Rajan Wilcox
Fuel tanks are containers designed to hold flammable fluids, such as gasoline, diesel fuel, or natural gas. They are typically part of an engine system, where the fuel is stored and propelled or released into the engine. The size, material, and structure of a fuel tank vary depending on its application and the type of fuel it stores. For example, a larger fuel tank can increase a car's range between refills, but the weight and space requirements of a larger tank can be undesirable, especially in smaller cars. Fuel tanks are constructed through a series of specific steps, including designing a mockup to determine size and shape, addressing design issues, and selecting the appropriate materials.
| Characteristics | Values |
|---|---|
| Definition | A fuel tank is a sealed container designed to hold natural gas, either CNG or LNG, for a specific period to power an engine. |
| Other Names | Petrol tank, gas tank |
| Contents | Flammable fluids, often gasoline or diesel fuel |
| Functions | Storage of fuel, feeding of the engine, determining the level of fuel in the tank |
| Construction Materials | Plastic (high-density polyethylene HDPE), metal, magnesium |
| Coating | Three-coat epoxy system (MIL-P-24441) |
| Design Considerations | Size, weight limits, available space, thickness, temper, alloy |
| Features | Outlet, drain, fluid level indicator, seams, baffles, lightening holes |
| Testing | Leak-tested |
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What You'll Learn
Fuel tank construction
Fuel tanks are designed to store flammable fluids, such as gasoline or diesel fuel, and feed them into an engine system. The size, structure, and material of a fuel tank are determined by its application, available space, and weight limits.
The construction of a fuel tank follows a series of specific steps. Firstly, a mock-up is created to determine the size and shape of the tank. This is usually made from foam board. Next, design issues are addressed, such as the placement of the outlet, drain, fluid level indicator, seams, and baffles. The thickness, temper, and alloy of the sheet metal are then decided upon. After cutting the sheet metal to the required shapes, the basic shell and ends of the tank are formed by bending the pieces.
Many fuel tanks, especially those used in aircraft and racecars, have lightening holes in their baffles. These flanged holes reduce the weight of the tank while adding strength to the baffles. The ends of the tank can be hemmed and soldered, flanged and brazed, or welded, and sealed with an epoxy-type sealant. To prevent leaks, the heads of rivets are often brazed or soldered. Once the assembly is complete, the tank undergoes a leak test.
Fuel tank coatings are essential to prevent corrosion and contamination of the fuel. They must be resistant to aliphatic and aromatic petroleum products. A three-coat epoxy system is commonly used, providing a total coating thickness of 250-300 μm.
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Fuel tank size
The size of a fuel tank is determined by its application and the type of fuel it will store. For example, natural gas fuel tanks for vehicles are designed to hold either CNG (Compressed Natural Gas) or LNG (Liquefied Natural Gas). The choice between CNG and LNG tanks depends on the travel distance and the accessibility of fuelling stations. LNG tanks are preferred for long-haul trailers as they offer a greater range, while CNG tanks are suitable for shorter distances where fuelling stations are readily available, such as in city buses.
The maximum size of a fuel tank is constrained by the weight and space limitations of the vehicle. In a passenger car, for instance, the fuel tank's size should ideally not exceed the trunk's dimensions to avoid compromising passenger space. Conversely, the minimum size of the fuel tank is determined by the minimum travel distance required before refuelling. For example, a garbage truck's fuel tank should be large enough to complete at least one round trip from the fuelling station to the garbage pickup and dump site before needing to refuel.
The design and construction of fuel tanks involve careful consideration of various factors. Craftsmen typically create a mockup to determine the size and shape of the tank, addressing design elements such as the outlet, drain, fluid level indicator, seams, and baffles. Baffles, which are structures that reduce sloshing and improve fuel capacity, often contain lightening holes to reduce weight and add strength. The thickness, material, and alloy of the sheet used to construct the tank are also crucial factors in determining its final size and capacity.
It is important to note that the indicated fuel level in a tank may not always be accurate. Variables such as the vehicle not being on level ground, the position of the driver's eye when reading the gauge, and the rated capacity being an estimate can all affect the perceived fuel level. Additionally, factors such as maintenance, cargo load, driving habits, terrain, and fuel composition can influence fuel consumption and, consequently, the optimal size of the fuel tank for a particular application.
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Fuel tank coatings
There are various products available for coating fuel tanks, each with its own unique features and application methods. One popular option is the POR-15 Fuel Tank Sealer, which serves as a liner and effectively stops rust, corrosion, and small fuel leaks. It is compatible with metal fuel tanks and provides superior strength and resistance to various fuels, including diesel, E10 ethanol, and high alcohol content fuels. Before applying this coating, it is crucial to ensure that the fuel tank is free from plastic parts, contamination, and structurally sound. The preparation process involves cleaning the tank with a degreaser, removing old sealers, and etching the metal for improved adhesion.
Another notable product is the Caswell Epoxy Gas Tank Sealer, which offers excellent chemical resistance and bond strength. This epoxy coating can withstand permanent immersion in harsh solvents, fuels, and oils, including ethanol-based fuels. It is known for its ability to form a thicker overall coating and its preference for bonding with rough rusty surfaces. The Caswell Epoxy Gas Tank Sealer is easy to apply and is suitable for salvaging old gas tanks, making it a popular choice among users.
