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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Diesel Fuels
Diesel fuel quality is an important factor in satisfactory engine life and
performance. Fuels must provide adequate combustion without producing
excess contaminates that can harm the engine. Additionally, fuel selection
involves economic and environmental considerations. The availability of
certain grades of diesel fuels may be cost prohibitive or inappropriate for
various applications. This Application and Installation Guide provides
information on the various diesel fuel oil types and how they relate to
Caterpillar engine installations.
SECTION CONTENTS
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SECTION CONTENTS
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Control Module (ECM) to control the delivery and timing of the fuel
amount of fuel injected into the injection(s). Similar to some other
cylinders. A solenoid on each systems, the common rail fuel
injector receives voltage signals from system has capability of multiple
the ECM to become energized. The injections for a given combustion
injectors will inject fuel only while event.
the injector solenoid is energized. The main components of a
The ECM controls the amount of common rail system include the
fuel that is injected by varying the high-pressure pump, the high-
signals that are sent to the injectors. pressure lines and rail system, and
By controlling the timing and the the injectors. The low-pressure fuel
duration of the voltage signal, the system utilizes similar components
ECM can control injection timing and to the unit injector fuel system. See
the amount of fuel that is injected. Figure 2 for a schematic of the
common rail fuel system.
HEUI Fuel System
The common rail fuel system does
The Hydraulically actuated
not continually circulate fuel through
Electronically controlled Unit
the entire system like the unit
Injectors (HEUI) use a hydraulic
injector fuel system. Instead, small
pump and engine oil to generate fuel
amounts of fuel are bypassed during
injection pressure, and an ECM to
the injection event. Due to the very
control the pressure and amount of
high pressure in the fuel manifold,
fuel injected into the cylinders.
more heat is put into the fuel than
The operation of the HEUI fuel on previous systems. Because of the
system is completely different from additional heat added to the fuel, it
any other type of fuel system that is is critical that the fuel inlet
actuated mechanically. The HEUI temperature is maintained within
fuel system is completely free of guidelines provided for the engine
adjustment. Changes in performance model. Recommended, and
are made by installing different sometimes required, is the use of a
software in the ECM. fuel cooler to maintain the
appropriate inlet fuel temperature.
Common Rail Fuel System Otherwise, the overheated fuel will
Unlike the MEUI fuel system, in a
have very low viscosity and film
common rail fuel system injection
strength which makes the fuel
pressure is created external to the
system components, especially the
unit injectors in a high-pressure fuel
injectors, more susceptible to
pump which is driven off the engine.
damage from fuel contaminants and
The pump pressurizes a high-
wear, hence the importance of
pressure fuel manifold that runs
proper filtration practices on
along both sides of the engine
common rail engines.
feeding high pressure fuel to the
injectors. The electronic fuel
injectors at each cylinder control the
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Figure 1
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Figure 2
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Figure 3
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Figure 4
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Diesel Fuels & Diesel Fuel Systems Application and Installation Guide
Figure 5
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Fuel returning to the main tank generally should not exceed the
may, because of its volume, aid with engine injector’s height. This
cooling, but returning to the day prevents possible fuel leakage into
tank is permissible. cylinders.
Above ground tanks provide
Fuel Tank Design
accessibility, allowing for easy
Considerations draining of impurities and reducing
Fuel Tank Sizing the danger of ground water
The fuel tank is typically one of the contamination.
least expensive items in an Underground tanks allow the earth
installation, and it is wise to provide to work as an insulator, limiting
too much, rather than too little, radical temperature changes which
storage capacity. However, while can cause flow restrictions,
the minimum required capacities of condensation, and possible power
fuel tanks can be estimated, as loss. Seasonal settlings are also
outlined in the previous discussion of avoided when burying the tank
fuel tanks, some applications may below frost line. In underground
need to meet the requirements of tanks, the water must be removed
outside organizations, such as the by pumping through a tube placed
U.S. National Electrical Code (NEC) down the fill pipe.
or National Fire Protection
Regulations governing the
Association (NFPA).
installation and maintenance of both
Fuel Tank Material above and below ground fuel tanks
Fuel tanks made from low carbon may apply.
