Mercedes Mullins
Diesel fuel tanks are a critical component of many industries, from transportation to maritime, and are used to power vehicles, generators, and heavy machinery. They are designed to safely store and dispense diesel fuel, which is a powerful yet corrosive substance. These tanks come in various sizes and shapes, each designed for a specific purpose, and are typically made from steel due to its durability and corrosion resistance. The function of the diesel fuel system is to inject a precise amount of atomized and pressurized fuel into each engine cylinder at the right time, with the fuel system consisting of the fuel tank, water separator, feed pump, filter, high-pressure pump, injector nozzle, and cylinder.
| Characteristics | Values |
|---|---|
| Purpose | To store and dispense diesel fuel |
| Importance | Critical component of diesel engines; indispensable for various sectors |
| Uses | Powering vehicles, generators, heavy machinery, industrial machinery, maritime industry, aircraft, etc. |
| Construction | Metal, steel, plastic (HDPE), bladder-style, custom and restoration tanks |
| Design | Different types and shapes designed for specific purposes; must be capable of storing enough fuel; closed to prevent contamination; vented to allow air to enter |
| Openings | Fill, discharge, drain, filler neck, fuel pickup, fuel-level sending unit |
| Fuel System | Consists of the fuel tank, water separator, feed pump, filter, high-pressure pump, injector nozzle, and cylinder |
| Fuel Injectors | Deliver precise amounts of atomized and pressurized fuel into each cylinder |
| Fuel Lines | Heavyweight, medium weight, and lightweight |
| Fuel Filters | Primary and secondary filters to remove water, sediment, and muck |
| Fuel Return Pipe | Returns unused or excess fuel to the tank |
| Fuel Cooling | Water cooling |
| Enemies | Water, which can cause seizure and component failure |
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What You'll Learn
Injecting atomized and pressurized fuel into each engine cylinder
The primary objective of diesel fuel injection systems is to achieve optimal fuel atomization, breaking the fuel into very small particles. This ensures that all the fuel has the opportunity to vaporize and participate in the combustion process. Any remaining liquid droplets may burn poorly or be exhausted from the engine without contributing to combustion. Therefore, fuel atomization is a key factor in the design of diesel fuel injection systems.
To achieve the desired level of fuel atomization, the injection system must control the injection timing, fuel quantity, and other parameters. Modern injection systems utilize high-pressure pumps to deliver fuel to the injectors, and the time between the start of delivery and the actual injection (SOI) is known as the injection delay. The injected fuel quantity is measured per power stroke, and the injection duration refers to the time during which fuel enters the combustion chamber.
The performance of diesel engines is heavily influenced by the design of their injection systems. The most notable advancements in diesel engines have resulted from improvements in fuel injection system designs. By optimizing the delivery of fuel to the cylinders, injection systems play a crucial role in enhancing engine performance, reducing emissions, and improving noise characteristics.
Diesel fuel injectors, such as those found in common rail fuel systems, utilize piezoelectricity to achieve extreme precision in handling high-pressure applications. The precise control of fuel injection timing, metering, and atomization ensures that the engine receives the correct amount of fuel at the right time, contributing to increased power, improved fuel economy, reduced engine noise, and smoother operation.
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Filtering diesel fuel
Diesel fuel filters are designed to remove these damaging particles and separate water from the fuel. The filters are typically made of materials that can capture extremely small particles, preventing them from reaching the engine and causing damage. The common unit of measurement for diesel fuel filters is the micron or micrometer, with primary fuel filters removing particles ranging from 10 to 15 microns, and secondary filters removing particles as small as 2 to 5 microns.
Most diesel fuel systems employ multiple stages of filtration to ensure the fuel is clean before it reaches the injectors. A typical system might have three stages of progressive filters: a filter screen at the tank or transfer pump, a primary fuel filter, and a secondary fuel filter. In series configurations, the fuel passes through one filter and then the other, while in parallel setups, the fuel is split, with a portion going through each filter.
The primary filter, also known as the fuel lift pump, has two main functions. Firstly, it separates any water present in the fuel, draining it into a see-through bowl, and secondly, it filters out sediment and other larger particles. The secondary filter is finer and focuses on removing any remaining muck or small contaminants before the fuel reaches the injector pump.
To combat the issues caused by asphaltene and wax crystal buildup, specialised products known as cold flow improvers can be used. These additives keep wax crystals in solution, preventing them from plugging the fuel filter and ensuring the smooth operation of the diesel engine. Additionally, fuel additives can increase fuel system lubricity and further protect fuel pumps and injectors from premature failure.
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The role of fuel injectors
There are different types of fuel injection systems, including pump-line-nozzle, unit injector, and common rail. In a common-rail system, fuel from the tank is supplied to a header (accumulator) and then sent through tubing to the injectors, which inject it into the combustion chambers. The accumulator has a high-pressure relief valve to maintain pressure and return excess fuel to the tank. The fuel is sprayed through a nozzle that is opened and closed with a solenoid-operated needle valve.
