Document Title: Technical Bulletin Revision No: 1

Description: Installation of Banlaw Refuelling Issue Date: 03/00

Equipment onto Dual Tanks

The purpose of this technical bulletin is to highlight common problems with dual fuel
tanks and the effect of both static and dynamic fluid head on the operation of the
quick-fill system.

Figure 1 below depicts the effect of dynamic head loss between 2 fuel tanks, linked
by pipe or flexible hose. The magnitude of the loss is a factor of the length of pipe,
the number and nature of fittings within that length, the flow-rate, and the internal
diameter of the pipe. The greater the amount of dynamic head loss, the greater the
differential between fluid level and internal pressure of each tank. Unlike static
head, dynamic head – as the term suggests – occurs only when fluid is moving.

Figure 1: Effect of Dynamic Head Loss

The difference in fluid level i.e. static head, between each tank is proportional to the
amount of dynamic head loss between the tanks. The greater the loss, the greater
the liquid level disparity.

The problems associated with high levels of dynamic head loss between dual tanks
causing preferential filling of the near-side tank are:

1. Reduced ullage gap in near-side tank during filling creating reduced

ullage gap in both tanks once fluid levels have equalised at the
completion of refuelling
2. Spillage from vent bleed hole in near-side tank during or after refuelling
3. Elimination of ullage gap in near-side tank during refuelling, creating risk
of rapid pressurisation of tank and exhausting of fuel from vent
emergency relief valve.
4. Risk of nozzle shut-off prior to far-side tank vent closing at tank full
condition, and subsequent insufficient fuel quantity being added at
completion of refuelling

Technical Bulletin – ‘Dual Tanks’ 03/00 ‘The Refuelling Specialists’

Measures to reduce the magnitude of dynamic head loss include:

1. Increase internal diameter of pipe/hose

2. Reduce number of fittings i.e. low radius bends etc. contained within the
pipe length
3. Reduce the length of pipework required, either by rerouting or reducing
the distance between tanks
4. Ensure any valves contained within the pipework are maintained in the
fully open position. Be aware of the inherently high dynamic head loss
created by such fittings as check valves and some flow control valves

The quick-fill vent may be removed from the near-side tank, and replaced with a
venting pipe linking the top regions of both tanks (see Figure 1b) thus eliminating
spillage from the near-side tank. This can only be achieved provided the dynamic
head loss is minimised between both tanks and there is no way which the two tanks
can be hydraulically isolated from each other, thus preventing the over-
pressurisation of the near-side tank.

Figure 1b: Alternative dual tank set-up

Figures 2 and 3 below depict the effect of static head with dual tanks. The
magnitude of static head is a factor of the difference in height that exists between 2
points. Both applications shown require additional modifications outside those
normally associated with quick-fill equipment, notably the vent pipe linking the
ullage regions of both tanks and the absence of a quick-fill vent on the lower tank.

Technical Bulletin – ‘Dual Tanks’ 03/00 ‘The Refuelling Specialists’

 Figure 2: Effect of static head (1)

The situation shown in Figure 2 occurs when positive static head exists between the
near-side (lower) and far-side (upper) tanks. A vent pipe must be installed linking the
top of the lower tank to the ullage gap in the upper tank. Neglecting dynamic losses
in the pipework linking both tanks, the pressure in the lower tank will be greater
than that contained in the upper tank - the difference being equal to the static head
between each tank.

Figure 3: Effect of static head (2)

Figure 3 occurs when negative static head exists between the near-side (upper) and
far-side (lower) tanks. As in Figure 2, a vent pipe must be installed linking the top of
the lower tank with the ullage gap in the upper tank. Again, neglecting dynamic
losses in the pipework linking both tanks, the pressure in the lower tank will be
greater than that contained in the upper tank - the difference being equal to the
static head between each tank.

Technical Bulletin – ‘Dual Tanks’ 03/00 ‘The Refuelling Specialists’

Many dual tank installations are designed incorrectly for quick-fill equipment. Most
of these faults are caused by little consideration being given to the effects of the
static and dynamic head existing between the two tanks. In addition, some
installations install a quick-fill vent onto the near-side or lower tank with no
knowledge of the 1/16” bleed hole in the vent valve being open to the atmosphere.
As mentioned earlier, provided a vent pipe is installed, the dynamic head loss is
minimised and there is no way the tanks may be hydraulically isolated, a quick-fill
vent is not required on the near-side or lower tank.

Note: any additional fittings or pipework linked to either tank will be momentarily
pressurised with the tank contents during the final stages of the refuelling process.
Care must be taken to ensure all such additions are rated to the certified pressure of
the tanks themselves.

Note that due to the requirement of a receiver on each side of the locomotive and
other unique details, rail installations will require specialist advice from Banlaw
personnel.

Further technical advice on the installation and operation of Banlaw equipment is

available from Banlaw head office or an authorised Banlaw distributor.

BANLAW PIPELINE PTY LTD - CONTACTS

Telephone: +61 (0)2 49714888
Fax: +61 (0)2 49714910
www.banlaw.com
SALES & MARKETING PRODUCTION & FUELTRACK & ENGINEERING
QUALITY ASSURANCE ELECTRONICS (MECHANICAL)
Nick FORAN Paul BUCKTON John GREGORY Adam PEATTIE
sales@banlaw.com.au paul@banlaw.com.au hoppy@banlaw.com.au adam@banlaw.com.au
Mob: 0408 497212 Mob: 0409 663072 Mob: 0408 492408

Technical Bulletin – ‘Dual Tanks’ 03/00 ‘The Refuelling Specialists’