Water In Diesel Fuel & How to Get Rid of It (2024)

Blog Post

It has become increasingly common knowledge that water poses a significant threat to engines when it accumulates in diesel fuel. Corrosion, engine damage, and unplanned downtime are just some of the issues caused by water contamination in diesel tanks.

In this post, we cover:

• Common sources of water contamination in diesel fuel
• Symptoms to watch out for with water contamination
• Effective solutions to remove water from diesel fuel
• Tips on how to prevent water contamination in diesel fuel.

What Are Common Sources of Water in Diesel Fuel?

Water contamination in diesel fuel can originate from a few common sources:

Condensation

Water condensation in fuel tanks occurs when moisture in the air comes into contact with the colder surface of the fuel tank. As the air cools, it reaches its dew point where the air can no longer hold all of its water vapor. At the dew point, the excess water vapor in the air condenses and forms liquid water droplets on the cold surface of the fuel tank. Over time, these droplets accumulate and mix into the fuel, leading to water contamination.

This process is particularly common in areas with high humidity or during temperature fluctuations, such as the transition from a warmer day to a cooler night.

Common areas for water condensation to occur in fuel tanks include:

• Top of the tank: This is a particularly common area, especially when the fuel level is low.
• Tank walls: Condensation can form on the inner walls of the tank, especially in areas that are exposed to cooler temperatures.
• Fuel lines: Water droplets can form in fuel lines, especially if they are exposed to cold air or if the fuel is not flowing regularly.

Compromised Fuel Storage

Whether it is your tank or another somewhere in the supply chain, compromised tanks do exist and for a variety of reasons. These tanks can create opportunities for rain or other water sources to be introduced into the fuel body, eventually wreaking havoc on the end user who takes on the delivery of contaminated fuel.

Common causes of compromised fuel storage tanks include:

• Corrosion: In addition to water itself, ethanol-based fuel and soil conditions can also contribute to accelerated tank corrosion. Small amounts of ethanol-based fuels can be introduced into diesel storage tanks and fuel lines are shared during transport. Underground storage tanks can also encounter corrosive soils which can contribute to the degradation of tank materials.

• Physical Damage: Improper handling and installation, natural disasters, and accidents can all weaken the structural integrity of tanks.
• Environmental Factors: Changes in soil conditions and tree roots can cause tanks to settle or shift, leading to leaks.

Contaminated Fuel Delivery Systems

Contaminated tanks and fuel delivery infrastructure can all introduce water and other contaminants into fuel before it is delivered to its final destination.

What Are The Symptoms of Water in Diesel Fuel?

Short of tank corrosion, unplanned downtime, and engine damage, water contamination in diesel fuel can manifest itself in a number of ways. The following symptoms are things to look out for before serious consequences occur:

• Engine misfires: Water can disrupt the combustion process, leading to misfires and uneven engine operation.
• Rough idling: The engine may idle roughly or experience vibrations due to inconsistent fuel delivery.
• Decreased power: Water can reduce the fuel's energy content, resulting in decreased engine power and performance.
• Hard starting: Water can make it difficult to start the engine, especially in cold weather.
• White smoke: In some cases, water in diesel fuel can produce white smoke from the exhaust.
• Fuel filter clogging: Water can accumulate in fuel filters, leading to clogging and restricted fuel flow.

If left unaddressed, water contamination can go on to corrode tanks, destroy injector tips in Tier-4 engines, promote rampant microbial growth, and even block fuel lines in freezing conditions. Unchecked microbial growth can result in sludge-like formations that later lead to premature filter clogging. Together, these issues can lead to expensive repairs and unplanned downtime, making it crucial to prevent and address water contamination in diesel fuel.

How Do You Remove Water in Diesel Fuel?

There are two methods for removing water from diesel fuel. You can either send the water into the engine to be vaporized out the exhaust or filter the water out from the fuel tank. For the first option, fuel additives are used to emulsify the water into the fuel body to ensure it gets sent into the engine alongside the diesel fuel. The latter option requires a fuel polishing system or service.

Fuel Additives

Fuel additives are a cheap and effective option for dealing with mild to moderate water contamination and often provide additional benefits beyond the surfactant used to emulsify the water. This is a great option for most users so long as the engine is not Tier-4 rated. Sending water through Tier-4 injector tips will most definitely cause damage and risk one blowing out their injector tips.

Fuel Filtration

Fuel filtration systems remove water from the diesel using one of two filtration methods. The first method involves a water separator that uses centrifugal force to separate the two substances. The second method involves filter media that captures water as the fuel flows through the system and back into the tank.

This option, although more expensive, is the only effective method to remediate serious water contamination in diesel fuel, especially in bulk storage applications.

For smaller, non-commercial, applications as well as some commercial cases, fuel polishing systems or services can be employed for periodic filtration of contaminated fuel. This option is great for remediating heavily contaminated fuel without relying on expensive filter elements.

For commercial and mission critical applications, fuel maintenance systems can be purchased and installed permanently for continual and automated filtration of the attached fuel storage tank(s). This option is great for maintaining fuel quality long-term and only requires periodic filter changes.

What Are Some Tips for Preventing Water Contamination in Diesel Fuel?

While there are reliable methods to remove water from diesel fuel, the best approach to any problem is prevention. Below are some precautions one can take to protect their diesel from water contamination:

1. Proper Fuel Storage:
   • Keep fuel levels as high as possible to minimize air space and mitigate condensation.
   • Ensure tanks or containers are tightly sealed to prevent moisture from entering..
2. Regular Fuel Tank Inspections:
   • Inspect your fuel tank regularly for signs of leaks or damage.
   • Repair any leaks promptly to prevent water from entering the tank.
3. Fuel Delivery Precautions:
   • Choose reputable fuel suppliers with a history of quality control.
   • Ensure that fuel delivery equipment is clean and well-maintained.
   • Avoid fueling from tanks that may be contaminated with water.
4. Fuel Maintenance Systems:
   • For larger tanks, install a fuel maintenance system to regularly filter contaminates from the tank before they can cause issues.
   • Replace fuel filters according to the manufacturer's recommendations.
   • Inspect and clean fuel lines, injectors, and other components regularly.
   • Drain water from fuel separators as needed.
5. Fuel Polishing Services:
   • Employ periodic fuel polishing services to filter contaminates from the tank before they can cause issues.
   • Regularly test your fuel for contamination in order to know how frequent to polish the fuel.
6. Winter Precautions:
   • Use winterized diesel fuel to help prevent fuel gelling and water separation.
   • Consider using fuel heaters or other measures to keep fuel warm in cold weather.

Conclusion

Water contamination in diesel fuel poses a significant threat to engine performance and longevity. By understanding the sources, symptoms, and effective solutions, you can take proactive measures to prevent and address this issue.

Key takeaways:

• Sources of water contamination: Condensation, compromised fuel storage, and contaminated fuel delivery systems are common culprits.
• Symptoms of water in diesel fuel: Engine misfires, rough idling, decreased power, hard starting, white smoke, and fuel filter clogging are indicators of water contamination.
• Solutions: Fuel additives and fuel polishing systems are effective methods for removing water from diesel fuel.
• Prevention: Proper fuel storage, regular inspections, fuel filtration system maintenance, and the use of fuel additives can help prevent future water contamination.

By implementing these strategies, you can protect your diesel engine from the harmful effects of water contamination and ensure its optimal performance.