iFLEET - Combat Injection Failure

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Combat Injector Failure
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Improve Fuel Lubricity
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Combat Injector failure

Modern Fuel Injection Systems operate at very high injection pressures with dramatically reduced clearances.

One of the main culprits of modern engine failures
Fact: 50-75% of modern engine failures are directly due to fuel system injector failure

Low lubricity and contamination (water, particle, surfactants and parrafin) are the two main reasons for injector failure.

Please read lubricity and contamination sections for more detail.

This simple graph gives an indication on how pressures and tolerances have changed in modern engines with fuel injector pressures exceeding 1800 bar, combustion pressures of 180 bar and micron clearances between moving parts. It is clear that a great challenge is on the horizon as we are now entering Euro 3 standards with Europe at Euro 5 levels. Euro 5 levels can only be achieved by treatment of emissions with either EGR or catalytic converters.

The one common challenge is how carbon "soot" generation, lubricity sensitivity and contamination increase exponentially with the change in Euro levels. The more these factors are addressed, the more economically these engines will perform. The slightest deviations on any of these factors will have costly results.

iFLEET fuel catalyst is a Material Lubricity Improver, which improves lubricity in all fuels. It even will protect against "Spiked" diesel.

Lubricity increased 42 -48% on dosing ratio 1:500 as tested on HFFR

Combustion Related Piston Damage
		Piston Damage Caused by Injector Failure iFLEET fuel catalyst not only prevents piston damage due to unburn't fuel, but also acts as a fuel saver and a Fuel Injector Cleaner.

Piston Damage Caused by Injector Failure

Spray Pattern of Defective Injector

Sleeve Damage Caused By Defective Injector

Correlation Between Piston Damage and Spray Position

Injector Needle Damage

iFLEET fuel catalyst is a Fuel Injector Cleaner

Fuel Effect's unique Fuel Additive is a Fuel Injector Cleaner

Damaged Fuel Injector
iFLEET fuel catalyst's unique Fuel Additive is a Fuel Injector Cleaner and increases Fuel Lubricity, which prevents injector damage. The more advanced technology the faster failure happens.

Needle Damage as Seen Under Microscope

Experience in Southern Africa has shown huge variations in Diesel Fuel. The present picture in Southern Africa shows two trends. The first is obvious in early engine failures, often well within warranty periods. The second is less obvious in reduced power and/or increased fuel usage high exhaust temps shorter engine lives

As the injectors wear atomization becomes less efficient, the droplets become larger, larger droplets take longer to burn, the heat does not go out.
In summary, the rate of injector wear increase with pressure, particle size, particle number, reduced viscosities and low lubricity
Easier starting especially on cold and old engines
Observed noise levels from injectors decreased especially on older models
The less obvious in reduced power and/or increased fuel usage, raised exhaust temps, shortened engine life
Thinner and lighter diesel fuels will result in more abrasive wear, also increase in consumption
In summary, low lubricity fuel can cause premature engine failures and reductions in engine performance and life

Wear and embedded particles in lift pump valve seat	Score marks on the top of needle	Score marks on Plunger stem

Worn delivery valve seats	Pump Plunger excessively worn at metering area	Carbon build up in the ring groove

Carbon build up in the ring groove	Carbon build up above the top ring	Burned Piston

Photo's courtesy of At Von Wielligh, PTA University

In summary iFLEET fuel catalyst is a Fuel Additive, which amongst other things, is as a Fuel Saver, Diesel Lubricity Improver and a Fuel Injector Cleaner. The product provides an optimum uniform fuel blend and open wax structures, which promotes complete fuel combustion with reduced toxic emissions and increased lubrication.

Engine Builders have been under huge pressure to Reduce Emissions and Improve efficiencies.

Fuel Companies have been under pressure to produce Fuels and Oils to satisfy the same demand.

Rates of Progress between these two players can vary in different parts of the world

Diesel engine failures caused by fuel with insufcient lubricity - A.J. von Wielligh
CAT POWER SYSTEMS Tech Tips Diesel Fuels and You engine
Fleetwatch Feb 2007 - Lorry Lurgy