fuel storage tank and accessories 130606

By ZMERLY & COEng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES

06-06-2013PROJECT LEBAON

German Technology, Reliable, Safe &

Easy for Operation

PROJECT LEBANON 2013Eng. Wael ZmerlyFUEL STORAGE TANK AND ACCESSORIESZMERLY & CO SARL.

INTRODUCTION

A complete oil-burning plant begins at the oil tank filling connection and ends at the chimney pipe.

Every parts of the plant must function so that the system is CLEAN, STABLE and ECONOMIC.


FUEL STORAGE TANK AND ACCESSORIES

- Fuel oil tank

- Types of tanks

- Type of installation

- Tank sizing

- Burner connection

- Fuel supply pipe

- Suction devices

- Level management

- Fuel oil filters

- Fuel Deaerator


INDOOR FUEL TANK

• Maximum capacity per tank 2500 Liter.

• Tank location in ground floor or basement.

• In a well ventilated room with fire rated door.

• The indoor tank can be Metallic or plastic

• In case of single wall tank, the retention tank is mandatory.

• If the tank is placed in a garage, it should be protected from shock.


INDOOR FUEL TANK – RETENTION TANK

• Capacity of retention volume must be equal to the maximum between:

100% of the volume of the biggest tank

• The retention tank is necessary to catch the fuel oil in case of tank leakage.

50% of the total volume of all tanks

• The retention tank can be Metallic or concrete.


PLASTIC TANKS

• Material HDPE.

• Light, tight, safe, shock resistant, ready to connect, optimal space use, easy to maintain.

• Maximum capacity 1500 Liter.

• The plastic tanks are the most used for small capacity, and for domestic use.

• Can be used for indoor and outdoorinstallation.

• Combi tank, or double wall tank, are safer and don’t need retention tank.

• Multiple tank in “Battery” installation up to 10.000 Liter.


TANK CAPACITY

The sizing of the fuel tank, start from a Rule of thumb:

Consumption of 0.1 liter/hour of fuel oil per 1 kW boiler output.

Consider an Average of 400 Hour of heating per year.

The consumption is around 40L/year for 1kW.

The tank is filled twice per year.

The tank capacity calculation is based on 20 Liter per kilowatt.


OIL QUALITY AND TEMPERATURE

The characteristics of the oil equipment arefactory-checked with a standard fuel oil havingclosely fixed flow properties measured at 20°C.(viscosity 6mm²/s).On plant where the oil tank may be exposed tolow temperatures, certain problems can occur.In an outdoor tank, the oil can easily becomecold and then thick .

The oil droplets become bigger , making theflame longer and more ”sluggish” in burning, andthe nozzle output increase which will usuallymean that combustion becomes sooty.

Oil tanks which are outside and aboveground, and all the exposed pipes, ought tobe insulated to avoid problems in wintertime.


WATER IN THE FUEL OIL TANK

Any water in an oil tank is an extra hazard. Whentemperatures drop to around freezing point the waterwill turn into ice and may block the oil pipe.

When atmospheric air comes into contact with a cold oiltank the air content will condense. After a time anamount of water collect at the bottom of the tank.

Also rainwater often seeps into the tank because of abadly seal filling cap, etc.

When the water in the bottom of the tank reaches sucha level that the suction line begins to draw water thereis a danger of the burner pump being damaged.

A special paste smeared on a dip stick, inserted intothe tank, it changes color to indicate the presenceof water in the tank.

Low outside temperature

Low air temperature


BURNER CONNECTION

Just as no human being can function without aheart, so the oil pump is vital to the operation of anoil-fired heating plant.

The fuel oil, is transported from the tank to theburner and is subjected to a suitably high andstable pressure.

The burner pump is usuallyconnected to two flexiblehose for supply and return.

An oil filter should be installedupstream of the burner to preventthe nozzle becomes clogged.


BURNER CONNECTION

On an installation wherethe tank is locatedhigher than the pump, aone-pipe system can beused, i.e. a suction lineand no return line.

On an installation where thetank is below the level of theburner, the oil must be lifted.Most commonly used for thisapplication is the two-pipesystem, i.e. a suction and areturn line.

Any excessive oil as well as air is returnedto the tank where the system vents itself.

In this type, the amount of return oil is higher than the supplied to the nozzle. The nozzle take only 5% and reject 95% of the fuel to the tank.

This kind of connectionis achieved by a smallmodification in theburner pump, or byinstalling a fuel filterwith integrated return.


TANK POSITION

The suction capacity of the pump and the associated pipe dimensions must beaccurately known. The reliability of the system depends entirely on whether the pumpcan lift oil from the tank and deliver it to the burner.

Operating with too strong vacuum must be prevented.

For system under pressure,burner catalogue must bechecked for maximumpermissible height.

The max. suction headdepend varies with altitude.


SUCTION PIPE SIZING

The fuel oil flow rate is based on a consumption of 0.1 liter/hour per 1 kW boiler output.

Dimensioning of the oil suction pipe and fittings is essential for the smooth and right operation of the oil burner.

Other parameters to be considered:

• The height of the tank above the burner.

• The total length of the pipe.

• The number of elbows and fittings in the pipe.

• The pressure drop for equipment installed.

• The viscosity of the fuel.

• The density of the fuel.

The velocity in the suction line should be between 0.2 and 0.5 m/s.


