(&$(1&%*>-$8*2*(#!&&&
Downtime Costs
/)*&23"#&1*#%'2*(#$-&$(1&
83"#-;&*B>*("*&+3%&$&:,"'(*""&
'"&#)*&'($:'-'#;&3>*%$#*!&&
S30(42*&83"#"&832>3,(1&
#)*&-3(6*%&'#&#$.*"&:*832*&
3>*%$43($-&$(1&8,#&'(#3&#)*&
:3R32&-'(*&3+&$&:,"'(*""!&&
Fuel Costs
T(6'(*"&",>>-'*1&0'#)&1'%#;&+,*-&
83(",2*&23%*&+,*-<&$"&#)*&
T(6'(*&L3(#%3-&U('#&VTLUW&)$"&
832>*("$#*&+3%&/00)#
/&)40)5,"3&&$(1&/0:&)#*022!&
This should not be the normL32>$('*"&$%*&$88,"#32*1&#)*&)'6)&83"#&3+&%*>$'%"&
$(1&2$'(#*($(8*&A&,($0$%*&#)$#&(3#&3(-;&'"&#)*&%33#&3+&
#)*&'"",*&>33%&+,*-&?,$-'#;<&:,#&#)$#&#)*&'(#*6%$43(&3+&$&
+,*-&2$($6*2*(#&>%36%$2<&0'--&%*1,8*&2$'(#*($(8*<&
%*>$'%<&$(1&>$%#"&83"#"&"'6('J8$(#-;!&
&
>*$%0<=%#'0:"A5,""0$#-ı/*&$&*.#,10+'&'(#
<"&?/&3$&'#/,)A,*#,"'#4<**#4<"3A0",*#4,+*<),"#-&6#
6. The COST OF neglect
X$(;&832>$('*"&832>%32'"*&*Y8'*(8;&%*1,8*&*B>*("*"<&
:,#&$#&0)$#&83"#Z&&[(&#)*&*(1<&#)*&%*1,8*1&*Y8'*(8;&3+&#)*&
*(6'(*&0'--&:*&$&>%*8,%"3%&832>-*#*&8$#$"#%3>)'8&+$'-,%*!&
F*A5,$&*.(#$%Į$#04#3,$,2$)0/%+3#4<"3A0",*#4,+*<),)#
0<$:&+=%2#$%Į$#04#/)&1&"A0"6#
The ultimate price is paid when neglect becomes common
Efficiency Vs. Failure
7. Explicit Costs
Explicit
costs,
an
absolute
monetary
value,
are
the
first
figures
seen
when
an
opera4onal
problem
arises,
i.e.
system
failure.
These
are
common
costs
typically
expected
and
budgeted.
These
costs
include:
Ø Replacement
Parts
• Filters
• Injectors
• Rota4onal
Assembly
(pistons,
crank,
etc.)
• Pumps
• Valves
Ø Shipping
Costs
Ø Labor
Costs
Ø Re-‐Fueling
Costs
Ø Miscellaneous
Costs
• Clean
Up
• Emergency
Backup
Equipment
Acquisi4on
Implicit Costs
Implicit
costs
are
considered
the
silent
killer,
and
stem
from
the
inability
to
run
the
business
as
normal.
These
costs
are
o`en
not
taken
into
considera4on,
despite
having
a
significant
impact
on
the
boRom
line
of
a
business.
These
costs
include:
Ø Loss
of
Business
Revenue
Ø Loss
of
Perishable
Inventory
Ø ReducAon
in
ProducAvity
Ø Delays
in
ProducAon
Ø Increased
Resource
Usage
• Idle/Standby
vehicles
consuming
fuel
• Shi`
of
workload
Often an oversight, true and potential loss are more than just estimates
OPPORTUNITY COSTS
8. Warranty claims are investigated&
@*+3%*&$(&b%'6'($-&T?,'>2*(#&X$(,+$8#,%*%&
VbTXW&>$;"&3(&$&0$%%$(#;&8-$'2<&#)*;&0$(#&
#3&*(",%*&#)*&+$'-,%*&0$"&1'%*8#-;&%*-$#*1&
#)*&*(6'(*!&[#&'"&+3%&#)'"&%*$"3(&#)$#&bTX"&
0'--&'(">*8#&$(1&"$2>-*&#)*&*?,'>2*(#&$(1&
+,*-!&&[+&+,*-&'"&+3,(1&:*&3,#&3+&">*8<&#)*&
bTX&8-$'2"&#)*&%'6)#&53'1&#)*&0$%%$(#;&
3+&#)*&*?,'>2*(#!&
]3%&*(6'(*&2$(,+$8#,%*%"<&#)*&[Cb&ccId&
%*?,'%*2*(#&'"&LMBLNBLO!&&]3%&'(7*8#3%&
2$(,+$8#,%*%"<&LPBQBN!&&[(&3%1*%&$8)'*5*&
#)*"*&8-*$(-'(*""&-*5*-"<&+,*-&%*?,'%*"&23%*&
#)$(&7,"#&J-#%$43(!&&],*-&2$($6*2*(#&'"&$(&
'2>3%#$(#&"#*>&'(&*(",%'(6&3>42$-&+,*-&
?,$-'#;!&],*-&'"&:*'(6&"$2>-*1&+%32&$(&*(6'(*&$`*%&0$%%$(#;&8-$'2&
Contaminated fuel can void engine and injector warranties
Warranty Loss
10. Fuel
Status
Min
Life
Max
Life
Injectors
per
Year
Cost
per
Year
Unacceptable
<
2,000
2,000
0.20
$30,000.00
Max
Engine
2,000
5,000
0.35
$17,142.86
Pref.
