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FPS-SX - Fuel Polishing System with Separ Primary Filtration - 150 GPH - 110V-60Hz
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FPS-SX - Fuel Polishing System with Separ Primary Filtration - 150 GPH - 230V-50Hz
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FPS-SX-R - Fuel Polishing System with Racor Primary Filtration - 150 GPH - 110V-60Hz
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FPS-SX-R - Fuel Polishing System with Racor Primary Filtration - 150 GPH - 230V-50Hz
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FPS SX-F - Fuel Polishing System with Primary & Secondary Filtration - 150 GPH - 110V-60Hz
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FPS SX-F - Fuel Polishing System with Primary & Secondary Filtration - 150 GPH - 230V-50Hz
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SX-F MP Upgrade - Multi-Point Flowpath - TSC-7000 Controller - 4-valves - 2 Foot Valves
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SX-F Upgrade - Multi-Point Flowpath Expansion Kit - 2 Valves and 1 Foot Valve
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FT-100 Liqui-Cult Fuel Test Kit - Box of 10 bottles
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FT-200KK Kolor Kut Water Finding Paste (3-oz tube)
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Amber Stack Light - 24V
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Audible Alarm - 24V
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WE-12 Water Eliminator - one per package, 12" unit
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AXI (formerly ALGAE-X®) SMART Fuel Polishing Systems (FPS) are programmable, fully automated Fuel Maintenance Systems that remove water, sludge and contaminants wherever fuel is stored or used. Adding a SMART FPS System that meets your requirement and needs will remove particulate, separate water, and condition fuel. This fuel polishing process conditions and stabilizes diesel and bio-fuels, eliminates microbial contamination, and ensures fuel remains clean and dry. These compact fuel maintenance systems are specifically designed for permanent installations indoors, as well as confined spaces, such as inside gen-set enclosures or engine rooms. SMART FPS Systems keep your tanks clean and your fuel in "Clear & Bright" pristine condition at all times providing maximum efficiency and minimal emissions. AXI’s LG-X Fuel Conditioner, included on every FPS System, reverses fuel deterioration and removes sedimentation to sub micron levels, preventing clogged filters, extending injection system service life, and reducing smoke, emissions and downtime.
All FPS Systems feature:
SMART Filtration Controllers
Fully Automated & Programmable Operation
Integration with Equipment Monitoring Systems
Modular "Plug & Play" Flexibility
Unique Safety and Alarm Features
Continuous-Duty Pumps, Viton Seals
Leak Detection with Emergency Shut-Down
An FPS Series Fuel Polishing System is the central component of a Fuel Management Plan. Establishing a fuel management and maintenance protocol should include removal of accumulated water, periodic fuel circulation for particulate filtration and polishing of the fuel, and treatment with a Diesel Fuel Catalyst made to work hand-in-glove with the Fuel Polishing System to clean the fuel tank without removing the fuel, assuring that the lights stay on when the power goes off.
The Smart FPS SX Series Tank Cleaning and Fuel Treatment Systems is available in three configurations: The SX, SX-F, and SX-R Fuel Polishing Systems. The FPS SX Systems are our smallest systems, from a flow capacity standpoint, that are AC powered. All three systems will circulate fuel at a flow rate of 150 Gallons per Hour, resulting in their ideal capability for the treatment of fuel tanks with a capacity of between 500 to 2,000 gallons (1,900 to 7,500 liters).
The FPS SX gives you the flexibility to have a system that runs for a fixed time period and then automatically shuts off. The FPS SX also will automatically shut down when high vacuum or high pressure is sensed in the system, possibly indicating a clogged primary filter or that the bowl requires attention due to a critical accumulation of water, or that a secondary filter element is in need of changing. The FPS SX also has a sensor that would automatically shut off the system if the system, operating while unattended, senses that there is a leak that accumulates fuel in the spill tray to the extent that the float valve will shut down the system down.
The FPS SX Series Tank Cleaning and Fuel Treatment Systems are efficient and capable Fuel Polishing Systems well suited for use on marine vessels with multiple fuel tanks when equipped with a manual manifold for switching the fuel treatment process between the various tanks, for emergency or backup power applications, maintaining farm fuel supplies or other facilities that may use diesel fuel for both emergency power and to fuel equipment used in the enterprises day-to-day operations.
The FPS-SX Series Systems operate on either 110V 60Hz 15A or 230V 50Hz 15A power. This gives you the flexibility to operate the unit in a repair shop environment where truck or other diesel power equipment is serviced and fuel polishing and tank cleaning is added to the services provided.
