Mercedes Mullins
Installing a permanent fuel tank in a marine setting requires careful planning and execution to ensure safety and functionality. The process involves several steps, including determining the optimal placement, preparing the necessary tools and components, and adhering to regulatory standards. Proper installation is critical to prevent fuel leakage and corrosion, which can lead to tank failure. This complex procedure demands a comprehensive understanding of marine fuel systems and, in some cases, custom engineering solutions.
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What You'll Learn
Ensure the tank is grounded, vented, and accessible for inspection
To ensure the tank is grounded, vented, and accessible for inspection, follow these steps:
Grounding
Firstly, it is important to understand the purpose of grounding. Fuel tanks can accumulate static or electrical energy, which can lead to fires or accidents. Grounding drains away this static charge, reducing the risk of fire. To ground the tank, connect an earth-end-ground wire to one of the terminals at the base of the tank's fill neck. Use a stainless steel split ring lock washer and screw fitting to secure the connection. Likely grounding sites include metal surfaces on your engine mount or outdrive. Do not attach the grounding wire to a painted surface, and ensure it is checked regularly for corrosive buildup.
Vented
Fuel tank vents are crucial for safety. They prevent a vacuum from forming in the tank as fuel is consumed, which can cause deformity or rupture. Vents also help to prevent explosions, spills, and the build-up of heat and pressure. To vent the tank, thread a hose barb into the tank's vent if it does not have a moulded one. Ensure you do not over-tighten it. Use a gasoline and diesel-resistant seal compound to guard against leakage. Slide a small hose clamp onto the vent hose and leave it loose. Check the hose length and trim as needed to avoid kinking, then secure the hose over the vent fitting by tightening the hose clamp.
Accessible for Inspection
Regular inspections are essential for maintaining your fuel tank. Ensure the tank is easily accessible for inspection and testing. Check the exterior for any signs of damage, such as dents, rust, or corrosion. If damage is present, repair or replace the tank as needed. Also, check the tank's foundation to ensure it is stable and level. Keep all documentation related to the tank, such as permits, inspection reports, and maintenance records, up to date and easily accessible.
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Avoid foam and crevice corrosion
Marine fuel tanks are susceptible to corrosion, which can be caused by several factors, including the oxidation of hydrocarbon ingredients, fluctuating temperatures, and the ingress of water and contaminants. To prevent corrosion and ensure the longevity of your marine fuel tank, it is essential to take proactive measures and avoid common pitfalls such as foam installation and crevice corrosion.
Firstly, it is highly recommended to avoid using foam to secure or insulate your marine fuel tank. While foam can provide cushioning and help hold the tank in place, it can also trap water, leading to premature corrosion and failure of the tank. Water ingress can occur even in sealed compartments, and the foam acts as a water retainer, accelerating the corrosion process. Instead of relying on foam, consider using brackets or tabs screwed to the hull to secure the tank in place.
Another critical aspect of preventing crevice corrosion is to ensure regular checks and maintenance. Small amounts of corrosion are inevitable due to the nature of the stored fuel, but proactive measures can significantly reduce the impact. Schedule inspections and cleaning every six months to identify and address any corrosion or contamination issues early on. Keep the tank full to minimise the risk of moisture accumulation and consider implementing a double-skin tank design for added protection against temperature fluctuations and impact damage.
Additionally, applying a corrosion-resistant finish to your tank can provide long-lasting protection. Products such as Hammerite Direct to Rust Metal Paint repel water and prevent rust from forming underneath. This extra layer of protection helps to safeguard against corrosion caused by weather conditions, condensation, and UV light exposure.
Finally, it is essential to address any water accumulation within the tank and its surrounding areas. Water often forms during warmer months due to heat gain and evaporation, leading to bacterial contamination. Implement measures to remove rainwater or condensation from exposed areas, such as bunds, to prevent spillages and reduce the risk of water-induced corrosion. Regular maintenance and proactive water management are crucial in preventing corrosion and ensuring the longevity of your marine fuel tank.
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Use stainless steel pipe fittings for the fuel supply
When installing permanent fuel tanks in a marine setting, it is important to use high-quality materials that can withstand the rigours of the environment and ensure the safety of the boat and its occupants. One key consideration is the use of stainless steel pipe fittings for the fuel supply. Here are several reasons why this is a recommended approach:
Firstly, stainless steel offers excellent corrosion resistance, which is crucial in the marine environment where salt, water, and humidity can accelerate corrosion. By using stainless steel fittings, you reduce the risk of leaks caused by corrosion over time.