Engine
5,000
20,000
1.25
$4,800.00
Pref.
Injector
20,000
20,000
2.00
$3,000.00
Annual
Hours
of
Usage
10,000
Hours
per
Year
Cost
of
Fuel
Injector:
500.00
Dollars/Injector
Injectors
Per
Engine:
12
Injectors
FUEL INJECTOR COSTS
Equipment
efficiency
isn’t
the
only
concern
regarding
contaminated
fuel.
Fuel
system
component
costs,
along
with
down4me
and
missed
revenue
can
have
an
even
larger
effect
on
the
boRom
line
of
a
business.
11. Engine
Life
10,000
Hours
600,000
Minutes
36,000,000
Seconds
Engine
Speed
1400
RPM
Average
Engine
Type
4
Stroke
Compression
Strokes
350
Per
Minute
Injec4on
Events
5
Per
Revolu4on
1750
Per
Minute
29.17
Per
Second
Life
Cycle
1,050,000,000
Cycles
FUEL INJECTOR LIFE CYCLEINJECTOR LIFE CYCLE CALCULATOR
To
beRer
understand
the
poten4al
degrada4on
to
injectors
and
other
sensi4ve
engine
components,
it
is
important
to
comprehend
their
life
cycle.
Wear
and
surface
degrada4on
isn’t
the
result
of
a
single
injec4on
event,
but
is
a
con4nual
process
occurring
throughout
the
life
of
the
engine.
12. Fuel injection requirementsFuel Injection system – Past and Present requirements
Time
Frame
1990
1995-‐2000
2005-‐2006
2010
2015
Emissions
Tier
0
Tier
1
Tier
2
Tier
4a
Tier
4b
Engine
Fuel
System
19
Liter
PT/STC
HPI
MCRS
MCRS
MCRS
23
Liter
-‐-‐-‐
HPI
MCRS
MCRS
MCRS
30
Liter
PLN
PLN
CRS
CRS
CRS
38
Liter
PT/STC
PT/STC
MCRS
MCRS
MCRS
45
Liter
-‐-‐-‐
HPI
MCRS
MCRS
MCRS
50
Liter
PT/STC
PT/STC
MCRS
MCRS
MCRS
60
Liter
-‐-‐-‐
HPI
MCRS
MCRS
MCRS
78
Liter
-‐-‐-‐
-‐-‐-‐
HPI
TBA
TBA
InjecAon
Pressure
1200
PSI
1400
PSI
1600
PSI
1800
PSI
2000
PSI
InjecAon
Events
1
1
2-‐3
3
3+
Final
FiltraAon
25
Micron
10
Micron
3
–
3
Micron
<3
Micron
<3
Micron
Pre-‐filtraAon
none
none
7
Micron
7
Micron
7
Micron
As
environmental
regula4ons
con4nue
to
become
less
tolerant
of
pollutants,
requirements
for
fuel
injec4on
systems
have
become
more
stringent.
These
requirements,
known
as
Tier
Ra4ngs,
establish
a
maximum
limit
of
par4culate,
sulfur,
and
other
forms
of
harmful
maRer,
to
be
allowed
in
fuel
in
order
to
become
compliant.
CRS
–
Common
Rail
System
HPI
–
High
Pressure
InjecAon
MCRS
–
Modular
Common
Rail
System
PLN
–
Pump
Line
Nozzle
PT/STC-‐Pressure-‐Time/Step
Timing
Control
(Injector
System)
TBA
Source-‐
PALL
Corpora4on
Presenta4on
28. The value of peace of mind
“Should
you
find
yourself
in
a
chronically
leaking
boat,
energy
devoted
to
changing
vessels
is
likely
to
be
more
produc;ve
than
energy
devoted
to
patching
leaks.”
