When your backup generator system refuses to start or maintain operation, the immediate reaction is often to blame the fuel. However, as Erik Bjornstad reveals in this enlightening episode of The Fuel Pulse Show, this common assumption can lead down an expensive path of unnecessary solutions and wasted resources.
The stakes are exceptionally high when dealing with generator problems in today's challenging operational environment. Consider the financial implications: fuel disposal alone can cost between $6,500 to $8,500 for just 500 gallons, with additional fees pushing the total close to $10,000. The costs quickly multiply when you factor in hazardous waste transportation fees, environmental charges, regulatory compliance costs, and the expense of replacing the disposed fuel with fresh stock.
Similarly, replacing system parts like fuel injection pumps can cost $5,000 or more, while new injectors start at around $1,000. These significant costs make it crucial to diagnose the real problem rather than jumping to conclusions accurately.
As Bjornstad explains, many generator service technicians default to blaming fuel quality without proper investigation. "Most of the generator service technicians who conclude that the condition's due to a fuel problem, they actually don't know much about fuel, but they'll blame the fuel anyway because it's the easiest thing to do," he notes. This insight underscores a critical issue in the industry: the tendency to opt for the simplest explanation rather than conducting a thorough investigation.
This situation is particularly troubling because lab testing often reveals supposedly "bad" fuel to be well within ASTM D975 specifications for diesel fuel. This contradiction between technician diagnoses and laboratory results points to a need for a more systematic approach to troubleshooting generator issues.
Bjornstad presents a methodical, four-step diagnostic process that can save organizations thousands of dollars in unnecessary repairs or fuel replacement. The process begins with the simple yet often overlooked step of changing fuel filters. This basic maintenance step can sometimes resolve the entire issue for the cost of a few filters. More importantly, examining the old filters can provide valuable information about potential microbial contamination in the system.
The second diagnostic step involves checking fuel lines for obstructions. This includes testing for clear fuel flow and ensuring no blockages are preventing proper fuel delivery to the engine. The third step focuses on inspecting and cleaning vital valves in the system, including foot valves and check valves that play crucial roles in preventing fuel drainage and maintaining proper fuel flow. The fourth step examines any additional inline filters that might be present in the system, particularly automotive-style filters that some systems incorporate.
Microbial contamination emerges as a critical concern in modern fuel systems, particularly with ultra-low sulfur diesel (ULSD) fuels. The episode provides detailed guidance on identifying five key indicators of microbial presence: black or clear slimy residues, distinct sour odors from sulfur-reducing bacteria, "leopard spotting" on filter media (indicating large bacterial colonies), visible organic matter clumps, and cloudy or milky liquid in separators suggesting fuel-water emulsification.
Professional testing methods, particularly ATP by filtration, can confirm suspected contamination and quantify its severity. When contamination is confirmed, treatment with appropriate biocides becomes essential, followed by filter replacement to remove the dead microorganisms. As Bjornstad emphasizes, "If you have evidence of microbial contamination, it's never a question of if it's going to lead to a future problem. It is always a question of when is that going to happen."
The winter season adds another layer of complexity to generator maintenance. As temperatures fluctuate and storms roll through, operators must transition from concerns about fuel gelling in cold weather to addressing water and microbial issues that emerge during warmer periods. This seasonal shift highlights the importance of year-round vigilance in fuel system maintenance.
The systematic approach outlined in this episode offers a practical framework for addressing generator problems while potentially saving thousands in unnecessary repairs or fuel replacement.
By following these methodical steps and remaining attentive to signs of contamination, organizations can maintain more reliable generator operations and avoid costly misdiagnoses.
The key lies in resisting the temptation to accept simple explanations without proper investigation and instead following a thorough diagnostic process that considers all potential causes of system failure.