Mercedes Mullins
Setting up multiple fuel tanks, also known as plumbing dual fuel tanks, is a process that involves connecting two or more fuel tanks together to increase fuel capacity and provide a backup fuel source. This setup is commonly used in vehicles such as trucks, SUVs, and boats, where the ability to carry extra fuel is advantageous for long-distance travel or off-road expeditions. The process of setting up multiple fuel tanks can vary depending on the vehicle and the specific fuel system configuration. Some key considerations when setting up multiple fuel tanks include ensuring proper plumbing and valving, maintaining fuel equilibrium between the tanks, and complying with safety regulations to prevent fuel leaks and spills.
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What You'll Learn
Filling up multiple tanks
In general, when filling up multiple tanks, it is important to ensure that both tanks are filled to the same level. This can be achieved by filling up one tank at a time, ensuring that the fuel level is equal in both tanks before moving on to the next pump. It is also crucial to never tamper with the nozzle or leave it unattended during filling, as this can lead to spills and safety hazards. If both tanks are not filled to the same level, it can cause issues with fuel equalization and fuel gauge accuracy.
To avoid the hassle of filling up multiple tanks separately, some people consider plumbing the tanks together to create a single larger fuel supply. This can be done by joining the supply lines, return lines, and vent lines between the two tanks. However, it is important to consult a professional or engineer before making any modifications to your fuel system, as there may be potential drawbacks or safety concerns with certain configurations.
Additionally, when filling up multiple tanks, it is important to follow safe work practices and adhere to any manufacturer specifications and pump instructions. This includes never dragging the nozzle under the vehicle or between the tractor and trailer, as this can damage the equipment and create safety hazards near hot exhaust pipes. Always prioritise safety and follow the recommended procedures for your specific vehicle and fueling station setup.
Overall, filling up multiple fuel tanks requires careful attention to ensure safety and proper fuel equalization. By following the manufacturer's instructions, adopting safe practices, and considering potential modifications, you can effectively manage multiple fuel tanks and extend the range of your vehicle.
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Plumbing design
Fuel Tank Connection:
- Supply lines, return lines, and vent lines can be connected between the tanks using a Y connector or a T-fitting. This allows for equilibrium, maintaining the same fuel level in both tanks.
- Consider the relative positions of the tanks and the potential need for additional tubing to ensure equal fuel levels.
- For dual fuel tanks, ensure both tanks fill simultaneously to avoid overfilling one tank before the other.
Fuel Transfer:
- Fuel transfer between tanks can be achieved using a fuel pump or by gravity feed. A fuel pump can be switched on to transfer fuel from the auxiliary tank to the main tank when needed.
- A gravity feed system may be simpler but can lead to overfilling and leakage issues. It also may not be legal due to the potential fire hazard from leaks.
- To avoid overfilling, consider using a timed switch or a momentary switch for fuel transfer.
Fuel Gauge and Switching:
- Install a fuel gauge to monitor fuel levels in both tanks. You may need to use a switch to display the level in the tank currently in use.
- For dual tanks with a single gauge, consider using a manual dual-port valve or a tank selector switch to switch between tanks.
- Wiring in a low-pressure fuel gauge or flow meter can help monitor fuel transfer and prevent overfilling.
Plumbing Materials:
- Use hard fuel lines whenever possible for durability. If not feasible, opt for braided stainless fuel lines.
- Ensure all connections are secure to prevent leaks.
Installation and Maintenance:
- Consider the location of valves and switches for easy access and anti-theft measures.
- Regularly inspect and maintain the fuel system, including checking for leaks and ensuring the proper functioning of pumps and switches.
- Be mindful of the legal requirements and safety standards, especially regarding leak prevention and fire hazards.
By carefully considering these plumbing design aspects and following best practices, you can effectively set up multiple fuel tanks to meet your specific requirements.
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Fuel transfer
One approach to fuel transfer is to connect the supply lines of both tanks using a Y connector, along with the return lines and vent lines. This method allows for equilibrium, maintaining the same fuel level in both tanks. However, it's important to consider the potential need to fill up both tanks during refuelling to maintain this equilibrium.
Fuel Equalization
To achieve fuel equalization, you can install an equalizing line at the bottom of the tanks. This setup ensures that fuel is drawn equally from each tank. However, it's important to be cautious when driving through rough terrain to avoid potential snag points.
Transfer Pumps
Transfer pumps play a vital role in facilitating fuel transfer between tanks. Some tanks come with built-in transfer pumps, while others require you to purchase them separately. Transfer pumps are designed to pump fuel at a specific rate, such as 15 gallons per minute, and often include a hose purge feature to prevent fuel drips by pulling residual fuel back into the tank.
Tank Configurations
When considering fuel transfer, it's important to select the appropriate tank configuration. L-shaped transfer tanks are a popular choice, especially when paired with a truck toolbox. These tanks efficiently utilize space, and their unique shape allows for additional equipment storage in the lower L space. Ensure you measure the available space below your existing toolbox before selecting an L-shaped tank to ensure a proper fit.
