Winter is Coming: A Comprehensive Guide to Preparing Your Fuel Storage Systems for Winter
Winter is coming, and with it come a range of challenges for bulk fuel storage. With decades of experience in fuel quality and storage, OTS Group provides the essential guidelines for preparing your fuel storage tanks for the colder months. Failing to winterise your fuel pumps and tanks can have serious consequences including fuel gelling (or diesel wax), microbial contamination, and even equipment failure.
This article will look at the risks of cold weather before breaking down what needs to be done to ensure that you are protecting your fuel distribution equipment from winter failures.
Part One: Understanding the Risks of Cold Weather on Fuel Storage and Distribution Equipment
Introduction: The Cold Weather Challenge
As the mercury drops, the cold presents a unique set of challenges to fuel storage and distribution systems. From residential heating oil tanks to large-scale fuel depots, the integrity and functionality of these systems are put to the test during winter months. This article explores the various risks and potential impacts of cold weather on fuel storage and distribution equipment.
The Science of Fuel in Winter
Before diving into the risks, it's important to understand how cold temperatures affect fuel. Diesel and heating oil, for example, can begin to cloud and gel at low temperatures, a result of paraffin wax naturally found in these fuels. When the fuel temperature drops, the wax crystals form and can clog filters and lines, leading to flow problems or even a complete shutdown of the system.
Diesel Wax: Understanding the Risks of Cold Weather on Fuel
Diesel fuel naturally contains paraffin wax, acting as a lubricity agent. In colder temperatures, this wax begins to crystallise, leading to fuel gelling, or diesel wax. This can be dangerously disruptive in cold weather operations as the fuel the clogs up fuel injectors and filters, ultimately causing engines to cease as they are starved of fuel. This can be much worse when there is a large proportion of FAME in the blend. This process is primarily influenced by two temperature points:
Cloud Point: The temperature at which wax crystals start to form in diesel fuel, generally between -16 to -10 degrees Celsius.
Pour Point: Occurs when the temperature drops to a level at which the fuel turns to gel, typically 5 to 8 degrees Celsius below the cloud point.
Primary Risks to Fuel Storage and Distribution Equipment
Fuel Gelling and Waxing
Risk: The paraffin in diesel and other fuels solidifies, leading to clogged fuel lines and filters.
Impact: Impeded fuel flow can cause equipment to work inefficiently or fail to operate.
Water Condensation and Ice Formation
Risk: Cold air holds less moisture, which can lead to condensation in tanks, potentially leading to microbial growth and corrosion.
Impact: Ice can form and obstruct lines; water can also promote rust within tanks and systems, leading to leaks or contamination.
Increased Viscosity of Fuel
Risk: Low temperatures can increase the viscosity of fuel, making it thicker and less able to flow freely.
Impact: Pumps and injectors may struggle or become damaged trying to move the thicker fuel.
Material Contraction and Seals Failure
Risk: Many materials contract in cold temperatures, which can lead to leaks at connection points and compromised seals.
Impact: Fuel leaks not only pose environmental risks but can also be costly and lead to system inefficiencies.
Battery Failure
Risk: The chemical reactions within batteries slow down in cold weather, reducing their effectiveness.
Impact: A battery failure can result in the inability to start pumps and generators essential for fuel distribution.
Pump and Machinery Malfunctions
Risk: Lubricants thicken and mechanical components are more prone to brittleness at low temperatures.
Impact: Increased wear and tear on components can lead to breakdowns.
Secondary Risks and Challenges
Operational Inefficiencies: Equipment has to work harder in the cold, which can increase operational costs.
Emergency Response Delays: Harsh weather can delay maintenance and emergency response, exacerbating issues.
Supply Chain Disruptions: If the distribution equipment fails, it can lead to broader supply chain disruptions, especially in industries dependent on constant fuel supply.
Understanding the Risks for Proactive Management
Awareness of these risks is the first step in preventing them. It is essential to conduct regular maintenance checks and prepare for the cold months in advance. This may include adjusting maintenance schedules, using winterised fuel blends, incorporating additives, and investing in equipment upgrades designed for low-temperature operations.
Part Two: Winterising Fuel Storage Equipment
Winterising Fuel Distribution Equipment (Fuel Pump PPM)
As temperatures plummet, the cold conditions exacerbate existing issues in the pump, leading to breakdowns. Having a preventative maintenance plan in place means that organisations can ensure that pumps and related equipment function as efficiently as possible in the harsh conditions. While there is an up-front cost to PPM, preventative maintenance ensures the integrity of the components preventing the possibility of multiple failures as conditions get worse.
