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Marine Diesel Center...

   "Diesel is What We Do"

Clean Fuel--Critical to the

performance and dependability of your diesel.  We can provide you with improvements to your filtering and separation system  which can make a big difference.  If you want, we can provide you with the ultimate fuel system...Learn more

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Installation of an Advanced Fuel Purification System—

A Case Study

 

Our staff was approached by a knowledgeable owner of an Amel sailboat who was looking for a dependable and serviceable fuel separation and filtration system.  He wanted a dual filter arrangement that would allow him to service one filter while the engine was running and supplied by the other.  Like many blue water cruisers, he had a "belt and suspenders" attitude when it came to the design of the system.

Rather than just installing the "Y" valved system he asked for, we spent some time talking with him in order to understand his fuel use habits.  As is typical of many sailboats he did not consume that much diesel every season and we advised him that fuel stability, water accumulation and sludge production were significant issues.  Accordingly, instead of the double Racor system, we recommended a less costly  fuel purifier by RCI Technologies and an Algae-X® fuel conditioner coupled with his existing single separator and engine mounted fuel filter.

The fuel purifier would prevent 95% of the sludge, water, and particles larger than 5 microns from reaching his filter elements while the conditioner would help to reduce the sludge, wax, gum and tar that is a product of diesel fuel breakdown. 

In addition we noted that the use of an electric fuel pump would allow him to cycle his fuel, allowing the purifier, conditioner and filter/seperator to clean and condition the fuel in his tank.  The electric pump also served as a backup to the primary fuel pump and would allow for easy priming of the system.

The customer understood and agreed with our analysis, but also specified the inclusion of a dual Racor unit.  Yes, certainly "belt and suspenders" but definitely an effective and dependable fuel separation, filtration, and conditioning and an on-board fuel polishing system.

 

Let's Look at an Actual Installation as We Track the

Flow of Diesel Fuel from the Tank to the Engine

 

Note: Throughout the installation we used hose clamps and common pipe and flare fittings.  We eliminated banjo fittings as well as proprietary connectors that were permanently crimped to hoses. 

 

Why?  The resulting hoses, connections and fittings are owner serviceable and standard parts are available virtually anywhere in the world.  The installation may not look quite as slick, but it is every bit as dependable and can easily be serviced or fixed by owners or mechanics anywhere.

 

First, the Auxiliary Electric Diesel Fuel Pump

 

Read About Our Philosophy on Fuel System Fittings

 

Note that the electric pump is mounted first in the system and can--when switched on via a remote switch--provide fuel pressure to the entire system.  This provides the following benefits:

  • With positive pressure from the electric fuel pump (not necessary for engine operation) the fuel purifier can be purged while the engine is operating--this is not possible with the engines primary lift pump that operates with suction.  With the primary lift pump operating and the electric fuel pump operating while the engine is running, the Racor suction/pressure gauge registers 7 pounds of positive pressure. Note that the Stewart Warner fuel pump we use is internally regulated to provide an optimal 7 pounds of pressure.
  • The pump can also be switched on at port to polish the fuel.  With the ball valve on the polishing return line closed, the pump slowly pumps fuel through the purifier, seperator, filter and engine bypass at the injector pump.  However, with the polishing return line open, the pump more rapidly pumps fuel through the system to provide polished fuel back into the tank.
  • The pump is relatively quiet, but just loud enough that it can be detected when the engine is off--very handy if you don't happen to remember that you've got a fuel polishing session going!
  • In addition, the Stewart Warner electric diesel fuel pump also functions as a backup to the primary mechanical fuel lift pump should it fail.  During engine use the electrical fuel pump need not be switched on--fuel flows freely through the pump when it is switched off..
  • The electric fuel pump can also be used to bleed the system in the event that there is a problem (unlikely in this system unless the boat's diesel fuel tank runs dry)
  • When one of the dual filters is changed, you can open the polishing return valve and use the electric pump to prime the dry filter and bowl and eliminate the possibility of any air bubbles in the fuel loop--you're ready to go if and when you need to
  • Finally it facilitates leak detection in the fuel system by positively pressuring  the fuel through its entire path including the return lines.  This is not possible with the suction based mechanical primary fuel pump.

