Baileys Performance Solutions - Refurbishment of Diesel Fuel Injection and Air-Charging Systems for Power-Generation Diesels

Baileys Performance Solutions (BPS), the industrial division of Baileys Diesel Fuel Injection, has over 35 years of specialist involvement in the refurbishment of diesel fuel injection systems. We are not engine overhaul contractors, consultants or advisers. Our work starts when everything else has failed to improve the fuel efficiency and combustion behaviour in medium-speed diesel engines.

Combustion behaviour is essentially influenced by fuel - air and compression qualities depending mainly on three sections of the entire diesel engine build up: the fuel injection system and governer unit, the charge-air system in single or twin-turbo configuration, and the mechanical side of the engine in the form of valves, pistons, rods and crankshaft.

Precision-engineered fuel injection and air-charging systems

Engine manufacturers segregate R&D and the manufacture of fuel injection and air-charging systems from the main engine block (the mechanical engineering aspect) while relying on specialist manufacturers and their accredited after-sales organisations for fluid and air power engineering disciplines. OEM engine handbook data - as prevalent on day one after commissioning - set out benchmarks for refurbishment credentials and capabilities mandatory to carry out certified refurbishment work on diesel fuel injection and air-charging systems.

Refurbishment of fuel injection and air-charging systems

Loss in engine efficiency is not a matter of the age of the engine; it is a matter of systems deviating from 'as factory-new standards' as specified in the OEM engine handbook. Too much fuel and not enough air or too much air and not enough fuel all have the same outcome: the combustion process is compromised, and compromise means inefficiency in diesel engine performance. Inefficiency costs money in the form of excessively high fuel bills, excessively low metering bills and premature engine componentry wear, resulting in unscheduled service and maintenance interventions (i.e. unnecessary downtime).

Distribution and refurbishment of fuel injection systems

Refurbishment, in contrast to service and maintenance work, replicates the initial manufacturing processes as applied by the OEM of the original fuel injection and air-charging systems. Factory new and genuine parts and components are merged with in-use system components, which maintains their useful and economical life.

BPS, as an authorised importer, distributor and refurbishment partner of fuel injection manufacturers such as L'Orange, DUAP, BOSCH, ZEXEL, Diesel KIKI and Lucas Bryce/Woodward, replicates factory conditions at its works in Unanderra, Australia, with the added benefit that a library of OEM handbooks and OEM masterpumps / injectors guarantees that 100% originality will be created in tolerance and standards during BPS's manufacturing processes.

Peak pressure calibration and ISO bench testing to factory standards

Manufacturing and component matching on its own will not guarantee 'as factory-new standards'. BPS employs assembly techniques and performance and efficiency testing to ISO standard 4008- 1, 2 and 3 on test benches with up to 30,000psi working pressure and pump lift capacities to up to 35mm x 35mm, resulting in equalisation factors of 0.02% across any range of pumps whether in six, 12, 18 or 20+ cylinder configuration.

Turbo rotor diagnostic and balancing services for diesel engines

The latest addition to our turbo rotor diagnostic and balancing centre features the 2010 Schenck CAB 920 system for the highest precision balancing / vibration elimination. Last but not least, our KRAL Volumeter fuel efficiency metering system will monitor and report reliably on any future deviations on engine efficiency drop without compromise, signalling rapid intervention opportunities thus avoiding costly fuel consumption and unnecessary emission of pollutants.

Environmental awareness encourages fuel efficiency policy

Power generation, transmission and distribution all commence with the conversion of energy encapsulated in diesel fuel. Optimising the conversion of energy into electricity means more than feeding diesel fuel from one tank into combustion chambers; it means turning fluid power stored underground for millions of years into life-enhancing electricity. Fuel efficiency, optimised engine longevity and commercial viability are truly only the tip of the pyramid. Fuel efficiency also stands for mastering the art of converting nature's energy resources into purposeful, ecologically sound and clean power supply.