–
Warren
BuffeB
Reliability
builds
confidence,
not
only
for
business
owners,
but
investors,
clients,
and
employees
alike.
When
a
business
invests
in
reliability,
they
are
securing
the
boRom
line,
and
in
turn,
the
future
of
their
business.
Starts in the tank with clean fuel
The ultimate Protection
your fuel
Contamina4on-‐free
fuel
can
deliver
more
power
and
lubrica4on
poten4al,
increasing
fuel
efficiency
Your systems
Clean
fuel
ensures
a
longer
lifespan
for
injectors
and
other
cri4cal
components
by
mee4ng
OEM
specifica4ons
Your business
Elimina4ng
debilita4ng
fuel
contamina4on
ensures
business
doesn’t
stop
for
unplanned
repairs
Your future
Extending
the
lifespan
of
fuel
and
equipment
sets
the
founda4on
for
long
term
opera4on
and
protec4on
29.
¡ Natekar,
A.
&
Menzel,
M.
(2010).
The
Impact
of
Tier
4
Emission
Regula4on
on
the
Power
Genera4on
Industry.
Cummins
Power
Genera4on.
¡ Understanding
the
Cost
of
Data
Center
Down4me:
An
Analysis
of
the
Financial
Impact
on
Infrastructure
Vulnerability.
(2011).
Emerson
Network
Power.
¡ Schaeffer,
A.
(2015).
More
Clean
Diesel
Trucks
Now
on
the
Road
Means
Lower
Fuel
Consump4on
and
Fewer
Greenhouse
Gas
Emissions.
hRp://www.dieselforum.org/cleandieseltrucking
¡ Spence,
R.
(2014).
How-‐To:
Combat
Unplanned
Equipment
Down4me.
Retrieved
from:
hRp://www.miningglobal.com/machinery/1107/How-‐To:-‐Combat-‐Unplanned-‐
Equipment-‐Down4me
on
Sept.
24,
2015.
¡ Theron,
A.
(2015).
Global
Revenue
for
Gensets
to
Reach
$68bn
in
2024,
Says
Report.
Retrieved
from:
hRp://www.esi-‐africa.com/global-‐revenue-‐for-‐gensets-‐to-‐reach-‐68bn-‐in-‐2024-‐says-‐
report/
on
Sept.
28,
2015
¡ True,
B.
(2002).
New
Solu4ons
for
Improving
Power
Plant
Asset
Availability.
Retrieved
from:
hRp://www.electricenergyonline.com/show_ar4cle.php?mag=&ar4cle=69
on
Sept.
25,
2015
SOURCES¡ Bulk
Diesel
Fuel
Filtra4on
for
Mining.
(2009).
Retrieved
from:
hRp://www.pall.com/pdfs/Industrial-‐Manufacturing/IMBULKDEN.pdf
on
Sept.
25,
2015
¡ Christensen,
P.,
Graf,
W.,
&
Yeung,
T.
(2013).
Refinery
power
failures:
causes,
costs
and
solu4ons.
Retrieved
from:
hRp://www.qualitrolcorp.com/uploadedFiles/Siteroot/Industry_Solu4ons/Refinery%20Power
%20Failures%20-‐%20Causes%20Costs%20and%20Solu4ons.pdf
¡ Cummins,
Inc.
(2015).
Agriculture.
Retrieved
from:
hRps://www.cumminsfiltra4on.com/html/en/about_us/markets/agriculture.html
on
Sept.
14,
2015
¡ Data
Center
Outages.
(2013).
Ponemon
Ins4tute.
PDF.
From:
hRp://www.emersonnetworkpower.com/documenta4on/en-‐us/brands/liebert/infographics/
documents/ponemon-‐infographic-‐cost%20of%20down4me-‐r11-‐13-‐final.pdf
on
Sept.
28,
2015
¡ DhuyveRer,
K.
(2014).
Machinery
Costs
&
Efficiencies:
What
are
the
Driving
Factors?
Retrieved
from:
hRp://www.agmanager.info/Faculty/dhuyveRer/presenta4ons/2014/
KCD_MachineryCosts&EfficienciesKARTA(Jan2014).pdf
on
Sept.
25,
2015
¡ Diesel
At
Work,
Power
Genera4on.
(2015).
Retrieved
from:
hRp://www.dieselforum.org/diesel-‐at-‐work/power-‐genera4on
on
Sept.
25,
2015
¡ Mallik,
A.
(2014).
Fuel
economy
standards
drive
down
projected
gasoline
use;
diesel
use,
product
exports
rise.
¡ Monthly
Biodiesel
Produc4on
Report.
(2015).
U.S.
Energy
Informa4on
Administra4on.
Retrieved
from:
hRp://www.eia.gov/biofuels/biodiesel/produc4on/
on
Sept.
25,
2015