All you need to know about fuel tanks

Types, materials and location

In most generator set’s user manuals, the fuel tanks are divided according to their location. At Genesal Energy we split the tanks in two types depending on their location with respect to the generator: Base frame or external.

Types

1- Base frame tanks:

Made of steel and located in the lower part of the genset. They are welded to the structure housing the genset.

2- External tanks:

These are tanks independent from the genset and provide longer running time. They are generally cylindric and double walled. We can find the following types depending on its location and capacity:

Indoor installation: Up to 1.500 litres, double walled. (Galvanized steel exterior and polyethylene interior)
Outdoor installation: Up to 120.000 litres, double steel walled.
- Aerial: on-legs for surface installation.
- Buried: buried underground.

Where To Install The External Tanks

When installing fuel tanks, the following facts must be considered:

1- If the external tank acts as main tank a fuel supply line and a fuel return line must be installed. In this case, the tank should ideally be located below the genset level allowing the gear-driven pump of the motor to draw-off fuel from the tank without any extra pumps and the non-burnt fuel to return to the tank by pull of gravity.

2- If the external tank is installed above the genset level our experts will determine the technical viability of the installation.

3- If the external tank acts as a storage tank, being the base frame tank the main tank and connecting both via a draw-off system, two scenarios are possible:

If the tank is located above the base frame tank level, the installation of a shut-off valve is advised. Fuel transfer from the external tank happens due to the pull of gravity.
If the tank is located below the base frame tank level, the installation of a fuel draw-off system and an overflow line (base frame – external tank) is advisable. Buoy electrovalves for fill-in and cut-off orders can be also installed.

The importance of design: Steel-made and sealed

There are a series of features reinforcing the efficiency and safety of the tanks, from the material used to built them to the finishing paint. Everything matters.

Genesal Energy designs tanks made of steel. Its interior is unpainted, and no zinc treatment or galvanizing is applied as these coatings react with fuel – generally diesel – producing damaging waste materials for both the fuel and the engine.

Finally, and depending on the type of application, the interior will be fitted with reinforcements, dividers or baffles (especially in large capacity and mobile applications). The aim is clear: to secure the tank’s structural integrity against the mechanical loads of the application.

Equipment

The base frame tanks are generally fitted with:

Filler cap
Valve-Vent
Level gauge (with signal to Control Panel)
Intake cap
Return cap
Free connection for the customer

NOTICE: In most cases, the level gauge, the fuel intake and overflow are fitted in a single element.

The external fuel tanks are fitted with custom made manholes for each single customer’s project. Including, at least, the following:

Filler cap
Valve-Vent
Intake cap
Return cap

Fuel pipes

How to install them and supply recommendations.

Genesal Energy always supplies fuel piping for base frame tanks. This way, the set is ready to fuel filling and starting. This piping is factory tested and therefore correctly installed.

When it comes to fuel piping supply for external fuel tanks or other type of installations, we recommend:

Avoid transit areas near engine heat. Manufacturers recommend a maximum fuel temperature of 60ºC in the injectors.
Avoid pipeline elbows.
It is important to ensure that the pipes are protected against mechanical wear and tightly fitted to withstand vibrations.
The use of flexible connections to the combustion engine is advisable to isolate the engine and tank.
Pipe’s internal diameter must be calculated according to the length of the installation.
The fuel return line must flow out in the upper part of the tank and not be coupled with the fuel intake line.
If the customer asks for specific piping, Genesal Energy will supply them factory tested, with appropriate the diameters and lengths and necessary connecting elements.

All you need to know about fuel tanks

Types, materials and location

In most generator set’s user manuals, the fuel tanks are divided according to their location. At Genesal Energy we split the tanks in two types depending on their location with respect to the generator: Base frame or external.

Types

1- Base frame tanks:

2- External tanks:

Where To Install The External Tanks

When installing fuel tanks, the following facts must be considered:

The importance of design: Steel-made and sealed

Equipment

The base frame tanks are generally fitted with:

Fuel pipes

How to install them and supply recommendations.

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