The principal components are a continuous-duty pump featuring Viton seals, a Separ SWK 2000/18 primary filter/water separator, with vacuum sensor and gauge (the FPS-SX and SX-F), or alternatively the Racor Turbine MA1000 Fuel Filter/Water Separator with vacuum sensor and gauge (the FPS-SX-R), for monitoring filter element changes, with water sensors for monitoring water in the bowl, a secondary spin-on filter utilizing either various fine particulate removal or water block filter elements, and an AXI Fuel Conditioner.
The fuel flow continues to the AXI Fuel Conditioner. Operating on the principal of induction on the process of combining kinetic and magnetic energy to influence the behavior of electrons, the AXI Fuel Conditioner provides a powerful magnetic field and the flow of fuel provides the kinetic energy.
Click on Graphic
As fuel deteriorates, clusters of fuel components break down and residue begins to accumulate, resulting in dark, hazy fuel with poor combustibility. The increase in size and mass of the fuel breakdown products lead to clogged filters and the build up of tank sludge. The AXI Fuel Conditioner dissolves the clusters, stabilizes the fuel, and eliminates tank sludge. The results are Clear & Bright Fuel, improved filterability, optimal combustion and clean fuel systems. The process of how the AXI Fuel Conditioner makes clear, bright and more combustible fuel as well as restoring degraded fuel and eliminating the effects of microbial contamination is compelling. As the AXI Fuel Conditioner does not filter the fuel, but treats it as it passes through the unit, there is seldom any reason to suspect that a restriction is in the AXI Fuel Conditioner. But you can remove the face plate, remove the magnet and wipe it off with a shop rag and replace the filter and face plate. A spare parts kit for the AXI Fuel Conditioner includes a new face panel O-Ring and replacement screws to fasten the face plate.
SMART FPS Systems reverse fuel deterioration while decontaminating, cleaning and optimizing the fuel for guaranteed continuous, uninterrupted service.
The FPS SX and SX-R System are similarly configured in all respects with the exception of the Primary Filter.
The FPS-SX and SX-F utilizes a Separ SWK 2000/10 Fuel Filter / Water Separator that incorporates an effective five stage system for the separation of water and particulates from the fuel. Both water and particulate matter can result in high levels of wear for fuel pumps and injectors, resulting in reduced reliability and expensive engine repairs:
The following is the five stage fuel system of the Separ 2000/10 Fuel Filter/Water Separator:
The FPS SX-R System utilizes a Racor Turbine MA1000 Fuel Filter/Water Separator providing 180 GPH fuel flow utilizing a three stage process:
Engine manufacturers generally want their engine fuel systems to be fed fuel that has been filtered to 4 microns or finer. The engine filter provided by the engine manufacturer, through which the stored fuel will pass prior to entering the engine fuel system, will typically be capable of filtering fuel to the level required by the manufacturer of the engine. But having a primary filter that will remove water and particulates down to 10 microns, presents a degree of assurance that many maintenance professionals feel is worth the extra effort. Not only does assuring that the fuel is filtered to 10 micron before reaching the engine manufacturer provided filter extend the life of the engine manufacturers filter, it also provides assurance that when the lights go out your fuel will be there to power your backup generator.
The FPS FX and FX-R Systems utilize the SFC-50 Automated Controller. This controller system monitors the performance of all components in the FPS system and automate the fuel maintenance cycles. The system is automatically operated by the programmable UL508A SMART Filtration Controller with text readout. The controller is full programmable, fully automated, has digital text readout, and has a Building Maintenance System/Building Automation System (BMS/BAS) interface. The system gives the operator an instant visual status report of system power, pump operations, and alarms for high vacuum and high water levels. A selector switch allows the option of manual operation or running the fully automated program.
The controller’s alarm functions and pump shut-down are triggered if filter elements require service, if high pump vacuum or pressure occurs, if system flow rate varies or if there is water in the separator. The wiring harness with plugs easily connects the SMART Filtration Controller with the FPS allowing for greater flexibility in installation and access where it’s most convenient. The controller can also be used with an optional remote pendant power control switch and an alarm strobe light for high visibility.
The FPS SX-F utilizes the SFC-55 controller. This controller includes all the capabilities of the SFC-50 Controller with additional functionality required for the additional components incorporated into the FPS SX-F System.