SUCTION PIPE SIZING

For Burner capacity 30kW

Single pipe system:Fuel Flow rate = 0.1x30 = 3 l/hIf we used a copper tube of 6x1mm, with inner diameter 4mm:Linear pressure drop R = 7mbar/m.Velocity V = 0.07m/s

Double pipe system:Fuel Flow rate = 0.1x30x20 = 60 l/hIf we used a copper tube of 10x1mm, with inner diameter 8mm:Linear pressure drop R = 8.5mbar/m.Velocity V = 0.33m/s.

The DIN 4755 specify a max. total pressure loss of less than 0.4 bar


SUCTION LINE DIVICES

A suction line is not merely a pipe between oil tank and pump. Extra equipmentis necessary in the line, to ensure reliability and to meet statutory requirements.

• quick acting isolating valve on the tank.• Pre-filter to protect the plant from dirt and

sediment in the oil tank• Manual shut-off valve integrated in the filter to

make it easy to clean or replace the cartridge.• Diaphragm anti siphon valves, to prevent the oil

in the tank being siphoned off if a leakage in thesuction pipe occurs.

• Pressure balance device.


FLOATING SUCTION “FLEXO-BLOC”

The heating oil is drawn off approx.4-6 cm below the oil level. This wayonly the cleanest oil is used.

When the tank is empty, a star-shaped spacer protects the suctionfrom immersing into the oil sump.

“Flexo-Bloc” with floating suction isused as oil draining facility forindividual and battery tanks.

The “Flexo-Bloc” is equipped with anquick acting isolating valve withrocker arm which can be operatedwith the help of a release cord.

An integrated non-return ball checkvalve prevents a drop of the oilcolumn during burner stop.


DIAPHRAGM ANTI-SIPHON VALVE “OILSTOP”

Diaphragm anti-siphon valves prevent the oil in the tank being siphoned off if a leakage in the suction pipe occurs.

Diaphragm anti siphon valves are installed in the suction pipes of heating oil installation, where the tank level is above the lowest point of the suction pipe.


PRESSURE BALANCE DEVICE “OLEX”

After inactivation of the burner, the oil in thesuction pipe between the non-return check valve atthe tank and the valve at the burner pump maybecome trapped. If the oil in the pipework warmsup, it expands and pressure increases.The expanding oil is absorbed by the pressurebalance device and an inadmissible pressureincrease is avoided.


MECHANICAL LEVEL INDICATOR

• Infinitely adjustable for tanks up to2 m height.

• Oventrop Mechanical level indicatormeasures the height of the fuel inthe tank in Cm

• According to DIN 4755, every oilstorage tank, and in the case ofmulti-chamber tanks, every chambermust be equipped with a facility formeasuring the liquid level.

• Easy to connect and adjust.


PNEUMATIC LEVEL INDICATOR

The level indicator measures the hydrostaticliquid pressure at the tank bottom. Thepressure is measured approx. 2Cm above thetank bottom and displayed on the gauge dial.

• It indicats the liquid height in %,from 0 to 100%, for rectangular andhorizontal cylindrical tanks.

• Capillary tubing, Cu tubing or PE hose can be used to connect to the tank.

• Infinitely adjustable for tank heights from 1 to 3 m, and up to 50m distance.

• the outside temperature can be in between -5°C and +55°C

• Install a condensate trap if the level indicator is mounted below the max. liquid level in the tank.

Up to 50m


LEVEL GAUGE WITH ELECTRONIC REMOTE INDICATOR

Indicating the current levelof the fuel, and monitoringminimum and maximum level.


OVERFILL PROTECTION

Tank filling limiter is installed to protect the tank fromoverfilling. It is mandatory for above and undergroundtanks exceeding 1000 liter.It consists of a probe (height adjustable), which protrudesinto the tank. At its lower end sits the sensor (PTC).

The thermistor changes resistancewhen immersed in the liquid abruptly.This change is transmitted to thetruck to stop the filling pump.


FEUL FLOTING LIMIT

Special fuel float valve, and float switch.


TANK FILLING WHISTLE

When the tank is being filled, withthe whistle in place, a whistling soundis made out through the vent pipenext to the fill pipe.

Installed in vent opening on fuel oil tank.

The vent cap must not end in a closed area.

Vent cap with screen

When the fuel oil reaches thewhistle tube the whistling stops,indicating the tank is near full.


FUEL OIL FILTER

One pipe Filter Two pipe FilterTwo pipe Filter

With return

Heating oil filters are manufactured in various types and sizes (filters for two pipe systems and one pipe systems with/without return flow feed).

A choice of differentfilter inserts is available.Filtration range between20 and 150 Microns.

On a domestic oil burner, in addition to the nozzle filter and the filter built into the oil pump, there should be a separate filter in the suction line immediately before the pump.

The cartridge must bechanged once per year.


AIR SEPARATOR

When oil is drawn up from the oil tank to the burner, some gas bubbles can bereleased from the oil. But also a big amount of bubbles is released from the fuelcoming back from the burner return.

The gas/air bubbles flow with the oil intothe oil pump and are the leading cause ofbreakdowns, increased build up of soot,unnecessary wear and tear on the oilpump, and higher oil consumption.

The OVENTROP Toc-duo, and Toc-Unode-aerators make each installation evenmore safe and efficient.

It ensures that oil passing through the oil pumpto the burner nozzle is completely air-free. Thisallows highly efficient combustion withoutdripping problems.

Oventrop heating oil de-aerator are used in one pipe systems with return flow feed (suction systems) for effective filtering and de-aerating of heating oil.


AIR SEPARATOR


FEUL FLOTING LIMIT

With the wide rang of Oventropheating oil products, the engineersand installers may fulfill the demandsof any installation.


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fuel storage tank and accessories 130606

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