Katerina Swanson
Many generators have small built-in fuel tanks, which can be a problem if you need to run your generator for an extended period of time. In this case, an auxiliary fuel tank can be a useful solution. An auxiliary fuel tank is an external tank that can be connected to your generator to provide additional fuel capacity. This allows you to run your generator for longer periods without having to refuel as frequently. There are a few different ways to set up an auxiliary fuel tank, depending on the type of generator you have and your personal preferences. Some people choose to use a gravity-fed system, where the auxiliary tank is placed above the generator, while others use a fuel pump to draw fuel from the auxiliary tank into the generator.
| Characteristics | Values |
|---|---|
| Purpose | To avoid having to refill the generator's built-in tank every few hours |
| Fuel tank capacity | 5 gallons (most common), 6 gallons, 7 gallons, 12 gallons, 14 gallons, 16 gallons, 18 gallons |
| Fuel type | Gasoline |
| Fuel tank placement | Directly above the generator (gravity-fed systems), or at a distance (with a longer hose) |
| Fuel tank material | Aluminum, plastic, or metal |
| Fuel connection type | "Hose barb" or "quick connect" |
| Additional components | Fuel pump, fuel filter, shut-off valve, fuel gauge, hand pump primer bulb |
| Safety considerations | Avoid leaks, ensure drip-proof tight connections, prevent fuel spillage and potential explosion |
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What You'll Learn
The benefits of using an auxiliary fuel tank
An auxiliary fuel tank is a great way to ensure your generator has enough fuel to last through power outages without needing to be refilled every few hours. This is especially useful if you're using a generator as a backup power source, as you won't have to worry about constantly monitoring fuel levels during an outage.
One of the main benefits of using an auxiliary fuel tank is the ability to extend the range of your generator. With an auxiliary tank, you can increase the distance you can cover, reducing the need to stop for refuelling. This is particularly advantageous for those who travel long distances or need to visit various job sites throughout the day. It allows you to be more selective about when and where you refuel, giving you the flexibility to choose cheaper gas stations without making unnecessary detours.
Auxiliary fuel tanks also enhance safety and convenience. They provide a safer and more secure option than carrying extra fuel in plastic containers, which can lead to accidents, spills, or theft. Properly installed auxiliary tanks, made from high-quality materials, meet official safety requirements for combustible fuel tanks. This gives you peace of mind and ensures a safer driving experience.
Additionally, auxiliary fuel tanks offer the convenience of maintaining good fuel levels without the effort of constant refuelling. Many auxiliary tank systems have features like shut-off valves, allowing you to control the flow of fuel to the main tank. This helps in situations where you suspect a leak or want to monitor fuel usage. Electrical pump systems often include a switch that lets you refill the stock tank as needed, making it easier to keep track of fuel levels.
Overall, an auxiliary fuel tank for your generator provides numerous benefits, including extended range, enhanced safety, convenience, and the ability to be selective about refuelling locations and timing.
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Fuel tank safety considerations
Fuel tanks are convenient but come with safety risks and requirements. If you're making your own auxiliary fuel tank for a generator, there are several safety considerations to keep in mind.
Firstly, you need to ensure that your fuel tank is the right size and has the capacity to meet your needs. This involves considering how much fuel you will require and the span of time over which you will consume it.
Next, you should be aware of any relevant safety guidelines, such as those provided by OSHA, and ensure that your fuel tank setup is compliant with regulatory laws. For example, the EPA requires regular testing of above-ground "bulk storage tanks" for structural integrity. Additionally, specific signage and labels must be posted on and near the tank. These include a contents sticker, National Fire Protection Association (NFPA) diamond placards, a "FLAMMABLE – KEEP FIRE AND FLAME AWAY" sign, and "No Smoking" signs.
It is also important to consider the placement of your fuel tank. If using a gravity feed system, the auxiliary tank must be higher than the generator's tank. Additionally, ensure that the tank is protected from any heat radiating from nearby engines or exhaust systems. If your tank is located outdoors, consider using a double-walled tank to protect the inner tank from the elements and contain any leaks.
Finally, be mindful of potential leaks in your fuel lines and connections. Ensure that all connections are drip-proof tight to prevent fuel from leaking onto the generator. Consider adding a fuel shut-off valve and a fuel filter to your setup. Regularly inspect your fuel tank and lines for any issues, and have a spill kit readily available in case of leaks.
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Fuel tank size and placement
The size of the auxiliary fuel tank you need depends on how long you want to be able to run your generator for without refuelling. A 1-gallon tank will run for approximately 3 to 4 hours, while a 5-gallon tank will need to be refilled every 5 or 6 hours. A 14-gallon tank will provide enough fuel for an entire production day.
The placement of the auxiliary fuel tank depends on the type of feed system you are using. If you are using a gravity feed system, the auxiliary tank must be placed higher than the generator's tank. If you are using a pressure feed system, you will need to monitor the generator's tank while transferring fuel to ensure there is no overflow.
If you are using a boat fuel tank as your auxiliary tank, you can buy a hose of any length to connect it to your generator. However, if the hose is longer than 15 feet and has a 5/16" or 3/8" inside diameter, you may need to reduce the hose size to 1/4" to avoid starving the motor for fuel.