Fuel Type Considerations
If you intend to carry different types of fuel in your multiple fuel tank setup, ensure you select the appropriate tanks. Split fuel transfer tanks are designed to hold more than one type of fuel, offering options such as gasoline, diesel, kerosene, methanol, or aviation fuel. Always verify that your chosen tank is DOT-approved for the specific fuel type(s) you intend to use.
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Safety considerations
Setting up multiple fuel tanks requires careful consideration of safety measures to prevent accidents and comply with regulations. Here are some essential safety considerations to keep in mind:
- Tank Type and Placement: The type and placement of the fuel tanks are crucial. Above-ground fuel tanks can be convenient for businesses with frequent fuelling needs, but they also present risks such as fires, explosions, pollution, and theft. To mitigate these risks, consider using double-walled tanks instead of single-wall tanks. Double-walled tanks provide an extra layer of protection against leaks, with the outer tank preventing punctures and containing fuel in case of a leak in the inner tank. If using single-wall tanks, ensure they are located in a diked area, typically a concrete containment structure, that can hold 110% of the largest tank's capacity, as per NFPA30 standards.
- Leak Detection and Prevention: Regularly inspect your tanks for any signs of corrosion, cracks, punctures, or leaks. For double-walled tanks, insert leak detectors between the inner and outer tanks. These detectors will float and trigger an audible or visual alarm if a leak occurs.
- Signage and Labelling: Proper signage and labelling are essential for safety and compliance. Ensure that visible labels are placed on the tanks, indicating their contents and associated hazards. Include hazard warnings, the type of material stored, storage capacity, and a tank ID number. Additionally, display conspicuous signs stating "Flammable – Keep Fire and Flame Away" and "No Smoking" to deter people from smoking or creating open flames near the fuel tanks.
- Fire Extinguishers: Place a fire extinguisher rated at least 10B within a specified distance of the fuel tanks. For tanks with a capacity of 5 or more gallons of flammable liquid, the fire extinguisher should be located within 50 feet. However, for tanks with a capacity of less than 5 gallons, ensure the fire extinguisher is placed not closer than 25 feet but no further than 75 feet away.
- Spill Kits and Basin Tanks: If using a single-walled tank, provide a spill kit in a conspicuous location to address any leaks or spills. For double-walled tanks, ensure they are properly identified, typically through a badge provided by the manufacturer. If a basin tank is provided, maintain the plugs to prevent the accumulation of rainwater, which could affect the volume of fuel the tank can hold.
- Fuel Transfer and Interconnection: When transferring flammable liquids between storage containers, ensure that the containers are electrically interconnected to prevent sparks and potential ignition sources. Additionally, consider using a Y connector to join the supply, return, and vent lines between multiple tanks to maintain equilibrium and balance fuel levels.
Remember to consult with professionals and refer to local regulations, such as those from the Environmental Protection Agency (EPA) and your local Department of Natural Resources (DNR), to ensure compliance and address any specific safety requirements for multiple fuel tank setups.
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Cost of installation
The cost of installing multiple fuel tanks varies depending on several factors, including the size of the tanks, the type of fuel, whether the tanks are aboveground or underground, and the complexity of the installation process.
For aboveground fuel tanks, the cost of installation typically ranges from $900 to $2,500. These types of tanks usually hold 275 to 330 gallons of fuel and are generally easier to install, repair, and remove compared to underground tanks.
Underground fuel tanks, on the other hand, are significantly more expensive to install, with costs ranging from $1,000 to $6,000 or more. This higher price tag is due to the required excavation work, specialised labour, and complicated vent and anchor systems involved in the installation process. Underground tanks typically have a larger capacity, ranging from 500 to 1,000 gallons, but are more costly to remove, install, and inspect.
The type of fuel also impacts installation costs. For example, propane tank installation can range from $600 for basic aboveground setups to $5,000 for underground systems, with most homeowners spending around $1,400. Additionally, the cost of filling a propane tank varies depending on its size and the season, with prices swinging depending on demand and location.
It is worth noting that the cost of installing multiple fuel tanks should also factor in the potential environmental impact and associated costs of a leaking tank. While hiring a professional installer ensures compliance with safety and environmental regulations, it is still crucial to consider the long-term maintenance and potential risks involved with fuel tanks.
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Frequently asked questions
Filling up multiple tanks can be a hassle, as you may need to fill up each tank individually. This can be time-consuming and may require specific fuel pumps. Additionally, there may be code-related issues, such as a 5-gallon maximum gasoline storage limit for generators and other homeowner gas-powered portable equipment.
One way is to connect the tanks in parallel using a "tee" or "wye" connector. Another method is to use a Y connector to join the supply, return, and vent lines between the tanks, allowing for equilibrium and equal fuel levels in both tanks. A third option is to add a tube between the tanks at the lowest level to maintain equal fuel levels.
One issue is the potential for fuel leaks, especially with gravity feed systems. To mitigate this, you can have a fuel shut-off valve that activates when the engine stops. Another concern is ensuring both tanks are filled equally to prevent running out of fuel in one tank. This can be addressed by adding a tube between the tanks at their lowest level or installing a second fuel gauge and an electric pump to transfer fuel between tanks.
