A fuel tank (also called a petrol tank or gas tank) is a safe
container
A container is any receptacle or enclosure for holding a product used in storage, packaging, and transportation, including shipping.
Things kept inside of a container are protected on several sides by being inside of its structure. The term ...
for
flammable
A combustible material is something that can burn (i.e., ''combust'') in air. A combustible material is flammable if it ignites easily at ambient temperatures. In other words, a combustible material ignites with some effort and a flammable mat ...
fluids. Though any
storage tank
Storage tanks are containers that hold liquids, compressed gases (gas tank; or in U.S.A "pressure vessel", which is not typically labeled or regulated as a storage tank) or mediums used for the short- or long-term storage of heat or cold. The t ...
for fuel may be so called, the term is typically applied to part of an engine system in which the
fuel
A fuel is any material that can be made to react with other substances so that it releases energy as thermal energy or to be used for work. The concept was originally applied solely to those materials capable of releasing chemical energy but ...
is stored and propelled (
fuel pump
A fuel pump is a component in motor vehicles that transfers liquid from the fuel tank to the carburetor or fuel injector of the internal combustion engine.
Carbureted engines often use low pressure mechanical pumps that are mounted outside the f ...
) or released (pressurized gas) into an
engine
An engine or motor is a machine designed to convert one or more forms of energy into mechanical energy.
Available energy sources include potential energy (e.g. energy of the Earth's gravitational field as exploited in hydroelectric power gen ...
. Fuel tanks range in size and complexity from the small plastic tank of a
butane
Butane () or ''n''-butane is an alkane with the formula C4H10. Butane is a gas at room temperature and atmospheric pressure. Butane is a highly flammable, colorless, easily liquefied gas that quickly vaporizes at room temperature. The name but ...
lighter
A lighter is a portable device which creates a flame, and can be used to ignite a variety of items, such as cigarettes, gas lighter, fireworks, candles or campfires. It consists of a metal or plastic container filled with a flammable liquid or c ...
to the multi-chambered
cryogenic
In physics, cryogenics is the production and behaviour of materials at very low temperatures.
The 13th IIR International Congress of Refrigeration (held in Washington DC in 1971) endorsed a universal definition of “cryogenics” and “cr ...
Space Shuttle external tank
The Space Shuttle external tank (ET) was the component of the Space Shuttle launch vehicle that contained the liquid hydrogen fuel and liquid oxygen oxidizer. During lift-off and ascent it supplied the fuel and oxidizer under pressure to the ...
.
Uses
Typically, a fuel tank must allow or provide the following:
* Storage of fuel: the system must contain a given quantity of fuel and must avoid leakage and limit evaporative emissions.
* Filling: the fuel tank must be filled in a secure way, without sparks.
* Provide a method for determining level of fuel in tank,
gauging (the remaining quantity of fuel in the tank must be measured or evaluated).
* Venting (if over-pressure is not allowed, the fuel vapors must be managed through valves).
* Feeding of the
engine
An engine or motor is a machine designed to convert one or more forms of energy into mechanical energy.
Available energy sources include potential energy (e.g. energy of the Earth's gravitational field as exploited in hydroelectric power gen ...
(through a pump).
* Anticipate potentials for damage and provide safe survival potential.
Plastic (
high-density polyethylene
High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a thermoplastic polymer produced from the monomer ethylene. It is sometimes called "alkathene" or "polythene" when used for HDPE pipes. With a high strength-to-density ratio, ...
HDPE) as a fuel tank material of construction, while functionally viable in the short term, has a long term potential to become saturated as fuels such as diesel and gasoline permeate the HDPE material.
Considering the inertia and kinetic energy of fuel in a plastic tank being transported by a vehicle,
environmental stress cracking
Environmental Stress Cracking (ESC) is one of the most common causes of unexpected brittle failure of thermoplastic (especially amorphous) polymers known at present. According to ASTM D883, stress cracking is defined as "an external or intern ...
is a definite potential. The flammability of fuel makes stress cracking a possible cause of catastrophic failure. Emergencies aside, HDPE plastic is suitable for short term storage of diesel and gasoline. In the U.S.,
Underwriters Laboratories
The UL enterprise is a global safety science company headquartered in Northbrook, Illinois, composed of three organizations, UL Research Institutes, UL Standards & Engagement and UL Solutions.
