Brig KAMAL RASOOL (Retd)

GM TECHNICAL SUPPORT SIGMA MOTORS LTD, ISLAMABAD

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SIGMA MOTORS LTD

Sigma Motors was established in 1995 as Land Rover Dealer. It started assembly of Land Rover Defender in 2004. Over 12000 Defender vehicles are operating in Pakistan. Sigma has 2S services all over Pakistan, while it has its own 3S Services at Karachi, Lahore and lslamabad. 3

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SEQUENCE

Important Fuel Properties Additives as Pour Point Improvers Sulpher - Emission Standards Common Rail Fuel System Effects of Poor Quality Fuel Ways to Overcome Ill Effects of Contamination Hazardous Practices Adopted in Cold Areas Types of Diesel Fuels Inducted in Pak Army Preventive Measures Against Fuel Contamination Fuel Storage and Supply Recommendations

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IMPORTANT FUEL PROPERTIES

Pour Point, is the lowest temperature at which the fuel could still be poured satisfactorily. The lower the pour point, the more desirable the fuel is when starting up at cold temperature.
Flash Point, is the lowest temperature at which the fuel gives off vapors which can ignite. It is dangerous for the fuel to ignite while in storage, so a high flash point is desirable. Contamination: All fuels particularly diesel should be free from sediments and water.
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ADDITIVES

Several types of additives are available to be mixed with diesel to lower its pour point. As a temporary measure 1 part of Kerosene when mixed with 20 parts of normal diesel lowers its pour point by about 7-8 C.

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SULPHER EMISSION STANDARDS

Emission Standards Euro 1 Euro 2 Euro 3 Euro 4, Euro 5 Gasoline S ppm max 1000 150 30 10 Diesel Fuel S ppm max 2000 (0.2%) 300 (0.03%) 50 10

Engines achieve improved performance and lower emissions with higher category fuels. Ultra Low Sulpher Diesel (ULSD) Fuel ULSD contains <15 parts per million sulpher. Regular Sulpher Diesel (RSD) Fuel RSD contains <5,000 ppm (0.5 wt %) sulpher, but >500 ppm (0.05 wt %). Since Oct.1, 2007, RSD fuel is to contain <500 ppm (0.05 wt %) sulpher. Note: Pakistan National Standard allow 1% sulpher in Diesel fuel.

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Diesel Engine Fuel Delivery Common Rail System

1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11.

High-pressure line Leak-off pipe Fuel injection line Fuel injector Pressure limiting valve (2000 Bar) Fuel rail Volume Control Valve (VCV) Fuel pressure sensor Fuel temperature sensor High-pressure fuel pump(1600 Bar) Fuel return

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EFFECTS OF POOR QUALITY FUEL

( Samples of fuel retrieved from some vehicles )

( Volume Control Valve ) ( Pressure Relieve Valve ) ( Fuel Filter/ Sedimentor) Sediments jams/ blocks these components preventing engine starting Dirty Fuel will wear fuel injection eqpt and cause loss of power, produce smoke and make starting difficult

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WAYS TO OVERCOME ILL EFFECTS OF FUEL / OIL CONTAMINATION

Several products are available in the market with different brand names for the following purposes: a. Fuel/ Air Induction Service b. Diesel Injection Service c. Drive Line Service Sigma service centers have been effectively using following BG products, with excellent results: a. BG Quick Clean for Engines restores power and performance to an engine by rapidly removing accumulated deposits that form in the piston ring belt, rocker arms etc. Add BG Quick Clean to the oil, then run engine for 10-15 minutes. When the old oil is drained, contaminants are quickly flushed away. b. BG Diesel Care is a highly effective cleaner which quickly decarbonizes diesel fuel injection systems. It is designed for the new electronically controlled common rail systems using direct injection, as well as traditional mechanical fuel injection systems.

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HAZARDOUS PRACTICES ADOPTED IN COLD AREAS

Following practices are being followed at Gilgit, Skardu and surrounding areas: Heating the fuel tanks / engine sumps for heating the diesel fuel prior to starting the vehicles in the morning. To overcome the freezing of moisture in diesel in the fuel tanks / pipes etc or to overcome issues related to Pour Point , vehicles should be parked under cover at night to facilitate starting in the morning; however, such cover is not generally available. Therefore, at times fuel is directly heated in pots and then poured in the fuel tanks which is very hazardous.

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TYPES OF DIESEL FUELS Inducted in Pakistan Army

(47/40)Dieso 4 C (47/20)Dieso -7 C (47/0)Dieso -18 C

47 Cetane 40 Pour Pt 47 Cetane 20 Pour Pt 47 Cetane zero pour Pt

For extreme cold conditions as experienced in Gilgit Baltistan area, diesel fuel (47/0) Dieso is recommended for use in diesel vehicles in winters.
Above diesel fuels should be made available in the country for cold areas.

PREVENTIVE MEASURES
SIGMA MOTORS

AGAINST CONTAMINATED FUEL

Avoid using contaminated diesel fuel directly from jericans

Fuel should be filled from pumps

Where use of jericans is unavoidable, the fuel should be filtered prior to filling in the fuel tanks, preferably by using chamois cloth. Drivers should remove the water & sediments from the sedimentor at least once a week.

Above precautions will extend the life of diesel injectors and other components in the fuel system.

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FUEL STORAGE & SUPPLY

Jericans
Bowzers Fuel Tanks

Fuel Pumping Stations

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RECOMMENDATIONS

Diesel fuel specifications should be revised particularly with respect to sulpher content to meet international EURO standard as well as to enhance engine life. Winterized fuel should be made available in cold areas. BG products may be used for flushing vehicle engine, in order to reduce overhauling cost. Fuel filter should be changed earlier than the period specified by manufacturers.