Fuel Tank Pipe Connection Guide
To connect pipes to a storage fuel tank safely and efficiently, follow these step-by-step guidelines, prioritizing leak prevention and structural integrity:
1. Prepare Tank Penetration Points
Most tanks have pre-welded nozzles for inlet, outlet, and vent pipes. If customizing, mark penetration spots at least 30 cm from seams to avoid stress concentrations.
Use a magnetic drill press for precise holes (e.g., 2" NPT for fuel lines). Deburr edges to prevent rust or debris contamination.
2. Select Compatible Pipe Materials
Fuel Compatibility:
- Steel pipes (galvanized or stainless) for diesel/gasoline
- FRP or HDPE pipes for ethanol-blended fuels to resist corrosion
Pressure Rating: Ensure pipes match tank design pressure (e.g., 10 bar for pressurized systems).
3. Install Valves and Fittings
Inlet/Outlet Lines:
- Attach a ball valve directly to the tank nozzle to control flow
- Use union fittings between the valve and pipe for easy disassembly (e.g., Victaulic couplings for steel pipes)
Install a flame arrestor at the vent outlet to prevent ignition. Angle vents upward with a 5° slope to drain condensation.
4. Welding vs. Non-Welding Methods
| Method | Materials | Key Specifications |
|---|---|---|
| Welding | Steel Tanks | TIG welding (argon shielded) for stainless steel or MMA welding for carbon steel. Maintain a 3-mm weld bead |
| Non-Welding | FRP/Plastic Tanks | Solvent cement (for PVC) or heat fusion (for HDPE). Apply a 20-mm overlap on socket joints and cure for 24 hours |
5. Pressure Testing and Leak Checks
Fill pipes with water and pressurize to 1.5x the operating pressure for 30 minutes. Monitor for pressure drops >0.5 bar.
Apply soapy water to all joints; bubbles indicate leaks. Tighten fittings or redo welds as needed.
Never use compressed air for leak testing with flammable liquids - always use water or inert gas.
6. Safety and Support Systems
Grounding: Connect a copper braid (10 AWG) from the pipe to the tank's grounding lug to prevent static discharge.
Pipe Supports:
- Install galvanized saddles every 3 meters to avoid sagging
- Use neoprene bushings to isolate vibration
Pro Tip: Always leave 10% expansion space in pipe runs to accommodate thermal movement.