Established in 1894, the UL enterprise was founded a ...
approved (UL 142) tanks would be a minimum design consideration.
Fuel tank construction
![Apollo Lunar Module Fuel Tank](https://upload.wikimedia.org/wikipedia/commons/d/df/Apollo_Lunar_Module_Fuel_Tank.jpg)
While most tanks are manufactured, some fuel tanks are still fabricated by metal craftsmen or hand-made in the case of bladder-style tanks. These include custom and restoration tanks for automotive, aircraft, motorcycles, boats and even tractors. Construction of fuel tanks follows a series of specific steps. The craftsman generally creates a mockup to determine the accurate size and shape of the tank, usually out of foam board. Next, design issues that affect the structure of the tank are
addressed - such as where the outlet, drain, fluid level indicator, seams, and baffles go. Then the craftsmen must determine the thickness, temper and alloy of the sheet he will use to make the tank. After the sheet is cut to the shapes needed, various pieces are bent to create the basic shell and/or ends and baffles for the tank. Many fuel tanks' baffles (particularly in aircraft and racecars) contain
lightening holes
Lightening holes are holes in structural components of machines and buildings used by a variety of engineering disciplines to make structures lighter. The edges of the hole may be flanged to increase the rigidity and strength of the component.
...
. These flanged holes serve two purposes, they reduce the weight of the tank while adding strength to the baffles. Toward the end of construction, openings are added for the filler neck, fuel pickup, drain, and fuel-level sending unit. Sometimes these holes are created on the flat shell, other times they are added at the end of the fabrication process. Baffles and ends can be riveted into place. The heads of the rivets are frequently brazed or soldered to prevent tank leaks. Ends can then be hemmed in and soldered, or flanged and brazed (and/or sealed with an epoxy-type sealant) or the ends can be flanged and then welded. Once the soldering, brazing or welding is complete, the fuel tank is leak-tested.
In the aerospace industry, the use of Fuel Tank Sealants is a common application for high temperature integral fuel tanks. This provides excellent resistance to fluids such as water, alcohols, synthetic oils and petroleum-based hydraulic fluids.
Automotive fuel tanks
The maximum distance a combustion-engine powered car with a full tank can cover is the product of the tank capacity and its
fuel efficiency
Fuel efficiency is a form of thermal efficiency, meaning the ratio of effort to result of a process that converts chemical potential energy contained in a carrier (fuel) into kinetic energy or work. Overall fuel efficiency may vary per device, wh ...
(as in miles per gallon). While larger tanks increase the maximum distance, they also take up more space and (especially when full) add to the total weight, requiring higher fuel consumption for the same performance. Fuel-tank capacity is therefore the result of a trade-off in design considerations. For most
compact car
Compact car is a vehicle size class — predominantly used in North America — that sits between subcompact cars and mid-size cars. "Small family car" is a British term and a part of the C-segment in the European car classification. However, p ...
s, the capacity is in the range ; the original model
Tata Nano
The Tata Nano is a compact city car that was manufactured and marketed by Indian automaker Tata Motors over a single generation, primarily in India, as an inexpensive rear-engined hatchback intended to appeal to current riders of motorcycles a ...
is exceptional with its fuel tank.
SUV
A sport utility vehicle (SUV) is a car classification that combines elements of road-going passenger cars with features from off-road vehicles, such as raised ground clearance and four-wheel drive.
There is no commonly agreed-upon definiti ...
s and
truck
A truck or lorry is a motor vehicle designed to transport cargo, carry specialized payloads, or perform other utilitarian work. Trucks vary greatly in size, power, and configuration, but the vast majority feature body-on-frame construction ...
s tend to have considerably larger fuel tanks.
For each new vehicle a specific fuel system is developed, to optimize the use of available space. Moreover, for one car model, different fuel system architectures are developed, depending on the type of the car, the type of fuel (gasoline or diesel), nozzle models, and region.
