When the lights go out:The crucial role of fuel polishing in backup power reliability
This applies to any backup power system running on diesel or alternative fuels such as HVO (Hydrotreated Vegetable Oil), which is becoming increasingly popular for reducing carbon emissions.
The Hidden Vulnerability: Fuel Degradation
Backup generators are often installed and then forgotten, assumed to be ready at a moment’s notice. However, diesel fuel, which powers many of these generators, is not a static substance. Over time, especially in storage, it can degrade due to microbial contamination, water ingress, and oxidation.
This degradation can lead to clogged filters, damaged injectors, and ultimately, generator failure. Regular testing, cleaning and polishing the fuel to remove contaminants is essential to maintain fuel quality and ensure generator reliability. Even refined fuels like HVO are not immune to this issue. In fact, we’ve seen cases where injectors on HVO-fuelled systems needed replacing every four weeks due to contamination – despite the fuel being filtered to just 1 micron and heated during use.
Case Study: Iberian Peninsula Blackout
On April 28, 2025, a massive power outage swept across Spain and Portugal, affecting tens of millions and disrupting critical infrastructure. Hospitals, transportation networks, and communication systems were all impacted. While some facilities managed to maintain operations using backup generators, others faced challenges getting back to normal. This event highlighted the importance of not only having backup systems in place but also ensuring their reliability through proper maintenance practices like fuel conditioning.
Case Study: Heathrow Airport Power Outage
In March 2025, London’s Heathrow Airport experienced a significant power outage due to a fire at a nearby electrical substation. The incident led to the closure of the airport for an entire day, causing widespread travel disruptions. Investigations appeared to suggest that while the primary power supply was compromised, backup systems in many cases were not always effective enough to deal with such a scenario, highlighting concerns about the maintenance, readiness and capacity of these critical backup systems.
The Cost of Neglect
The consequences of inadequate backup power systems are not just operational but also financial and reputational. Downtime can lead to significant revenue losses, especially in sectors like healthcare, data centres, and transportation. Moreover, the failure to provide essential services during outages can erode public trust.
This is true regardless of fuel type. HVO systems, while more environmentally friendly, must still be protected from contamination to avoid frequent and costly component failures.
Investing in regular maintenance, including fuel polishing, is a cost-effective strategy to mitigate these risks.
Conclusion
The recent power outages serve as a stark reminder of the critical role backup generators play in maintaining essential services. However, the reliability of these systems hinges on regular maintenance practices, particularly fuel testing and polishing. Whether you’re running on traditional diesel or HVO, protecting your fuel quality is non-negotiable if you want dependable performance. By ensuring fuel quality, organisations can safeguard their operations against unexpected power disruptions.
About IPU Group
At IPU Group, we specialise in providing high-quality fuel polishing equipment designed to maintain the integrity of your backup power systems, as well as diesel testing, both on-site or at our West Bromwich based premises. Our solutions are suitable for systems running on diesel or HVO, helping prevent the contamination issues that can shorten the life of critical components. Our solutions are tailored to meet the needs of critical infrastructure, ensuring that when the grid fails, your operations continue seamlessly.