When placing your auxiliary fuel tank, consider the convenience of storage and the elevation of the tank. You may also want to consider the safety implications of the placement, as refuelling a generator can be hazardous.
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Fuel line size and fittings
When creating an auxiliary fuel tank for a generator, it is important to consider the fuel line size and fittings. The fuel line size will depend on the specific generator model and the flow rate required. As a general rule, a larger generator will require a larger fuel line to ensure adequate fuel supply. Standard fuel line sizes for generators typically range from 1/4" to 3/8" in diameter. However, it is important to consult the manufacturer's specifications or seek advice from experts to determine the exact fuel line size required for your particular generator model.
There are various fittings available for connecting the fuel line to the auxiliary tank and the generator. The two most common types of fittings are "hose barb" and "quick connect". Hose barb fittings are more permanent and involve securely attaching the fuel line to the tank and generator with a tight seal to prevent leaks. Quick-connect fittings, on the other hand, offer convenience and ease of use. They allow for simple and fast connection and disconnection of the fuel line, making it easier to switch between tanks or perform maintenance.
When selecting fittings, it is important to ensure compatibility with your fuel line size and the specific connection types on your generator and auxiliary tank. The fittings should create a secure and leak-proof connection to prevent fuel leakage, which can pose safety hazards. It is also crucial to consider the material and quality of the fittings to ensure durability and resistance to corrosion, especially if they will be exposed to outdoor elements.
In addition to the fittings themselves, there are several other components that can be incorporated into the fuel line assembly. For example, a fuel filter can help ensure that clean fuel is delivered to the generator, while a shut-off valve allows for the convenient cessation of fuel flow when necessary. A squeeze bulb or primer bulb can aid in priming the fuel line, ensuring that it is filled with fuel before use. These additional components enhance the functionality and safety of the auxiliary fuel tank system.
The setup of the fuel line and fittings will depend on the specific configuration of your generator and auxiliary tank. If the auxiliary tank is placed higher than the generator, a gravity feed system can be utilised, allowing fuel to flow downwards through the fuel line. Alternatively, if the auxiliary tank is at the same level or lower than the generator, a fuel pump may be required to facilitate the transfer of fuel. Proper elevation and positioning of the auxiliary tank can help optimise fuel flow and ensure the efficient operation of the generator.
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Fuel tank materials
When making a fuel tank, it is important to consider the material used, as it will play a significant role in the durability and longevity of the tank. Here are some factors to consider when choosing the material for your auxiliary fuel tank:
Material Options:
- Aluminum: Aluminum is a popular choice for fuel tanks due to its lightweight and corrosion-resistant properties. It is commonly used in marine applications and often coated with corrosion-inhibiting epoxies. ABYC guidelines specify that aluminum tanks should be constructed of 5000 series alloys, such as 5052, 5083, or 5086, with a minimum thickness of 0.090 inches. Thicker aluminum is generally preferred for added durability.
- Steel: Steel fuel tanks are often made of thicker plates to account for sacrificial rusting. While steel is strong and cost-effective, it is heavier and not as easy to work with as aluminum. ABYC guidelines for steel tanks require a minimum thickness of 0.0747 inches.
- Stainless Steel: Stainless steel is another option that offers good durability and resistance to corrosion. It is commonly used in marine diesel fuel tank manufacturing.
- Plastic: Plastic fuel tanks are lightweight and relatively inexpensive. They are often used in small engines and portable generators. However, plastic tanks may not be as durable as metal tanks and can be susceptible to leaks.
Considerations:
- Material Thickness: Thicker materials generally provide better durability and corrosion resistance. Insist on thicker options like 1/8-inch aluminum, 12-gauge steel, or 14-gauge stainless steel to ensure your tank lasts longer.
- Coating: If you're using a metal tank, consider the coating to protect it from the elements. Ask the manufacturer about rust-resistant coatings, such as enamel-based paint or powder coating, especially if you live in an area with road salt or near coastal waters.
- Weld Types: The type of weld used on the flanges can affect the life of your tank. Ensure the manufacturer uses high-quality welding techniques and materials.
- Compatibility: Be mindful of material compatibility when connecting your auxiliary tank to the generator. For example, bronze and brass plumbing fittings should not be directly attached to aluminum fuel tanks due to the risk of corrosion.
- Safety: Always prioritize safety when working with flammable fuels. Ensure your fuel tank is properly vented and all connections are drip-proof tight to prevent fuel leaks.
By carefully considering the material options and following the necessary safety precautions, you can effectively make an auxiliary fuel tank for your generator that is durable and safe to use.
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Frequently asked questions
An auxiliary fuel tank eliminates the need to refuel the generator during use, reducing the risk of fuel spillage and potential explosions. It also saves you from having to fill the generator every few hours.
Ensure that all connections are drip-proof tight to prevent fuel leakage onto the generator. If using a hose, ensure it is not too long, as this may cause the fuel pump to work overtime, leading to fuel starvation.
You can use a gravity feed tank, which requires the auxiliary tank to be higher than the generator's tank. Alternatively, you can use a pressure feed system, but this requires monitoring to prevent overflow. You can also use a fuel pump to connect the auxiliary tank to the generator.
