Electricity and Control August 2025

Plant maintenance, test + measurement The hazards of fuel adulteration in machine maintenance Fuel adulteration remains one of the most insidious threats to industrial machinery, safety, and environmental compliance across multiple sectors. Craig FitzGerald, Chief Executive Oƒicer of ISO-Reliability Partners, points out that this issue is widespread and, as well as undermining mechanical performance and operational safety, it raises significant legal and financial risks.

Mechanical reliability is also compromised. Poor fuel quality can cause diesel engines to fail under load, potentially creating hazardous conditions, particularly in heavy industrial or transport environments. Environmental and economic fallout As well the harm it does to equipment and people, adulterated fuel undermines environmental protection and public finances. “The practice leads to the illegal disposal of hazardous industrial oils and long-term soil, air, and groundwater contamination,” says FitzGerald. “It is a form of environmental abuse hiding in plain sight.”

ISO Reliability Partners warns that fuel adulteration remains one of the most prevalent hidden threats to industrial machinery.

“A dulterated fuel is not just a matter of poor performance; it is a danger to equipment integrity, worker safety, and environmental sustainability,” says FitzGerald. “The problem is far more prevalent than many realise, and the consequences are escalating.” Quality concerns Central to the issue is the adulteration of diesel with substances such as illuminating paraˆin (IP), used transformer oil, and gear oils. These agents significantly degrade fuel quality. “IP, for instance, reduces diesel’s lubricity, which is essential for the protection of high-pressure fuel injection systems. Without proper lubrication, operations will see elevated costs, premature wear and mechanical failure,” says FitzGerald. In addition, adulteration alters the fuel’s viscosity and density, directly aˆecting combustion eˆiciency and engine output. This results in increased maintenance frequency, unexpected breakdowns, and markedly higher operational costs over time. “We are seeing cases where seemingly minor dilution leads to major engine damage, simply because the physical and chemical properties of the fuel are no longer within operational parameters,” adds FitzGerald. Safety risks and invisible hazards The safety implications extend beyond engine wear. Used transformer oil, a common adulterant, o“en contains polychlorinated biphenyls (PCBs), a class of highly toxic chemicals strictly regulated under the Basel Convention. “The combustion of PCBs in engines produces extremely harmful by-products, including hydrogen chloride and dioxins, many of which are carcinogenic and mutagenic,” FitzGerald notes. “When you are running equipment using adulterated fuel, you are creating chemical hazards that aˆect machine operators and the broader environment.”

Moreover, the economic consequences are serious. FitzGerald highlights that losses to the South African fiscus from fuel adulteration and associated tax evasion are estimated to exceed R3.6 billion annually. “These are funds that could otherwise support environmental enforcement, infrastructure, and community development,” he says. Proactive industrial measures FitzGerald advocates a combination of advanced technology and sound procurement practices to combat adulteration. Real-time sensor technology like the Yateks® Africa FuelTrust system allows for real-time on-site detection of critical fuel parameters, including density, viscosity, and dielectric constant, which flags contaminants such as paraˆin and PCBs as well as moisture content and temperature. The sensors are particularly suitable for continuous monitoring in high-volume operations. In addition to technological solutions, regular fuel sampling, laboratory testing, and comparative analysis against EN590 standards remain essential. “Even when using unbranded or ‘white site’ fuel suppliers, it is critical to analyse lubricity and chemical composition to avoid surprises,” FitzGerald says. Accountability from suppliers ISO-Reliability Partners advises industries to tighten their fuel procurement standards. FitzGerald recommends demanding written certification of compliance with EN590 or similar recognised standards, batch test results for viscosity, density and sulphur, and contractual audit rights. “Fuel suppliers must be held accountable.” He advises industry to choose branded suppliers with traceability and a reputation to lose, as they are statistically less likely to be involved in adulteration. He also emphasises the value of contractual protections: “Include clauses that enforce penalties for non-compliance, allow

22 Electricity + Control AUGUST 2025