Gasoline Tank Integrity Testing Guide
⚠ Safety First: Always work in well-ventilated areas away from ignition sources. Use spark-proof tools and wear chemical-resistant gloves during testing.
- Step 1 Preparation: Empty tank to <5% capacity. Clean exterior with degreaser and inspect for visible dents >3mm deep or cracks >10cm that require immediate attention.
- Step 2 Visual Inspection: Check all welds, seams, and fittings under bright light. Use mirror for hidden areas. Document any rust spots covering >25% of surface area.
- Step 3 Pressure Test: Seal ports and apply 3-5 psi air pressure. Spray soap solution (1:4 detergent:water). Bubbles forming within 30 seconds indicate leaks.
- Step 4 Dye Test: Add 5ml fluorescent dye per 10L tank capacity. Circulate for 15 minutes before UV inspection at 365nm wavelength.
- Step 5 Vacuum Test: Apply -5 psi vacuum. Pressure rise >0.5 psi/min suggests significant leakage.
Pressure Test Setup: Use regulated air supply with 0-10 psi gauge. Cap all openings with AN-6 blanking plugs. Maintain pressure for 10 minutes while inspecting.
Post-Test Verification: After repairs, conduct final pressure test and 24-hour stand test with 50% fuel load. Check for >0.5% volume loss and inspect all gaskets and O-rings (replace if hardened or cracked).