Fuel tank and accessories

FUEL STORAGE TANK AND ACCESSORIES German Technology, Reliable, Safe & Easy for Operation

06-06-2013 PROJECT LEBAON

By ZMERLY & CO Eng. Wael Zmerly

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. ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

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 ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

INDOOR FUEL TANK • The indoor tank can be Metallic or plastic • Maximum capacity per tank 2500 Liter.

• Tank location in ground floor or basement.

• In a well ventilated room with fire rated door.

• 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.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

INDOOR FUEL TANK – RETENTION TANK • The retention tank is necessary to catch the fuel oil in case of tank leakage.

• The retention tank can be Metallic or concrete.

• Capacity of retention volume must be equal to the maximum between: 9 100% of the volume of the biggest tank 9 50% of the total volume of all tanks ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

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

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

• Maximum capacity 1500 Liter.

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

• Can be used for indoor and outdoor installation.

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

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

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.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

OIL QUALITY AND TEMPERATURE The characteristics of the oil equipment are factory-checked with a standard fuel oil having closely fixed flow properties measured at 20°C. (viscosity 6mm²/s).

On plant where the oil tank may be exposed to low temperatures, certain problems can occur.

In an outdoor tank, the oil can easily become cold and then thick .

The oil droplets become bigger , making the flame longer and more ”sluggish” in burning, and the nozzle output increase which will usually mean that combustion becomes sooty.

Oil tanks which are outside and above ground, and all the exposed pipes, ought to be insulated to avoid problems in wintertime.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

WATER IN THE FUEL OIL TANK When atmospheric air comes into contact with a cold oil tank the air content will condense. After a time an amount of water collect at the bottom of the tank.

Low outside temperature Low air temperature

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

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

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

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

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

BURNER CONNECTION The fuel oil, is transported from the tank to the burner and is subjected to a suitably high and stable pressure.

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

The burner pump is usually connected to two flexible hose for supply and return.

An oil filter should be installed upstream of the burner to prevent the nozzle becomes clogged.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

BURNER CONNECTION

On an installation where the tank is below the level of the burner, the oil must be lifted.

Most commonly used for this application is the two-pipe system, i.e. a suction and a return line.

Any excessive oil as well as air is returned to 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.

ZMERLY & CO SARL. Eng. Wael Zmerly

On an installation where the tank is located higher than the pump, a one-pipe system can be used, i.e. a suction line and no return line.

This kind of connection is achieved by a small modification in the burner pump, or by installing a fuel filter with integrated return.

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

TANK POSITION The suction capacity of the pump and the associated pipe dimensions must be accurately known. The reliability of the system depends entirely on whether the pump can lift oil from the tank and deliver it to the burner.

The max. suction head depend varies with altitude. For system under pressure, burner catalogue must be checked for maximum Operating with too strong vacuum must be prevented. permissible height.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

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

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

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

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.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

SUCTION PIPE SIZING For Burner capacity 30kW Single pipe system: Fuel Flow rate = 0.1x30 = 3 l/h If 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/h If 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 ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

SUCTION LINE DIVICES A suction line is not merely a pipe between oil tank and pump. Extra equipment is 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 the suction pipe occurs.

• Pressure balance device.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

FLOATING SUCTION “FLEXO-BLOC” “Flexo-Bloc” with floating suction is used as oil draining facility for individual and battery tanks.

The heating oil is drawn off approx.

4-6 cm below the oil level. This way only the cleanest oil is used.

When the tank is empty, a starshaped spacer protects the suction from immersing into the oil sump.

The “Flexo-Bloc” is equipped with an quick acting isolating valve with rocker arm which can be operated with the help of a release cord.

An integrated non-return ball check valve prevents a drop of the oil column during burner stop.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

DIAPHRAGM ANTI-SIPHON VALVE “OILSTOP” 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.

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

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

PRESSURE BALANCE DEVICE “OLEX” After inactivation of the burner, the oil in the suction pipe between the non-return check valve at the tank and the valve at the burner pump may become trapped. If the oil in the pipework warms up, it expands and pressure increases.

The expanding oil is absorbed by the pressure balance device and an inadmissible pressure increase is avoided.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

MECHANICAL LEVEL INDICATOR • According to DIN 4755, every oil storage tank, and in the case of multi-chamber tanks, every chamber must be equipped with a facility for measuring the liquid level.

• Oventrop Mechanical level indicator measures the height of the fuel in the tank in Cm

• Infinitely adjustable for tanks up to 2 m height.

• Easy to connect and adjust.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

PNEUMATIC LEVEL INDICATOR

Up to 50m

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

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

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

• the outside temperature can be in between -5°C and +55°C • Capillary tubing, Cu tubing or PE hose can be used to connect to the tank.

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

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

LEVEL GAUGE WITH ELECTRONIC REMOTE INDICATOR

Indicating the current level of the fuel, and monitoring minimum and maximum level.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

OVERFILL PROTECTION Tank filling limiter is installed to protect the tank from overfilling. It is mandatory for above and underground tanks exceeding 1000 liter.

It consists of a probe (height adjustable), which protrudes into the tank. At its lower end sits the sensor (PTC).

The thermistor changes resistance when immersed in the liquid abruptly.

This change is transmitted to the truck to stop the filling pump.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

FEUL FLOTING LIMIT Special fuel float valve, and float switch.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

TANK FILLING WHISTLE Installed in vent opening on fuel oil tank.

When the tank is being filled, with the whistle in place, a whistling sound is made out through the vent pipe next to the fill pipe.

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

Vent cap with screen

The vent cap must not end in a closed area.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

FUEL OIL FILTER 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.

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 different filter inserts is available.

Filtration range between 20 and 150 Microns.

One pipe Filter ZMERLY & CO SARL. Eng. Wael Zmerly

Two pipe Filter

Two pipe Filter With return

The cartridge must be changed once per year.

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

AIR SEPARATOR 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.

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

It ensures that oil passing through the oil pump to the burner nozzle is completely air-free. This allows highly efficient combustion without dripping problems.

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

The OVENTROP Toc-duo, and Toc-Uno de-aerators make each installation even more safe and efficient.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

AIR SEPARATOR

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

FEUL FLOTING LIMIT

With the wide rang of Oventrop heating oil products, the engineers and installers may fulfill the demands of any installation.

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013

FIND THE PRESENTATION ON THE LINK:

www.zmerly.com/fueltank.pdf

ZMERLY & CO SARL. Eng. Wael Zmerly

FUEL STORAGE TANK AND ACCESSORIES PROJECT LEBANON 2013