rolled steel are best. Locate storage tank fill tubes for
CAUTION: Zinc, either in the form of convenience and safety of filling
plating or as a major alloying operations. Vents are necessary to
component, should not be used with relieve air pressure created by filling
diesel fuels. Zinc is unstable in the and prevent vacuum as fuel is
presence of sulfur, particularly if consumed.
moisture is present in the fuel. The
Fuel Tank Drains
sludge formed by chemical action is
All fuel tanks should have easily
extremely harmful to the engine’s
accessible drain connections. Water
internal components.
and sediment that collects in the
Fuel Tank Installation bottom of the tank must be
Large capacity storage tanks allow eliminated regularly. Provide clean-
bulk purchases and minimize dirt out openings for periodical removal
contamination. Maintaining full tanks of sediment and trash that settles
reduces condensation, particularly if out of fuel tanks.
fuel is seldom used. Well-designed tanks have large
Tanks may be above or below enough clean-out openings so the
ground level, but high fuel level
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
between the day tank and engine of a fuel transfer system is shown in
exceeds the requirements discussed Figure 6.
in Auxiliary Fuel Tanks. An example
Typical Fuel Transfer System
(Distillate Fuel Supply System)
Figure 6
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
• Coalescing filter systems work two (2) centrifuges, with one of the
effectively to remove centrifuges acting as a standby.
sediment and water. If the The required flow rate of a
level in the day tank is not centrifuge can be approximated as
maintained at a consistent follows:
level, install them between
P x b x 24 x 1.15
the main tank and the day Q=
tank. If proper day tank levels Rxt
are maintained, a smaller
system can be used between Where:
the main tank and the day
tank to clean only the fuel Q= Flow required, L/hr
being burned. These filters P= Total Engine Output, kW
can plug and careful attention b= Fuel Consumption, g/kW-hr
must be given to fuel pressure
R= Density of fuel, kg/m3
levels at the injectors to guard
against misfiring. T= Daily separating time in
• A centrifuge system can be automatic operation: 23 hr
used, particularly if the fuel
quality consistently falls Or:
below the defined limits
f x be x 24 x 1.15
discussed in this guide. Q=
Rxt
Centrifuges
The centrifuge represents the most
expensive and complex method of Where:
water separation, but it is the most Q= Flow required, gal/hr
effective. It is used extensively in
P= Total engine output, bhp
marine, offshore and power
generation applications where a Be= Specific fuel consumption,
continuous power supply is lb/bhp-hr
essential, and the continuous supply R= Density of fuel, lb/gal
of clean fuel cannot be left to T= Daily separating time in
chance. A typical distillate fuel automatic operation: 23 hr
centrifuge schematic is shown in
Figure 9. Note the following considerations
for configuring a centrifuge.
A centrifuge manufacturer should
be consulted to determine the proper • The centrifuge manufacturer
centrifuge type, size and flow should assist in the final
requirements for a specific centrifuge selection.
application. • The centrifuge flow has been
increased by 15% as a safety
While Figure 9 shows a single factor for operational
centrifuge schematic, many tolerances.
applications will require the use of
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Figure 9
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Figure 10
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Appendix 1
heat transfer from the tank to the
Day Tank Sizing (When surrounding environment due to the
Day Tank Serves as a Heat temperature difference between the
Sink) fuel mix temperature and the
ambient temperature. This
The fuel supply temperature must convective heat transfer then
be within specified limits for determines the resultant tank
optimum injector life and maximum temperature. The fifth step evaluates
power capability. the impact of the final fuel supply
Fuel systems without fuel coolers temperature on the engine’s
rely on the day tank to dissipate the maximum power capability.
heat of fuel returning from the The included example calculations
engine. Day tank temperatures are should only be used to provide
affected by the following conditions. general guidance. If the day tank
• Day tank wetted surface area size is marginal, use a fuel cooler.