Two technologies are used to make fuel tanks for automobiles:
* Metal (
steel
Steel is an alloy made up of iron with added carbon to improve its strength and fracture resistance compared to other forms of iron. Many other elements may be present or added. Stainless steels that are corrosion- and oxidation-resistant ty ...
or
aluminum
Aluminium (aluminum in American and Canadian English) is a chemical element with the symbol Al and atomic number 13. Aluminium has a density lower than those of other common metals, at approximately one third that of steel. It has ...
) fuel tanks welded from stamped sheets. Although this technology is very good in limiting fuel emissions, it tends to be less competitive and thus less on the market, although until recent times automotive fuel tanks were almost exclusively made from sheet metal.
* Plastic
high-density polyethylene
High-density polyethylene (HDPE) or polyethylene high-density (PEHD) is a thermoplastic polymer produced from the monomer ethylene. It is sometimes called "alkathene" or "polythene" when used for HDPE pipes. With a high strength-to-density ratio, ...
(HDPE) fuel tanks made by
blow molding
Blow molding (or moulding) is a manufacturing process for forming hollow plastic parts. It is also used for forming glass bottles or other hollow shapes.
In general, there are three main types of blow molding: extrusion blow molding, injection ...
. Blow molded HDPE can take complex shapes, for instance allowing the tank to be mounted directly over the rear axle, saving space and improving crash safety. Initially there were concerns over the low
fracture toughness
In materials science, fracture toughness is the critical stress intensity factor of a sharp crack where propagation of the crack suddenly becomes rapid and unlimited. A component's thickness affects the constraint conditions at the tip of a c ...
of HDPE, when compared to steel or aluminum. Concern for safety and long term ability to function should be considered and monitored.
Modern cars often feature remote opening of the fuel tank fuel filler flap using an
electric motor
An electric motor is an Electric machine, electrical machine that converts electrical energy into mechanical energy. Most electric motors operate through the interaction between the motor's magnetic field and electric current in a Electromagneti ...
or cable release. For both convenience and security, many modern fuel tanks cannot be opened by hand or otherwise from the outside of the car.
Reserve tank
Sometimes called the
reserve tank is a secondary fuel tank (in many cars/bikes it contains around 15% of the capacity of the primary tank) these are more commonly found on bikes, older cars (some without a fuel gauge) and vehicles designed for long distance or special use. A light on the instrument panel indicates when the fuel level dips below a certain point in the tank. There is no current standard, although some efforts are made to collect this data for all automobiles.
In vehicles modified for endurance the primary tank (the one that comes with the car) is made into a reserve tank and a larger one installed. Some 4×4 vehicles can be fitted with a secondary (or sub-tank) by the dealership.
Ship in a bottle
The ''ship in a bottle'' fuel tank is a manufacturing design developed by
TI Automotive
TI Fluid Systems is a British multinational company which develops, manufactures and supplies automotive fluid storage, carrying and delivery systems. The company serves the automotive aftermarket through Bundy, Walbro and Marwal brands. The compa ...
in
Rastatt, Germany wherein all fuel delivery components including the pump, control electronics and most hosing are encased within a blow-molded plastic fuel tank, and named after the traditional
ship-in-a-bottle mechanical puzzle. The technique was developed to reduce fuel vapor emissions in response to
Partial Zero-Emission Vehicle (PZEV) requirements. The first application was for the 2005
Ford GT
The Ford GT is a mid-engine two-seater sports car manufactured and marketed by American automobile manufacturer Ford for the 2005 model year in conjunction with the company's 2003 centenary. The second generation Ford GT became available for th ...
.
Racing fuel cell
![Porsche GT3 trunk (front) (6293634244)](https://upload.wikimedia.org/wikipedia/commons/e/e5/Porsche_GT3_trunk_%28front%29_%286293634244%29.jpg)
A ''racing fuel cell'' has a rigid outer shell and flexible inner lining to minimize the potential for punctures in the event of a collision or other mishap resulting in serious damage to the vehicle. It is filled with an open-cell foam core to prevent explosion of vapor in the empty portion of the tank and to minimize sloshing of fuel during competition that may unbalance the vehicle or cause inadequate fuel delivery to the motor (
fuel starvation
In an internal combustion engine, fuel starvation is the failure of the fuel system to supply sufficient fuel to allow the engine to run properly, for example due to blockage, vapor lock, contamination by water, malfunction of the fuel pump or in ...
