Mercedes Mullins
A protected fuel tank is a safety feature designed to prevent fuel leaks and fires in vehicles and aircraft. The protection can take the form of an outer coating, an additional internal or external layer, or a complete encasing of the fuel tank in armoured steel. The primary purpose of a protected fuel tank is to limit the potential hazards of fuel leaks and fires, which can occur due to accidents, gunfire, or explosions. The use of protected fuel tanks is particularly important in military applications, where vehicles and aircraft may be subjected to ballistic and shrapnel impacts.
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What You'll Learn
Safety standards for protected fuel tanks
Fuel tanks are essential components of vehicles and equipment that require frequent fuelling, such as company cars, construction vehicles, lawn mowing equipment, and power tools. While they offer convenience, fuel tanks also pose significant risks, including fires, explosions, pollution, and theft. Therefore, adhering to safety standards for protected fuel tanks is crucial to mitigate these hazards. Here are the key considerations for maintaining safety standards for protected fuel tanks:
Design and Construction
The design and construction of fuel tanks must meet recognised safety standards such as UL142 and UL2085. UL142 sets the requirements for the design and construction of steel atmospheric storage tanks used for flammable and combustible liquids like diesel and gasoline. It serves as the basis for fuel tank manufacturing, addressing aspects like materials of construction and shop test procedures. UL2085 builds upon UL142 by providing additional protection for aboveground tanks, often incorporating double walls or insulation to enhance safety.
Protection from External Threats
Protected fuel tanks aim to safeguard against external threats such as bullets, explosions, accidents, gunfire, mines, and shrapnel. This can be achieved through armoured fuel tank protection, utilising specialised ballistic materials such as Kevlar, composite panels, and reinforced steel. Self-sealing fuel tank protection is another solution, where entry and exit holes seal instantly to prevent fuel leakage and reduce the risk of fire and explosion.
Compliance with Regulations
It is essential to comply with local fire safety codes and regulations, such as NFPA30, NFPA30A, or the International Fire Code. Additionally, consider the requirements of authorities like the Environmental Protection Agency (EPA) and your local Department of Natural Resources (DNR). Regular inspections, at least monthly, are necessary to identify and address potential issues like cracks, punctures, leaks, and rainwater accumulation.
Proper Fuel Handling and Storage
Fuel handling and storage practices should adhere to guidelines provided by the Occupational Safety and Health Administration (OSHA). This includes securing fuel containers to prevent movement, shielding containers from direct heat radiation, providing adequate ventilation, and protecting valves and connections from damage. Liquefied gas-fuelled vehicles require specific precautions, such as ensuring there are no fuel system leaks and avoiding parking near sources of ignition.
Weight Considerations
The weight of fuel tanks can impact vehicle performance and payload capacity. Steel tanks or those protected with armour plates can add significant weight. Alternatively, lightweight materials like sheet metal, plastic, or aluminium can be used in conjunction with protective coatings or outer layers to achieve a balance between safety and weight optimisation.
By adhering to these safety standards and considerations, protected fuel tanks can effectively mitigate risks, ensuring the safe operation of vehicles and equipment while safeguarding individuals and the environment from potential hazards.
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Protection from external threats
Fuel tanks face a variety of external threats, from accidents to gunfire, explosions, and shrapnel. A compromised fuel tank can lead to leaks, fuel loss, and potential fire hazards, which can jeopardize safety and cause significant damage. To protect fuel tanks from these dangers, several methods can be employed, including the use of specialized materials, self-sealing technology, and protective coatings.
One way to safeguard fuel tanks is by utilizing advanced materials such as Kevlar, composite panels, and reinforced steel. These materials act as a strong barrier against potential threats and are integrated into the vehicle's design. Armormax, for instance, offers armored fuel tank protection for various vehicles, ensuring maximum safety against external hazards.
Self-sealing fuel tanks are another effective solution. This technology, commonly used in military aircraft and some military vehicles, prevents fuel leakage and ignition after the tank has been damaged. Self-sealing tanks typically have layers of rubber and reinforcing fabric. When punctured, the fuel seeps into these layers, causing the untreated rubber layer to swell and seal the puncture. This innovation has proven to increase survivability, as seen in the Pacific War, where American aircraft with self-sealing tanks fared better than Japanese aircraft without them.
Additionally, protective coatings play a crucial role in fuel tank protection. TSS International, for instance, offers a lightweight alternative to armored steel: a self-sealing and flame-retardant coating. This coating limits fuel leakage when the tank is compromised and has been tested against various types of ammunition. The final outer coating is flame-retardant, providing essential heat resistance and safeguarding against chemical and fuel damage.
Beyond these measures, certain standards and certifications, such as UL142 and UL2085, exist to ensure the safety of fuel tanks. UL142 sets requirements for the design and construction of steel atmospheric storage tanks used for flammable liquids. UL2085, on the other hand, offers extra protection, often involving double-walled tanks with insulating materials to limit heat transfer during fires. These standards are recognized by fire safety codes, providing assurance that fuel tanks meet stringent safety criteria.
In summary, protecting fuel tanks from external threats is of utmost importance to ensure safety and maintain operational capabilities. By employing advanced materials, self-sealing technology, protective coatings, and adhering to safety standards, fuel tanks can be effectively safeguarded against a range of external dangers.
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Self-sealing fuel tanks
A self-sealing fuel tank (SSFT) is a type of fuel tank that prevents fuel leakage and ignition when damaged. They are typically used in aircraft fuel tanks or fuel bladders.