It is recommended that diesel fuel be treated with the AXI Fuel Catalyst AFC-705 (for pre-2007 engines) or AFC-710 (Tier 4 compliant) Diesel Fuel Catalyst prior to the initial tank cleaning and at least every six months thereafter to assure the fuel tank remains clean and the fuel is stabilized. This will enhance and accelerate the tank cleaning process by breaking down and dissolving existing tank sludge. Always check the fuel tank for an accumulation of water in the bottom of the tank. Using a rod, sometimes used to measure fuel in a storage tank, or a length of PVC pipe, spread a line of Kolor Kut Water Finding Paste on the side of the rod or pipe and insert to the bottom of the tank. If the paste touches water, it will change colors, showing how much water is in the tank requiring removal.
Pump accumulated water out of the tank for proper disposal. It is often the case that all of the water is impossible to remove. AFC-705 contains a surfactant that will emulsify the residual water up into the fuel for removal by a Water Block Filter on the AXI Fuel Polishing System AFC-710 does not include this surfactant component). Depending on the condition of the fuel and the amount of sludge build-up, it is recommended to initially use a double dose of one to twenty-five hundred (1:2500 - one oz. to 20 gallons of fuel) and circulate the capacity of the tank five times. Always treat the tank when the tank is full of fuel. If you perform a treatment with a half tank of fuel, you will only be cleaning the bottom half of the tank. The use of AXI Fuel Catalyst has proven to be essential in accelerating the tank cleaning process. AFC-705 and 710 contains detergent, dispersant, corrosion inhibitor, lubricity enhancer and combustion catalyst. AXI Additives do not contain biocides.
For engines manufactured in 2007 and later, use AFC-710, available in both liquid and powdered form. AFC-710 does not contain the surfactant (used to emulsify residual water into the fuel for removal in the circulation process as does AFC-705), a component that does not allow for qualification as a Tier 4 product. AFC-705 and AFC-710 should always be used periodically in particular to stabilize fuel that is stored for longer periods of time.
After the initial cleaning, the AFC-705 or AFC-710 in the fuel will continue to stabilize the fuel for six months or more. Every six months, or more often if the region in which you reside is a humid climate, treat the fuel again and circulate the capacity of the tank three times. In applications where fuel from a treated tank is distributed to other equipment, the additive will also clean the downstream tanks and continue to stabilize the fuel.
For cold weather operations, AXI Fuel Catalyst AFC-805 is a unique and powerful anti-gelling broad-spectrum fuel additive specifically formulated for use in Diesel, Bio-fuels, Gasoline, Kerosene, and HFO. AFC-805 should be used as part of any preventative fuel maintenance program, and is ideal for use in bulk storage fuel tanks in cold weather environments. AFC-805 enhances the breakdown and removal of sludge, slime, and bio-fouling from tank walls and baffles that are difficult to access.
AFC-805 effectively decontaminates and cleans an engine&rsquot;s entire fuel and injection system. It continues to work in storage tanks cleaning and stabilizing fuel for up to 12 months with a single dose. AFC-805 is ideally used for cold weather applications where there is long term fuel storage, such as bulk fuel farms, winterized recreational and work boats, and also smaller engines. AFC-805 is recommended at a ratio of 1:5000 (one oz of AFC-805 to 40 gallons of fuel)
The fuel you depend on should always be in optimal condition. Periodic circulation of fuel assures optimal combustibility and fuel cleanliness. All major diesel engine manufacturers have set minimum fuel standards for the diesel fuel to be used in their engines, and failing to maintain fuel that meets those standards could lead to engine component failures and denied warranty claims. As an example, Caterpillar has published "Cat Commercial Diesel Engine Fluids Recommendations" (SEBU6251-17 September 2014 [a more recent version may be available]) that states "In order to meet expected fuel system component life, 4 micron(c) absolute or less secondary fuel filtration is required for all Cat diesel engines that are equipped with common-rail fuel systems." (Page 34) You should not assume that fuel being delivered to you meets the engine manufacturer’s requirements, and certainly fuel that has been in your storage tank for an extended period of time is unlikely to meet requirements of diesel engine manufacturers without a Fuel Management Program.
Cleanliness standards for diesel fuel, established in the late 1990&rsquot;s by the International Organization for Standardization (ISO), apply to diesel fuel. Caterpillar recommends that the fuel dispensed into the machine tank meets "ISO 18/16/13" cleanliness level." (Page 49) For more information on fuel cleanliness specifications and what those requirements mean to you, review the "Diesel Fuel & Injector Failure" web page on this site.
Continued vigilance to assure that your fuel is in the best condition possible and always meets the requirements to maintain engine manufacturer's warranty requirements is a major challenge without the use of an AXI Fuel Conditioning & Tank Cleaning System to address the need for periodic Fuel Polishing.