 

We positioned the waterproof pull-push switch in the engine room so that the operator is positioned to monitor the fuel system and read the Racor pressure gauge when turning on the system.  It is also an ideal location if you are bleeding or priming the system.  Other arrangements including a timer or indicator light are possible.

 

 

Next, the Fuel Flows Through the RCI Marine Fuel Purifier

 

This unique device uses centrifugal and coalescence separation principles to remove up to 100% of the water and 95+% of contaminants from the diesel fuel BEFORE it goes to your primary filter or filter/separator!

 

Ever wonder how professional fuel polishers filter hundreds of gallons of fuel without going through a million Racor filter elements?  The answer is in this type of device--you will see them on their fuel polishing units.  It simply prevents the lion's share of water and contaminants from ever reaching the filter element or water separation bowl of the primary filter or filter/separator.  It vastly reduces any filter clogging!

 

It contains no replaceable elements and has no moving parts.  It requires no maintenance except purging (draining) the contaminants and water via a UL approved brass drain valve at the bottom of the unit.

 

The blue marine version of this purifier differs from the versions used on trucks, buses and emergency vehicles in that it has a specially designed baffle system that prevents contaminants from migrating to the outlet in rough seas.  It also uses a special powder coating and stainless mounting hardware.  You can learn more about this useful fuel component by visiting the RCI Technologies site awww.rcipurifier.com

 

Click to View the RCI Technologies Site

 

 

Then, On to the Algae-X® Fuel Conditioner

 

The LG-X fuel conditioner is designed to reverse the effects of fuel deterioration and the agglomeration of particles that build into filter clogging entities.  You can read more about this by visiting our page Algae-X® Answers FAQ's on Diesel Fuel or by visiting the Algae-X site at www.algae-x.net

 

 

 

Note that the Algae-X conditioner is allowed to be mounted in any orientation except with the flat edge up this allows a sturdy snug mount close to the intake fitting of the Racor assembly.  Notice the output fitting from the filters directly behind the input.  The brass T on the output allows filtered fuel to be routed to the owner's Espar forced air diesel heater.   A check valve was also installed to assure that no air or fuel was allowed to pass into the engine line while the engine and heater be operated simultaneously.  Racor uses double ball valves connected to the control handle to valve both fuel input and output.

 

 

And Finally...the Racor 75/500Max Filter/Water Separator

 

The Racor 75/500MAX uses Separation (large solids and free water are separated using enhanced centrifugal force, Coalescing (smaller water droplets gather on the conical baffle and fall to the collection bowl) and Filtration (use of water repelling Aquabloc™ media and replaceable filter elements) to assure that any contamination making it past the RCI purifier is stopped.  It uses a see through contaminant collection bowl to allow the user to check for contamination and has metal shields to adhere to the USCG requirement for fire and heat resistance. 

 

It also uses a vacuum/pressure gauge to help determine when a filter element needs to be changed.

 

With a maximum flow rate of 120 gallons per hour it is more than adequate for most small and medium sized diesel engines, even when considering normal fuel bypass or operating in the fuel polishing mode.  We also can obtain larger capacity units from Racor.

 

It features a control handle that allows an operator to service one filter while the other continues to supply diesel to the engine.

 

The single handle provides Off (pointer up), Left (pointer left), Right (pointer right), and Both (pointer down) positions and controls both the input and output through two linked ball valves.

 

 

Although two separate filters can be plumbed together to create the same arrangement, the Racor 75/600 allows the use of one control handle to simultaneously  control the two ball valves.  The compact arrangement also allows  mounting on a single teak plywood board for a neat, organized, and rugged installation.  It also weighs a reasonable 17 lbs.

 

We haven't found the installation and information sheet that comes with the unit anywhere on the internet, so we've taken the trouble of scanning it and converting it to a PDF document for you if you want to read more--it is a large file (1.5 MB so give it time to load)  racor_75_500.pdf 

 

If you are interested in an advanced filtration/separation system or even an on-board fuel polishing system please contact us We can provide the parts, expert and experienced installation, or just give you some advice. 

 

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