The concept of self-sealing fuel tanks was developed during World War I, with several companies involved in advancing the technology during World War II. Early attempts at creating self-sealing fuel tanks involved layering rubber over the tank, which would be held in place by a layer of doped or painted canvas. Later, companies like Fireproof Tanks Ltd and the Henderson Safety Tank Company manufactured self-sealing fuel tanks that were installed in aircraft.
The design of self-sealing fuel tanks typically involves layers of rubber and reinforcing fabric. One layer is made of vulcanized rubber, while the other is untreated natural rubber, which swells when it absorbs fuel, sealing any punctures. The use of a middle layer of sponge rubber was also explored as a way to reduce weight, but this was found to be ineffective as it lacked strength and was torn by bullets.
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Materials used for protection
A 'protected' fuel tank is designed to limit the heat transferred to the primary tank during a fire and protect the tank from physical damage. This is achieved by adding insulating or reinforcing materials between the inner and outer tank walls.
The materials used for fuel tank protection depend on the type of tank and the level of protection required. Here are some commonly used materials:
- Steel is a popular material for fuel storage tanks due to its durability, effectiveness, and cost-effectiveness. It is resistant to corrosion, UV rays, fire, and rust. Steel tanks can be galvanised, which provides additional anti-corrosion protection. However, there are concerns about the negative interaction of the zinc coating with diesel, which can be mitigated with regular tank cleaning.
- Plastic is another option for fuel tanks, with certain types of plastic being suitable, such as ethyl vinyl alcohol, high-density polyethylene (HDPE), plastic adhesive, regrind plastic, and polypropylene. Plastic tanks are lightweight and can be moulded into various forms. However, they may sag under extreme heat and crack in cold temperatures.
- Fiberglass is used for industrial storage tanks due to its durability, corrosion resistance, and impermeability. Fiberglass tanks are more economical and require less maintenance than concrete tanks.
- Composite panels and reinforced steel are used in armoured vehicles to provide protection against bullets, explosions, and accidents.
- Kevlar is a specialised ballistic material used in armoured fuel tank protection to create a strong barrier against potential threats.
- Self-sealing coatings, such as the Hutchinson SAFETANK, have an outer flame-retardant layer that is resistant to heat, chemicals, and fuel. This coating seals entry and exit holes instantly, retaining fuel inside the tank and minimising potential ignition.
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Testing and quality assurance
A protected fuel tank is a tank designed to limit the heat transferred to the primary tank during a fire and protect the tank from physical damage. This is typically achieved by adding an insulating material between the inner and outer tank walls.
Quality assurance and testing are critical aspects of managing and maintaining the integrity of fuel and fuel tanks. Testing and quality assurance procedures for protected fuel tanks aim to ensure the safety and performance of the tank and the fuel. Here are some measures and procedures that can be implemented:
- Visual inspections: Regular visual inspections, typically conducted monthly or quarterly, help detect any external damage, corrosion, or abnormalities such as rust, dents, or cracks. This proactive approach allows for the early identification of potential issues, enabling prompt corrective actions.
- Leakage testing: Regular leakage testing is essential to identify any leaks in the tank or associated piping. This proactive measure helps prevent fuel spills, which can pose environmental and safety hazards.
- Fuel quality testing: Regular fuel quality testing ensures that the fuel meets applicable standards and is free from contaminants. This includes checking for water in the tank, as water contamination can lead to equipment malfunction and reduced fuel lifespan.
- Ultrasonic testing: Ultrasonic testing is performed periodically, usually every five years, to measure the thickness of the tank walls. This test identifies any thinning or corrosion that may compromise the integrity of the tank.
- Spill containment inspection: For fuel tanks with spill containment devices or spill buckets, thorough inspections are required to ensure they are free of fuel, water, or debris. This equipment is crucial in preventing the release of petroleum into the environment during loading and unloading activities.
- Compliance with regulations: Adhering to local regulations and recognised fire safety codes, such as NFPA30, NFPA30A, or the International Fire Code, is essential for ensuring the safe operation of the protected fuel tank.
- Ballistic and impact testing: For protected fuel tanks designed for vehicles, especially in high-risk environments, ballistic and impact testing are crucial. These tests ensure that the tank can withstand gunfire, explosions, accidents, and other external threats, minimising the risk of fuel leakage and potential fires or explosions.
- Quality Management System (QMS): Implementing a QMS standardises testing procedures, reduces errors, and improves efficiency. It provides a framework for continuous improvement and ensures that testing processes are consistently evaluated and optimised.
- Maintenance: Regular maintenance, including cleaning tanks and pipes, fuel polishing, and monitoring for leaks, is vital to prevent tank deterioration, fuel contamination, and equipment malfunction.
By implementing comprehensive testing and quality assurance procedures, organisations can enhance the safety, performance, and lifespan of their protected fuel tanks, while also ensuring compliance with relevant regulations.
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Frequently asked questions
A protected fuel tank is designed to limit the heat transferred to the primary tank during a fire and protect the tank from physical damage.
Protected fuel tanks can be categorised into two types based on the safety standards they adhere to: UL142 and UL2085. UL2085 tanks offer more protection than UL142 tanks, which act as the basis for fuel tank manufacturing.
Protected fuel tanks can be made of materials such as Kevlar, composite panels, reinforced steel, and lightweight sheet metal. Self-sealing fuel tanks use materials like rubber and reinforcing fabric to prevent fuel leakage.
Protected fuel tanks offer enhanced safety and security for vehicles and their passengers. They safeguard against external threats such as bullets, explosions, and accidents, reducing the risk of fuel leaks, fires, and explosions.