).
Aircraft
![Jet-liner's main fuel tanks](https://upload.wikimedia.org/wikipedia/commons/8/80/Jet-liner%27s_main_fuel_tanks.PNG)
Aircraft typically use three types of fuel tanks: integral, rigid removable, and bladder.
* Integral tanks are areas inside the aircraft structure that have been sealed to allow fuel storage. An example of this type is the "
wet wing
A wet wing (also referred to as ''integral fuel tanks''Crane, Dale: ''Dictionary of Aeronautical Terms, third edition'', page 557. Aviation Supplies & Academics, 1997. ) is an aerospace engineering technique where an aircraft's wing structure is se ...
" commonly used in larger aircraft. Since these tanks are part of the aircraft structure, they cannot be removed for service or inspection. Inspection panels must be provided to allow internal inspection, repair, and overall servicing of the tank. Most large transport aircraft use this system, storing fuel in the wings, belly, and sometimes tail of the airplane.
* Rigid removable tanks are installed in a compartment designed to accommodate the tank. They are typically of metal construction, and may be removed for inspection, replacement, or repair. The aircraft does not rely on the tank for structural integrity. These tanks are commonly found in smaller general aviation aircraft, such as the
Cessna 172
The Cessna 172 Skyhawk is an American four-seat, single-engine, high wing, fixed-wing aircraft made by the Cessna Aircraft Company. .
* Bladder tanks, or fuel cells, are reinforced rubberized bags installed in a section of aircraft structure designed to accommodate the weight of the fuel. The bladder is rolled up and installed into the compartment through the fuel filler neck or access panel, and is secured by means of metal buttons or snaps inside the compartment. Many high-performance light aircraft,
helicopter
A helicopter is a type of rotorcraft in which lift and thrust are supplied by horizontally spinning rotors. This allows the helicopter to take off and land vertically, to hover, and to fly forward, backward and laterally. These attributes ...
s and some smaller turboprops use bladder tanks. One major down-side to this type of tank is the tendency for materials to
work harden through extensive use making them
brittle
A material is brittle if, when subjected to stress, it fractures with little elastic deformation and without significant plastic deformation. Brittle materials absorb relatively little energy prior to fracture, even those of high strength. Bre ...
causing cracks. One major plus side is the ability to use as much of the aircraft as possible to store fuel.
* Combat aircraft and helicopters generally use
self-sealing fuel tank
A self-sealing fuel tank is a type of fuel tank, typically used in aircraft fuel tanks or fuel bladders, that prevents them from leaking fuel and igniting after being damaged.
Typical self-sealing tanks have multiple layers of rubber and reinforc ...
s.
Fuel tanks have been implicated in
aviation disasters, being the cause of the accident or worsening it (fuel tank
explosion
An explosion is a rapid expansion in volume associated with an extreme outward release of energy, usually with the generation of high temperatures and release of high-pressure gases. Supersonic explosions created by high explosives are known ...
). For example:
* The official "probable cause" for the explosion and subsequent crash of
TWA Flight 800
Trans World Airlines Flight 800 (TWA800) was a Boeing 747-100 that exploded and crashed into the Atlantic Ocean near East Moriches, New York, on July 17, 1996, at about 8:31pm. Eastern Daylight Time, EDT, 12 minutes after takeoff from John F. K ...
is that an explosive fuel/air mixture existed in one of the aircraft's fuel tanks. Faulty wiring then provided an ignition source within the tank, destroying the airliner. While the accuracy of the official findings is still questioned in this case, similar explosions have occurred in other aircraft. It is possible to reduce the chance of fuel tank explosions by a
fuel tank inerting system or
fire-fighting foam
Firefighting foam is a foam used for fire suppression. Its role is to cool the fire and to coat the fuel, preventing its contact with oxygen, thus achieving suppression of the combustion. Firefighting foam was invented by the Russian engineer and ...
in the tanks.
* Burning fuel can explode or set fire to the same airplane or adjacent objects and people. In the
1960 Munich Convair 340 crash
On 17 December 1960, a Convair C-131D Samaritan operated by the United States Air Force on a flight from Munich to RAF Northolt crashed shortly after take-off from Munich-Riem Airport, due to fuel contamination. All 20 passengers and crew on b ...