A Fuel Maintenance Plan should be a part of every periodic engine Preventative Maintenance Program. Preventative Maintenance Programs are common in all major industries today, but monitoring the fuel condition is often taken for granted and not included in the Preventative Maintenance Program. Many of today's maintenance personnel have many years of experience, but until changes in sulfur content in diesel fuel were regulated within the past decade, and with the government&rsquot;s push for blending some amount of bio-diesel into regular diesel fuel, maintenance professionals were never presented with the problems that we are experiencing today. With today&rsquot;s advances in design and engineering of diesel engines, especially the new fuel injection systems, and with more emphasis being placed on critical requirements that equipment have longer life cycles and near 100% uptime, fuel management can no longer be ignored. It is now just as important as changing the oil, ensuring the batteries are charged, and the air filter is clean.
Service Agreements with an outside contract company to perform Preventative Maintenance typically do not cover fuel-related management and monitoring unless specified. In-house maintenance personnel are usually pressed for time, and fuel management can be easily glossed over. Fuel has a limited shelf-life and even "fresh fuel" could contain water, sediment, microbes, asphaltene agglomeration, or other contaminate components upon delivery and cause immediate engine performance issues.
Emergency power installations are especially susceptible to unexpected interruptions due to fuel related issues. Periodic generator tests-runs are too short to determine if fuel quality is adequate for the demands of continuous, full-load operation. In fact, generator test runs have been found to significantly accelerate the fuel polymerization and degradation process, resulting in the accumulation of gums and resins in the fuel system, by returning fuel that has been compromised by heat and pressure back to the tank. Thirty minute tests, often performed every month, create the environment in the tank for problems to grow. After extended periods of testing, sometimes years, without having been subjected to an extended full load, operation is interrupted by clogged filters when the lights go out.
Now that you have decided to institute a Fuel Management Plan for your operations, there is work to do. Consider the following as the basis for your Fuel Management Program to further assure that your equipment will run when it is needed most at it&rsquot;s peak level of performance and repair costs will remain under control:
Place in service an AXI Fuel Treatment & Tank Cleaning System appropriate to your operations that are capable of performing a complete tank cleaning and fuel conditioning on each fuel tank in service at least once per year (more often in regions of high humidity). Evaluate what other aspects of fuel monitoring and testing is needed to assure that critical equipment needs, including down-stream equipment, may need to be included in your Fuel Management Plan.
Use AXI Broad Spectrum Fuel Catalyst Ultra Concentrate AFC-705 or AFC-710 every six months to enhance the breakdown and removal of sludge, slime, gums, resin, and bio-film from tank walls and baffles that are difficult to access and normal fluid flow does not break loose. Having this unique fuel additive present when fueling downstream equipment also assures that these downstream tanks are being cleaned in the normal course of operations (although separate water removal will be necessary).
Periodically (every 30 to 60 days, depending on your climate) use a Fluid Sampler or a hand Fuel Sample Pump to take samples of your fuel from each storage tank and critical equipment fuel tanks for in-house testing for acidity (pH) and use Liqui-Cult Fuel Test Kits to perform testing for microbial contamination. If initial tests indicate fuel problems, utilize laboratory analysis to evaluate the condition of your fuel to assure your fuel supplier is providing fuel that meets the specification of the engine manufacturer you depend on to keep your equipment running.
Use a Portable Particle Counter to test each incoming load of fuel to assure that the cleanliness of fuel provided by your supplier meets the specifications established by the manufacturers of the engines that power your equipment. Your engine warranty depends on it!
If the quality of your fuel is suspect, consider establishing a quarantine tank to accept new shipments (do not add new shipments of fuel to your stored fuel that has been de-watered and to which you have performed fuel polishing, and is known to meet your Fuel Management protocols).
Use Kolor Kut Water Finding Paste at least every 30 to 60-days to monitor the accumulation of water in your storage and equipment fuel tanks due to condensation or from fuel fills. If any amount of water is detected, take steps to remove it.
Install Desiccant Breathers on all your fuel storage tanks to help prevent moisture from entering your tanks through the vent as fuel is consumed.
Use Water Eliminators in each storage and equipment fuel tank to capture water and remove it before it can cause problems with engine operations or seasonally prevent water from freezing in fuel lines?
With only moderate effort, you can be assured that your diesel fuel will provide optimal performance and enjoy the expected life of your engine’s fuel filters, fuel system components, and your substantial investment in the diesel engine.