Mercedes Mullins
A fuel tank reservoir is a component of a vehicle's fuel system. It is used to store and supply fuel to the engine, allowing the vehicle to operate. The size, structure, and material of a fuel tank reservoir vary depending on the type of fuel used and the specific requirements of the vehicle. For example, in cars, the fuel tank capacity typically ranges from 50 to 60 litres, and it is often made of metal or plastic. The fuel tank reservoir plays a crucial role in ensuring the vehicle has enough fuel to function properly and can refuel when needed.
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What You'll Learn
Fuel tank size, structure and material
The size, structure, and material of a fuel tank are determined by its application and the type of fuel it will store. The maximum size of a fuel tank is limited by the available space and weight allowance on a vehicle. For example, in a passenger car, the fuel tank is usually smaller than the trunk to preserve passenger compartment space. The minimum size depends on the minimum travel distance within a refuelling cycle. For instance, a garbage truck's fuel tank should be large enough to complete at least one round trip from the fuelling station to the garbage pickup, and back.
Cylindrical tanks made of layered composite materials with an impermeable inner shell are often used for CNG fuel. The inner shell is typically made of aluminium due to its corrosion resistance, lightweight, and low cost. LNG tanks, on the other hand, carry more fuel mass than a CNG tank of the same size but tend to be heavier and more expensive. LNG tanks have an inner layer made of corrosion and low-temperature-resistant materials such as titanium, aluminium, or stainless steel. The outer layer can be made of cheaper materials like carbon steel but is ideally made of the same substance as the inner layer to ease thermal expansion and contraction and reduce manufacturing costs.
The most common materials for fuel tanks are metal or plastic. Metal tanks are usually constructed by welding stamped sheet metal parts, while plastic tanks often use blow moulding, allowing for more complex shapes. Steel tanks are highly durable, withstanding harsh weather and external damage, and offering greater resistance to fire and explosions, making them ideal for industrial use. However, they require regular maintenance, including cleaning and painting to prevent corrosion. Plastic tanks are more affordable, easier to produce, and less prone to leaks, but they are more susceptible to damage from UV exposure, extreme temperatures, and harsh weather conditions.
The construction of a fuel tank involves several steps. Craftsmen typically create a mockup to determine the size and shape, then address design issues like the placement of the outlet, drain, fluid level indicator, seams, and baffles. The thickness, temper, and alloy of the sheet material are also crucial considerations. After cutting and bending the sheets to form the shell, ends, and baffles, openings are added for the filler neck, fuel pickup, drain, and fuel-level sending unit. To prevent leaks, rivets are often brazed or soldered, and ends are sealed with soldering, brazing, welding, or epoxy-type sealants.
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Tank construction
The size, structure, and material of a fuel tank reservoir are determined by its application and the type of fuel it will store. For example, the fuel tank for a passenger car will be limited by the weight and space available, and one may not want the tank to be bigger than the size of the trunk.
When constructing a fuel tank, it is important to first create a design on paper, and then build a prototype to ensure that the final product will fit and meet the user's requirements. Cardboard is a good material to use for this purpose. Once the design has been finalised, the next step is to choose the material that the tank will be constructed from.
Steel is a common choice for fuel tanks due to its durability, reliability, and cost-effectiveness. It is also able to withstand harsh weather and environmental conditions. However, steel is susceptible to corrosion over time, so protective coatings will need to be applied to address this issue. Stainless steel is a popular option as it is highly resistant to corrosion and is relatively easy to weld.
Aluminium is another popular choice for fuel tank construction due to its corrosion resistance and light weight. It is about 33% lighter than steel of equal strength, making it a good choice for applications where weight is an important factor. However, aluminium is very difficult to weld, so this may increase the cost and complexity of construction.
Polyethylene is a further option for fuel tank construction, offering exceptional flexibility in design and the ability to be tailored to suit diverse applications. It is lightweight and easy to install, making it a favoured choice across multiple industries. Polyethylene tanks also offer superior stress-cracking resistance and enhanced toughness.
Once the material has been chosen and cut to size, the final step of construction is to lay out the pieces that will move fuel in and out of the tank. This includes adding components such as a fuel level sensor and a filler neck. It is also important to pressure test the tank to ensure that there are no leaks.
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Tank maintenance
Fuel tanks are used to store fuel that powers engines. They are commonly made of metal or plastic, with the specific material depending on the application. For example, the inner cylinder of a natural gas fuel tank should be made of corrosion and low-temperature-resistant materials such as titanium, aluminium, or stainless steel.
Regular Inspections
It is important to carry out regular inspections and checks to keep your fuel tank in top condition. These inspections should be done seasonally, with spring and summer being ideal for more thorough checks and tests, and autumn and winter inspections focusing on ensuring no damage is caused by extreme weather.
Location
The fuel tank should be located away from any falling hazards, such as trees or branches that could damage the tank in a storm.