, a transport crashed into a major street. Burning fuel set fire to a tramcar. All 20 people aboard the plane and 32 passengers of the tram died.
In some areas, an aircraft's fuel tank is also referred to as an ''aircraft fuel cell''.
Water supply
Water supply systems can have primary or backup power supplied by diesel-fueled generators fed by a small "day tank" and a much larger bulk storage fuel tank.
Safety
Proper design and construction of a fuel tank play a major role in the safety of the system of which the tank is a part. In most cases intact fuel tanks are very safe, as the tank is full of fuel vapour/air mixture that is well above the
flammability limit
Mixtures of dispersed combustible materials (such as gaseous or vaporised fuels, and some dusts) and oxygen in the air will burn only if the fuel concentration lies within well-defined lower and upper bounds determined experimentally, referred to a ...
s, and thus cannot burn even if an ignition source were present (which is rare).
Bunded oil tanks are used for safely storing domestic heating oil and other hazardous materials.
Bunding
Bunding, also called a bund wall, is a constructed retaining wall around storage "where potentially polluting substances are handled, processed or stored, for the purposes of containing any unintended escape of material from that area until ...
is often required by insurance companies, rather than single skinned oil storage tanks.
Several systems, such as BattleJacket and rubber bladders, have been developed and deployed for use in protecting (from explosion caused by enemy fire) the fuel tanks of military vehicles in conflict zones.
Monitor: Bang but no boom
For stationary fuel tanks, an economical way to protect them from hazards like extremes of temperature and vehicle crashes is to bury them. However, buried tanks are difficult to monitor for leaks. This has led to concern about Underground storage tank, environmental hazards of underground storage tanks.
See also
* Electrification
Electrification is the process of powering by electricity and, in many contexts, the introduction of such power by changing over from an earlier power source.
The broad meaning of the term, such as in the history of technology, economic histor ...
* Explosion
An explosion is a rapid expansion in volume associated with an extreme outward release of energy, usually with the generation of high temperatures and release of high-pressure gases. Supersonic explosions created by high explosives are known ...
* Fast fuel system
* Fuel container
A fuel container is a container such as a steel can, bottle, drum, etc. for transporting, storing, and dispensing various fuels.
Construction
A wide variety of container types and constructions are used for fuels. Each has its own enginee ...
* Fuel filter
A fuel filter is a filter used to screens out foreign particles or liquids from the fuel. Most internal combustion engines use a fuel filter, in order to protect the components in the fuel system.
Filters for foreign particles
Unfiltered fuel m ...
* Fuel leak
* Fuel line
A fuel line is a hose or pipe used to transfer fuel from one point in a vehicle to another. The United States Environmental Protection Agency defines a fuel line as "all hoses or tubing designed to contain liquid fuel or fuel vapor. This includes ...
* Fuel pump
A fuel pump is a component in motor vehicles that transfers liquid from the fuel tank to the carburetor or fuel injector of the internal combustion engine.
Carbureted engines often use low pressure mechanical pumps that are mounted outside the f ...
* Jettison
* Fuel bladder
Fuel bladders, fuel storage bladders are a type of Flexi-bag used as a fuel container. They are collapsible, flexible storage bladders (also known as tanks) that provide transport and storage (temporary or long term) for bulk industrial liquids ...
References
External links
Reduction of Fuel Tank Flammability in Transport Category Airplanes
(U.S. Environmental Protection Agency
The Environmental Protection Agency (EPA) is an independent executive agency of the United States federal government tasked with environmental protection matters. President Richard Nixon proposed the establishment of EPA on July 9, 1970; it be ...
).
Fuel tank harmonization
(Aviation Rulemaking Advisory Committee)
U.S. Unveils New Rule On Airplane Fuel Tanks
by United States Department of Transportation
The United States Department of Transportation (USDOT or DOT) is one of the executive departments of the U.S. federal government. It is headed by the secretary of transportation, who reports directly to the President of the United States and ...
.
2005 Ford GT Powertrain
{{DEFAULTSORT:Fuel Tank
Vehicle technology
Fuel containers