Modern diesel fuel injectors, such as those in common rail fuel systems, use piezoelectricity. These injectors are extremely precise and can handle the very high pressures found in these applications. The use of piezoelectric injectors allows for increased precision, with fuel pressures up to 300 MPa or 44,000 psi.
The performance of diesel engines is heavily influenced by their injection system design. The way fuel is delivered to the cylinders makes a significant difference in engine performance, emissions, and noise characteristics. For example, highly atomized, pressurized fuel distributed evenly throughout the cylinder results in increased power and fuel economy, decreased engine noise, and smoother operation.
Additionally, the timing of fuel injection is crucial. Start of injection (SOI) refers to the time when injection of fuel into the combustion chamber begins. The difference between the start of delivery and SOI is influenced by the length of time it takes for a pressure wave to travel between the pump and injector. End of injection (EOI) is when fuel injection stops, and the injected fuel quantity is the amount delivered per power stroke.
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Water in the fuel system
Water in diesel fuel is a critical issue that can cause significant damage to fuel quality and engine performance. Water can enter the fuel during transit, storage, or handling, and it is more common in diesel fuel than most people realize. This is partly because diesel fuel has hygroscopic qualities, meaning it attracts and absorbs moisture from the air at the molecular level.
Water in diesel fuel can result in rust particles entering the fuel, promote the growth of bacteria and microorganisms, and cause premature wear and corrosion in fuel injectors and other engine parts. If water enters the injection system, it will rapidly oxidize ferrous metal (steel) components. Some of the most common failures attributed to water include injection component seizure, sticky metering components, and governor/metering component failure.
To prevent water contamination, it is important to buy diesel fuel from reputable sources with well-maintained systems. Most fuel retailers and distributors use water-detecting filters in their dispensing equipment, but these must be adequately maintained to be effective. Additionally, condensation can occur in storage tanks, especially in above-ground tanks and in truck fuel tanks, due to temperature fluctuations and the drawing down of fuel during operation. One way to reduce condensation is to top off the tank before parking it.
If water is suspected in diesel fuel, it is important to treat it with products designed to disperse and remove water, such as FPPF Fuel Power. Removing as much water content as possible is crucial to ensuring fuel purity and preventing free water from infiltrating the engine's injection system. High-quality filtration systems, such as the AirDog® FPII system, can effectively separate air and water from the fuel entering the engine.
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The construction of diesel fuel tanks
The tank body is the most prominent part of a diesel fuel tank. Typically, it is crafted from high-strength steel, aluminium, or, in some cases, high-density polyethylene (HDPE). Steel tanks offer excellent durability and impact resistance, making them suitable for heavy-duty applications. Aluminium tanks, on the other hand, are lightweight, which helps improve fuel efficiency in vehicles. HDPE tanks are corrosion-resistant, making them ideal for long-term use in various environments. The interior of the tank is often coated with a special material to prevent rust and corrosion, ensuring the purity of the diesel fuel.
The construction process typically involves the following steps: First, a mock-up is created to determine the accurate size and shape of the tank, usually out of foam board. Next, design issues that affect the structure of the tank 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 determined. After the sheet is cut and bent into the required shapes, various pieces are assembled to create the basic shell, ends, and baffles of the tank. Many fuel tank baffles contain lightening holes, which reduce weight while adding strength. Towards the end of the construction, openings are added for the filler neck, fuel pickup, drain, and fuel level sending unit.
Diesel fuel tanks are equipped with a ventilation system to prevent pressure build-up inside the tank. This allows air to enter and exit as the fuel level changes, and some systems capture and recycle fuel vapours, reducing emissions and improving fuel efficiency. Additionally, fuel tanks must be placed in a safe location to prevent fires. They should be kept separate and visible, appropriately distanced from potential ignition sources, such as the diesel generator set. Smoking is strictly prohibited near the fuel tanks.
On construction sites, there are various options for diesel fuel storage, including tanks and trailers, which can be small and portable or larger and stationary. Drums and barrels are also used for short-term or moderate diesel fuel storage, offering portability and ease of handling. Larger, above-ground storage tanks are designed for long-term diesel fuel storage and are equipped with safety features like spill containment. Fire safety measures, ventilation, grounding and bonding, and spill response plans are crucial considerations to ensure the safe storage of diesel fuel.
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Frequently asked questions
Diesel fuel tanks are robust containers that are specifically designed to safely store and dispense diesel fuel. They are made from materials such as steel, plastic, or crafted metal, and come in a variety of sizes and shapes to suit different applications.
The diesel fuel system consists of the fuel tank, water separator, feed pump, filter, high-pressure pump, injector nozzle, and cylinder. The low-pressure feed pump pulls the fuel from the tank through a filter and water separator, then pushes it through another filter. The high-pressure pump then steps up the fuel pressure before it is injected into the cylinder.
One of the most common issues with diesel fuel systems is water contamination, which can lead to the oxidation of steel components and the failure of injection components. Other issues include leaks in the pipework, usually caused by vibration, and the hardening and cracking of bladder-style tank materials over time.