(including tank bottom) To simplify the following
• Engine(s) fuel consumption calculations, it is assumed the day
rate tank walls are surrounded by free
• Day tank replenishing level moving air. If the tank walls are
• Storage tank fuel temperature contiguous to the shell plating, heat
• Ambient temperature transfer from the day tank will be
• Spaces contiguous to the day enhanced. Conversely, if the day
tank (void tanks, cofferdams, tank is bounded by void spaces and
vessel shell plating, etc.) cofferdams, heat rejection from the
• Return fuel temperature day tank will be retarded. Typically,
Tank temperature calculation are most day tanks are located with
performed in five [5] steps. The first various combinations of the
determines the fuel mass in the tank preceding boundary elements. The
at each time interval. The second individual performing the evaluation
step is based on a fuel mix must be familiar with the installation
temperature resulting from the as well as the fundamental
engine driven transfer pump flow engineering concepts of the formulas
rate to the engine and the return used in the calculations.
flow rate to the day tank. The third
step determines the day tank fuel Day Tank Calculations
height for each incremental time The following information is
element. Typically, the calculations required to perform the calculations:
will be based upon a 30-60 minute • Engine model
iterative time function. The end • Engine developed power (MCR
point for the calculation is assumed or CSR)
to be when the day tank is refilled. • Engine speed
The fourth step approximates the
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Q
∆TENG = Incremental Tank Fuel Capacity
Mrtn x Cp Time (Min) Quantity (lb) (%)
0 40258.6 100.0
60 38746.0 96.2
1252 Btu/min
= 120 37233.4 92.5
(109.70 lb/min x
180 35720.8 88.7
0.5 Btu/lb-°F)
240 34208.2 85.0
300 32695.6 81.2
= 22.83°F 360 31183.0 77.5
420 29670.4 73.7
480 28157.8 69.9
5. 95% Capacity of Diesel Oil Day
540 26645.2 66.2
Tank, (lb)
600 25132.6 62.4
Weight density (p) for #2 diesel
660 23620.0 58.7
oil = 52.42 lb/ft3
720 22107.4 54.9
MDT = L x W x H x pDO = 12 ft x Refill 40258.6 100.0
8 ft x 8 ft x 52.42 lb/ft3 = Table 6
40258.6 lb.
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Step 2
Calculate the fuel oil mix temperature (Tmix):
MDT(t -1) - [(Mxfer x t)] TDT(t -1) + (MRTN x t) x (TDT(t -1)+ ∆ TENG)
MDT(t -1) - (MBR x t)
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Incremental Mix
Time (Min) Temperature (°F)
0 85.0
60 88.9
120 92.9
180 97.1
240 101.5
300 106.1
360 110.9
420 116.0
480 121.3
540 126.9
600 132.9
660 139.3
720 146.1
Refill
Table 7
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Step 3
Calculate the height of fuel Incremental Time
contained in the day tank at t = Height (ft)
(min)
incremental time step. Prepare a 0 8.0
summary table for each time 60 7.7
increment (t) as shown in Table 8. 120 7.4
180 7.1
240 6.8
MDT
H= 300 6.5
pxLxW
360 6.2
420 5.9
Where: 480 5.6
H = Height of fuel in the tank 540 5.3
600 5.0
MDT = Fuel contained in the day
660 4.7
tank at each incremental time
720 4.4
step
Refill 8.0
p = Weight density of #2 DO
Table 8
(52.42 lb/ft3)
L = Length of day tank (12 ft)
W = Width of day tank (8 ft)
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Step 4
Calculate the heat transferred between the fuel in the day tank and the
atmosphere, the ∆T of the fuel in the day tank due to the heat transfer, and
the resulting fuel day tank temperature.
a. Heat transferred between the day tank and the atmosphere:
(TMIX + TDT)
QTK = U x [ (H x (2L + 2W) + (L x W) ] x [ TAMB -
2 ] xt
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time step. The resulting value for QTK This process is then repeated for
is then used to compute the ∆ TDT. each incremental time step.
∆TDT is then used to determine TTK.
Example a.:
(TMIX + TDT)
QTK = U x [ (H x (2L + 2W) + (L x W) ] x [TAMB -
2 ] xt
(88.9 + 85)
QTK =0.0424 x [7.7 (40) + 96] x [ 95 -
2 ] x 60
QTK = 8283.6 Btu
Example b.:
QTK
∆ TDT =
MDT x Cp
8283.6 Btu
∆ TDT =
(38746.0 lb) (0.5 Btu/lb °F)
Example c.:
TDT = TMIX + ∆TDT
TDT = 88.9 °F + 0.43°F
TDT = 89.3 °F
This series of calculations is then repeated for the subsequent incremental
time steps.