Cleaning
The area around the tank should be cleared of debris, vegetation, and any fallen trees or branches after a storm. This weekly maintenance helps to identify drips, leaks, or spills early on. The tank itself should also be cleaned, with the frequency depending on local regulations.
Water and Contaminants
Water is one of the biggest factors that can damage a fuel tank, and regular monitoring and cleaning are necessary to prevent this. Water can enter the tank through condensation, loose fittings, or damaged fill boxes. Contaminants can also cause sludge build-up, which results in tank corrosion. Monthly or even daily inspections for water and contaminants are recommended.
Pumps, Vents, and Valves
Pumps, vents, and valves should be checked weekly to maintain fuel flow. Filler caps should be removed and cleaned with a wire brush if necessary. A small amount of lithium grease can be applied to prevent rust build-up.
Fuel Quality
It is important to check the quality of the fuel as poor-quality fuel can damage the tank and equipment.
Safety
Proper care should always be taken when cleaning the tank, and any fuel, residue, or chemicals should be disposed of following local regulations.
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Tank refilling
The process of refilling a fuel tank depends on the type of fuel and vehicle in question. Here is a general overview of the process for refilling a fuel tank reservoir, with some specific examples for different contexts.
For vehicles that use propane as fuel, such as cars, trucks, and grills, the refilling process typically involves the following steps:
- Turn off the tank valve to prevent any propane leakage.
- Place the tank upright and secure it to prevent movement during transport.
- Open windows for ventilation during transport.
- Drive to the nearest propane refill station.
- Remove the cylinder from the vehicle and place it near the refill pump.
- Allow an expert technician to inspect and refill your cylinder, ensuring it is not underfilled or overfilled.
For vehicles with a main fuel tank and a reservoir, such as in the video game Elite Dangerous, the refilling process may vary. In this game, the reservoir is used to power the ship and is slowly drained over time, while the main fuel tank is used for hyperspace jumps and refilling the reservoir. When the reservoir is low, players may opt to dock at a station and purchase fuel. Alternatively, they can use a fuel scoop to fill up the main tank, which will then automatically refill the reservoir as needed.
In the context of LNG (liquefied natural gas) and CNG (compressed natural gas) tanks, the refilling process may differ based on the vehicle's travel distance and access to fuelling stations. LNG tanks are preferred for long-haul trailers as they offer a greater range, while CNG tanks are suitable for applications where fuelling stations are easily accessible and travel distance is less critical, such as transit buses in cities.
The size, structure, and material of a fuel tank reservoir can vary depending on its application and the type of fuel it stores. For example, in passenger cars, the fuel tank size is typically limited by weight and space constraints, while in a garbage truck, the tank should be large enough to complete at least one round trip before refuelling.
Overall, the process of refilling a fuel tank reservoir involves ensuring the safe transportation of the tank or vehicle to a refilling station, where an expert technician can inspect and refill the tank to the correct capacity. The specific steps may vary depending on the type of fuel, vehicle, and unique characteristics of the fuel tank reservoir in question.
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Fuel reservoir usage
In the case of aircraft, some planes include a smaller reserve tank to be used when the main fuel tank is empty. Additionally, 4WD vehicles may have a large secondary tank to increase the range of the vehicle. In the context of the video game Elite Dangerous, the fuel tank is used for regular flying, while the reservoir is used for hyperspace jumps. Each segment of the reservoir is equal to a full fuel tank, and the hyperspace drive pulls fuel from the reservoir for jumps.
It is important to note that the terms "fuel tank" and "reservoir" are sometimes used interchangeably, and their usage can vary depending on the specific context and vehicle or craft being discussed.
In motorcycles and older vehicles, a reserve setting is available that allows the rider to access a small volume of fuel to reach a petrol station. This reserve fuel is usually a small quantity of the total supply and is drawn from the same tank as the main fuel supply. It is advisable to refill the tank before the level reaches the reserve outlet to prevent the fuel from running out without warning and to avoid blockages in the fuel line caused by water and solid materials at the bottom of the tank.
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Frequently asked questions
A fuel tank reservoir is a component of a vehicle's fuel system. It is used to store a small volume of fuel that can be used to power the vehicle in certain situations, such as during regular flight or super cruise. The main fuel tank is used for hyperspace jumps and refilling the reservoir.
The fuel tank reservoir is usually represented by a thin line or a single pip on the fuel gauge, while the main fuel tank is represented by a thick line or multiple pips. When the reservoir runs out of fuel, it automatically refills from the main tank.
The fuel tank reservoir ensures that you have enough fuel to power your vehicle for specific functions or in emergencies. It allows you to continue operating the vehicle even if the main fuel tank runs out, providing a reserve supply of fuel.
The fuel tank reservoir is typically visually represented on your vehicle's fuel gauge. You can monitor the level of fuel in the reservoir and refill it as needed. It is advisable to refill your main fuel tank before the level reaches the reserve outlet to prevent any issues with substances accumulating in the fuel system.
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