Secondly, stainless steel provides superior strength and durability compared to some other materials. The fuel supply system is subject to constant pressure and vibration, and stainless steel fittings can withstand these stresses without deforming or failing. This helps maintain the integrity of the fuel supply system over the long term.
Additionally, stainless steel fittings offer ease of installation and maintenance. They are designed to be compatible with industry standards, ensuring that connections are secure and leak-free. The fittings can also be easily sourced and replaced if necessary, ensuring the fuel supply system remains in optimal condition.
To ensure a proper installation, it is recommended to follow manufacturer guidelines and industry best practices. This includes using appropriate thread sealants or Teflon tape to prevent leaks, torqueing fittings to the specified tightness, and inspecting the system regularly for any signs of wear or corrosion.
By choosing stainless steel pipe fittings for the fuel supply, you benefit from their corrosion resistance, strength, and ease of installation, contributing to a safe and reliable permanent fuel tank system in marine applications. Remember to consult with professionals and adhere to safety guidelines during the installation process.
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Prevent water entrapment and corrosion
Water often forms in fuel tanks during warmer months due to heat gain and evaporation, leading to water and bacterial microbial contamination. This contamination can cause internal corrosion, which can then lead to equipment failure. To prevent this, you can use a corrosion-resistant finish, such as Hammerite Direct to Rust Metal Paint, which will protect the tank by repelling water and preventing rust from forming.
Another method to avoid leakage and water entrapment is to tank dewater at outlet pipes. This will detect liquid interfaces between oil and water. It should be fitted 1/4 inch from the bottom of the tank to allow water to escape and keep the oil contained. Tanks must be dewatered every six months to prevent water build-up and resulting corrosion.
A bund, or secondary containment, made of concrete or brick is also necessary to contain and prevent spillages that can happen due to tank penetration. It must be able to hold 110% of its contents, so if there is a leak, it is overfilled, or water forms in the tank, the outer bund can contain it safely.
Regularly checking and testing the condition of your fuel to monitor any recurrences of contaminants will enable you to act quickly. Fuel analysis can assess water content, viscosity, density, and the level of microbial contamination.
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Use a vented, dedicated vent for permanent tanks
It is essential to use a vented, dedicated vent for permanent marine fuel tanks. This is to prevent a vacuum block, which would hinder fuel from being pumped from the tank to the motor. The vent should be open when the motor is in operation and closed during storage to prevent evaporation and the loss of fuel. It also stops dangerous fumes from escaping, which could cause an explosion.
When installing a vent hose, avoid sags or traps in the vent line. This is because they allow fuel to puddle, which prevents the vent system from functioning correctly. A typical vent line will run across the top of the tank and then angle upward to the vent fitting. The hose should be as straight as possible, allowing any fuel to drain back into the tank. It is also important to keep the boat's fuel vent screen clean.
A no-spill valve (or fuel surge protector) is another useful addition to your vent system. This prevents fuel from spilling out of the vent when filling the tank and stops the hull from being stained by fuel. There are several brands that offer these valves, such as Attwood and Racor.
If your tank does not have a moulded vent, thread a hose barb into the tank's vent and secure it with a hose clamp. Check the hose length and trim as needed, ensuring that the vent hose is the correct length to avoid kinking.
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Frequently asked questions
Gather the necessary tools: a tape measure, a flat-blade screwdriver, pliers or a wrench. Determine the best placement for your below-deck tank, likely where your old tank was positioned. Remove your old tank.
Slide two large hose clamps onto the fuel fill hose and leave them loose. Slip the hose over the tank fill fitting and secure it by tightening the clamps into place from the end of the hose. Connect an earth-end-ground wire to one of the two terminals found at the base of your tank's fill neck. Likely grounding sites include metal surfaces on your engine mount or outdrive.
The ABYC specifies that permanent tanks must be grounded, vented to the outside, and accessible for inspection and testing. Horizontal metallic tank tops should be slanted or angled to shed water, and they should angle inboard to ensure that leaking water runs down the side of the tank that is visible.
It is best to use only stainless steel pipe fittings for the fuel supply. Do not mix a variety of metals and do not use steel or galvanized. Make sure that wherever the tank is sitting is a stable surface; always use the hull stringers and never the bottom of the hull.