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Prepare a summary table for each time increment (t) as shown in Table 9.
Incremental Time Heat Rejection to/from Temperature Chg. in Day Tank Temperature
(min) Day Tank (Btu) Day Tank (°F) (°F)
0 - - 85.0
60 8283.6 0.43 89.3
120 4069.7 0.22 93.2
180 -4.0 0.00 97.1
240 -4022.0 -0.24 101.3
300 -7966.3 -0.49 105.6
360 -11818.7 -0.76 110.2
420 -15561.4 -1.05 114.9
480 -19257.8 -1.37 120.0
540 -22802.6 -1.71 125.2
600 -26253.3 -2.09 130.8
660 -29655.5 -2.51 136.8
720 -32973.6 -2.98 143.1
Refill - - 116.9
Table 9
Where:
MDT full = Capacity of day tank, (lb)
MDT tn = Fuel in day tank prior to refilling, (lb)
TMUF = Temperature of make-up fuel, (°F)
TTK n = Temperature of tank fuel prior to refilling, (°F)
Example:
[(40258.6 - 22107.4) x 85] + (22107.4 x 143.1)
TDT refill =
40258.6 lb
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Step 5
The last step calculates the Corrected
Incremental Day Tank
maximum power capability of the Engine Power
Time (min) Temp. (°F)
(bhp)
engine at the resultant day tank
temperature for each time interval. A 0 85.0 -
summary table for each increment (t) 60 89.3 4625
is also prepared and shown in Table 120 93.2 4607
10: 180 97.1 4588
240 101.3 4569
Note: The engines are power set at
300 105.6 4549
the factory with 30 ±3°C (86
360 110.2 4528
±5°F) fuel to the engine transfer
420 114.9 4506
pump. Higher fuel temperatures 480 120.0 4482
reduce maximum power capability. 540 125.2 4458
The fuel stop power reduction is 1% 600 130.8 4432
for each 5.6°C (10° F) fuel supply 660 136.8 4405
temperature increase above 30°C. If 720 143.1 4375
the engine is operating below the Refill 116.9 4497
fuel stop limit, the governor will add
fuel as required to maintain the Table 10
required engine speed and power.
Conclusion
[1 - ]
(TDT - Tref ) 1 The previous calculations indicate
Pcorr = Prated x X
10°F 100 day tank fuel temperatures can have
an effect on the maximum power
capability of the engine. The
Where: example was based upon a fixed
pitch propeller application. Typically,
Pcorr = Corrected Engine Power, a fixed pitch propeller is selected
bhp and sized to absorb 85-90% of the
Prated = Rated bhp engine's name plate rating. In this
Tref = 86° (Power setting) example, this would equate to 3950-
4175 bhp. The lowest calculated
TDT = Actual day tank fuel
corrected power was determined to
temperature, °F
be 4375 bhp. This would leave a 5-
Example: 10% power margin and vessel
For t = 60, the corrected power of performance would not be affected.
the engine is:
While vessel performance may not
be affected in this example, the
maximum fuel temperature of
Pcorr = 4640 bhp x [1 - (89.3°F - 86°F)
10°F
X
1
100 ] 143.1°F will put the fuel viscosity
near or below the minimum
Pcorr = 4625 bhp allowable viscosity of 1.4 cSt at the
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Density
SG =
998 kg/m3
Density (kg/m3) = SG x 998 kg/m3
1 lbm/ft3 1 ft3
Density (lbm/gal)= SG x 998 kg/m3 x x
16.02 kg/m3 7.48 gal
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
Appendix 2
components and to permit
Crude Oil Fuel satisfactory starting capability.
Note: Crude oils are not suitable for The same diesel power ratings may
use as fuel in all engine applications. not always apply for Caterpillar
The suitability of these fuels for use engines burning crude oil.
is determined on a case-by-case Reasonable engine service life can
basis. A complete fuel analysis is be achieved when proper procedures
required. are followed. However, the greater
NOTICE: Use of permissible crude oil risks involved make it good practice
fuels can result in higher to include slightly higher than normal
maintenance costs and in reduced maintenance costs when figuring the
engine service life. overall economics to be gained.