It is important to note that the type of coating used depends on the specific requirements of the fuel tank application. For example, in the aerospace industry, fuel tank sealants that provide resistance to fluids such as water, alcohols, synthetic oils, and petroleum-based hydraulic fluids are commonly used. Additionally, coatings for fuel tanks must prevent contamination of the fuel by corrosion products or coating materials. They must also protect the tank from corrosion damage and be resistant to aliphatic and aromatic petroleum products. A three-coat epoxy system meeting MIL-P-24441 is often recommended for this purpose.
The size, structure, and material of a fuel tank are also influenced by its intended application and the type of fuel it will store. For instance, the maximum size of a fuel tank is typically limited by weight and space constraints in a vehicle, while the minimum size is determined by the minimum travel distance within a refuelling cycle.
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Fuel tank capacity
The size of a fuel tank is determined by its application and the available space in the vehicle. For example, in a passenger car, the fuel tank size is typically limited by the size of the trunk to avoid compromising the passenger compartment space. On the other hand, a garbage dump truck may require a larger fuel tank that can last at least one round trip from the fuelling station to the garbage pickup and back.
The material and structure of the fuel tank also play a role in determining its capacity. Fuel tanks can be made of metal, plastic, or other materials such as composite fibres. Metal fuel tanks are usually constructed by welding stamped sheet metal parts together, while plastic fuel tanks are often created using blow moulding, allowing for more complex shapes. Custom and restoration fuel tanks for aircraft, motorcycles, boats, and even tractors may be handcrafted by craftsmen.
The choice of material and construction method can impact the weight and safety of the fuel tank. For example, plastic fuel tanks (made from high-density polyethylene or HDPE) are functionally viable in the short term, but they have the potential to become saturated by fuels like diesel and gasoline over time. This can lead to environmental stress cracking, which, coupled with the flammability of the fuel, could result in catastrophic failure. Therefore, the selection of the appropriate material and construction technique for a fuel tank is critical to ensure its safety and longevity.
To find the specific fuel tank capacity of a vehicle, one can refer to the owner's manual or the manufacturer's website, which typically provides detailed specifications for different vehicle models.
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Fuel tank safety
Fuel tanks are designed to safely store flammable fluids, such as gasoline, diesel fuel, or natural gas. The safety of a fuel tank is dependent on several factors, including its design, construction, and maintenance.
The design of a fuel tank must consider the size, material, and structure, which are determined by the application and fuel type. For example, the weight and space limitations of a vehicle will dictate the maximum size of a fuel tank, while the minimum size will depend on the desired travel distance between refuelling. The material and structure of the tank must also prevent leakage and limit evaporative emissions. Fuel tanks made from plastic, for instance, may become saturated over time as fuels like diesel and gasoline permeate the material, leading to the possibility of stress cracking and catastrophic failure. To avoid this, certain coatings are applied to the interior of fuel tanks to prevent corrosion and contamination of the fuel. Zinc coatings, for instance, should not be used as zinc can dissolve into the fuel and cause engine problems.
In terms of construction, fuel tanks are typically crafted by metal craftsmen who follow specific steps to ensure safety. These include creating a mockup to determine size and shape, addressing design issues such as outlet and fluid level indicator placement, and determining the thickness and alloy of the sheet metal used. Once the tank is constructed, it undergoes leak testing to ensure safety.
To ensure safety during fuelling, it is important to fill the tank in a secure way, without sparks, as this could ignite the flammable fuel. Additionally, consumers should be aware that fuel gauges may not always provide an accurate representation of the remaining fuel due to variables such as the vehicle not being on level ground, or the position of the driver's eye when reading the gauge. Understanding these variables can help prevent overfilling the tank, which could lead to fuel spillage and potential safety hazards.
Overall, fuel tank safety is a critical consideration in the design, construction, and use of fuel tanks. By following established guidelines and best practices, the risks associated with storing and using flammable fuels can be significantly mitigated.
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Frequently asked questions
A fuel tank is a sealed container designed to hold flammable fluids, often gasoline or diesel fuel. It can also hold natural gas, either CNG or LNG. The size, material, and structure of the tank are determined by its application, with considerations for weight limits and available space on the vehicle.
The size of a fuel tank is determined by the available space on a vehicle and the weight of the tank. For example, in a passenger car, the tank should ideally not be bigger than the trunk to avoid compromising the space of the passenger compartment. The minimum size of the fuel tank depends on the minimum travel distance within a refuelling cycle.
The materials used for fuel tanks vary. Plastic (high-density polyethylene HDPE) can be used for fuel tanks, but it is not ideal for long-term use as fuels can permeate the material. Metal craftsmen also fabricate or hand-make fuel tanks. They use alloys and sheets of metal to create the basic shell and ends of the tank. In the past, magnesium was used for fuel tanks in German aircraft in the early 1930s, but its use has decreased in commercial aircraft today.
