Identifying and counting common rail fuel system pressure relief valve opening events

A controller for a common rail fuel system operatively coupled to an engine system including an engine, the common rail fuel system including a fuel pump, a fuel rail, and a pressure relief valve (PRV), the controller including at least one processor and at least one memory storing instructions which, when executed by the at least one processor, cause the at least one processor to perform operations comprising:

• determining if the controller reset;
• determining if the PRV opened;
• in response to determining that the PRV opened, incrementing a PRV opening events counter;
• determining if the PRV opening events counter has exceeded a PRV opening events threshold;
• and
• in response to determining that the PRV opening events counter has exceeded the PRV opening events threshold, outputting a signal indicating that the PRV should be repaired or replaced.

A common rail fuel system operatively coupled to an engine system including an engine, the common rail fuel system comprising:

• a fuel rail;
• a fuel pump fluidly coupled to the fuel rail;
• a pressure relief valve (PRV) fluidly coupled to the fuel rail;
• a rail pressure sensor;
• an engine speed sensor;
• and
• a controller, communicatively coupled to the rail pressure sensor and to the engine speed sensor, configured to:
• increment a PRV opening events counter based on sensor data received from the rail pressure sensor or sensor data received from the engine speed sensor;
• determine if the PRV opening events counter has exceeded a PRV opening events threshold;
• and
• in response to determining that the PRV opening events counter has exceeded the PRV opening events threshold, output a signal indicating that the PRV should be repaired or replaced.