NOTICE: Caterpillar does not A fuel analysis should be
recommend using any of the heavier performed. Include a distillation
fractions such as residuals or curve. Operation at light load is not
bottoms in engines that are recommended. On occasion,
configured to use distillate diesel operation at 50% load has
fuel. Failure to follow this reportedly caused smoking.
recommendation will result in severe Engines for crude oil fuel operation
wear of components and engine should be equipped with higher
failure. temperature thermostats, bypass
Residual fuels or blended fuels centrifugal oil filter, and fuel injector
with residuals are unsuitable pushrod keepers.
because they have a high viscosity
Pretreatment of Crude Oils
range, low ignition quality and high
1. The crude may contain excessive
vanadium and sodium contents that
amounts of sediment and water
shorten engine life. Such fuels may
that will require removal before
cause high wear rates in the fuel
they get to the engine. This can
system, on the piston rings, cylinder
usually be accomplished with a
liners, and exhaust valves. Also,
settling tank, Figure 11, a
filter problems and deposits in the
centrifuge or special filtering
piston ring belt may be evidenced.
equipment or a combination of
Special crude oil fuel pretreatment these methods. The crude may
equipment may be required and is also contain solid particles of
available from suppliers of fuel wax at ambient temperature that
treatment equipment. Also, it may would plug the filters rapidly. It is
be essential to start and stop the impractical to try to remove the
engine on a better quality, ASTM wax, but the crude can be heated
No. 2-D type fuel to prevent sufficiently to dissolve it. The
plugging and sticking fuel system amount of heat needed will vary
from one crude to another and
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
avoid short oil changes. The use During this time, fuel is being used
of Caterpillar S•O•SSM, is strongly from a second tank. Temperature
recommended. inside the settling tank building
should be maintained above 70°F
Crude Oil Maintenance (21°C), and the tanks must be
Intervals vented outside the building.
Engine inspection intervals should A two-day supply of diesel fuel
be reduced by 50% when using should be maintained for emergency
crude oil as fuel, and maintenance use. This supply can also be used to
routines should be modified based start and stop engine when the
on the results of these increased crude oil fuel is highly viscous or
inspections. heavy with paraffins.
Crude Oil Settling Tanks
A great deal of sludge can be
removed from crude oil by proper
settling. A recommended settling
system consists of two cone-
bottomed tanks, Figure 11, each
holding a little more than four days
usable supply of fuel.
Sludge in the bottom third is
discarded before refilling. The tanks
must be housed in a heated building,
and each fitted with heating coils.
Immediately after filling, hot water
is circulated through the heating coil Figure 11
until the tank is heated to 100°F
(38°C). The heat is then shut off
and the fuel allowed to settle
undisturbed for four days.
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Application and Installation Guide Diesel Fuels & Diesel Fuel Systems
viscosity is used, cooling of the fuel may be required to maintain 1.4 cSt or greater viscosity at the fuel injection
pump. Fuels with a high viscosity might require fuel heaters in order to bring down the viscosity to either 4.5 cSt or
less for rotary fuel injection pumps or 20 cSt viscosity or less for other fuel injection pumps.
(3) Via Standards tables, the equivalent specific gravity using the “ASTM D287” test method temperature of
15.56°C (60°F) for the minimum API gravity of 30 is 0.8762, and for the maximum API gravity of 45 is 0.8017.
The equivalent kg/m3 (kilograms per cubic meter) using the “ASTM D287” test method temperature of 15.56°C
(60°F) for the minimum API gravity of 30 is 875.7 kg.m3, and for the maximum API gravity of 45 is 801.3 kg/m3.
(4) Follow the test conditions and procedures for gasoline (motor).
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Diesel Fuels & Diesel Fuel Systems Application and Installation Guide
Reference Material
The following information is
provided as an additional reference
to subjects discussed in this manual.
SEBD0717
Diesel Fuels and Your Engine
SEBU6251
Caterpillar Commercial Diesel
Engine Fluids Recommendations
SEBU7003
3600 Diesel Engine Fluids
Recommendations for Lubricants,
Fuels, and Coolants
REHS0104
Guidelines for 3600 Heavy Fuel Oil
(HFO) Engines
SENR9620
Improving Component Durability:
Fuel Systems
WECAP
Web Engineering Cataloging and
Procuring website
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LEBW4976-00 ©2005 Caterpillar Printed in U.S.A.
All rights reserved.