To winterise fuel pumps and associated fuel distribution equipment, organisations should:
Implement a Preventative Maintenance Plan: Establish a routine maintenance schedule to ensure pumps and related equipment function efficiently in cold conditions and to mitigate the risk of exacerbating existing issues.
Address Water Condensation: Actively manage the risk of water condensation within the pump which can freeze and strain internal mechanisms including the motors, and belts as this can lead to expensive breakdowns requiring multiple replacements.
Inspect and Maintain Delivery Hoses: Regularly check delivery hoses for integrity to prevent cold-induced damage like cracks and leaks, which can cause environmental and safety issues.
Maintain Seals and Couplings: Consistently maintain the seals and couplings on hanging hardware and within the pump to ensure they are in optimal condition to withstand cold temperatures.
Monitor and Replace Filters: Regularly inspect and replace filters as necessary to prevent fuel separation and contamination, which helps maintain pump efficiency and averts costly emergency repairs.
Conduct an OTS Condition Report: Use OTS's condition reporting service to assess the condition of equipment, including evaluations of dispensing speed and pressure, leak sources, pump cavitation, and the condition of the motor, pulley, belts, filters, seals, safety breaks, couplings, electronics, electrics, nozzles, and hoses.
By taking these recommended actions, organisations can adequately prepare their fuel distribution equipment for the winter season, ensuring operational efficiency and safety without the need to insulate the pumps.
Winterising Tanks, Pipework and Bunding
Conducting a Thorough Visual Inspection
Before winterising, it's imperative to clean and inspect your fuel storage tanks for:
Dirt and grime accumulation
Signs of leaks or puddles beneath the tank
Damage or wear in components like delivery hoses or nozzles
Should you identify a leak, immediate action is required to drain and repair the tank using industry-recognised procedures.
Basic Steps for Ensuring Winter Readiness:
Tanks and Pipework: Inspect tanks and pipework for corrosion, physical damage, and ensure they are in good condition to prevent bursts due to freezing temperatures.
Bunding: Assess the integrity of bunds to prevent leaks or environmental contamination due to cracking.
Separators: Check separators for blockages and ensure they are compliant with standards to prevent pollution.
Drainage: Ensure drainage systems are clear of blockages from leaves and debris to prevent flooding.
Eliminate Water Contamination
Water has a higher freezing point than diesel's cloud point. It is therefore necessary to ensure that your fuel tanks are devoid of water. We recommend using high-efficiency water separator filters and conducting dipstick tests to confirm the absence of water in your tanks.
Maintenance & Monitoring
Replace Fuel Filters: After removing water, change the tank’s fuel water separator filter to ensure clean fuel delivery.
Check Valves and Hoses: Examine the valves for leaks and the hoses for any damage due to weather exposure. Replace if necessary.
Treatment: Lastly, treat your diesel fuel with anti-gel and moisture-dispersing agents.
Advanced Winterisation Techniques
For more advanced winter fuel storage preparation, why not consider some of these additional steps?
Fuel Tank Insulation
Just like home insulation, insulating your fuel tanks can help maintain a consistent temperature, reducing the risk of diesel wax formation.
Insulating Jackets: Use insulating jackets or blankets specifically designed for fuel storage tanks. These can provide an extra layer of protection against the cold.
Windbreaks: If your tank is in an exposed location, consider setting up a temporary windbreak. This can shield the tank from cold winds and help maintain its temperature.
Regular Fuel Testing
Regular fuel testing during the winter months ensures that any contaminants are detected early.
Cold Filter Plugging Point (CFPP): This test measures the lowest temperature at which a given volume of diesel type fuel still passes through a standardised filtration device in a specified time when cooled under certain conditions.
FAME Content: Knowing the FAME content can help, as fuel with different FAME content has varying gelling temperatures.
Tank Heating Solutions
For extremely cold climates, consider using tank heating solutions.
Tank Heaters: Electric or steam tank heaters can keep the fuel at a consistent temperature, reducing the risk of gelling.
Heated Fuel Lines: Using heated fuel lines ensures that the fuel remains liquid as it travels from the tank to the engine.
Maintain Vent Filters
Ensure that tank vent filters are clean and functional.
Breather Vents: These allow tanks to "breathe", letting air in and out without letting in contaminants. Ensure these are checked and cleaned to prevent moisture from entering.
Educate and Train Personnel
Ensure that those responsible for the fuel storage tanks are adequately trained.
Regular Checks: Personnel should be trained to perform daily checks during the winter months, looking for signs of gelling or other issues.
Emergency Protocols: Ensure that there are clear procedures in place for what to do if fuel gelling or another issue occurs.
Choose the Right Fuel for Winter
Switching to a winterised premium diesel during the colder months can be helpful. This specialised fuel offers cold-weather protection, improved engine efficiency, and superior performance.
Consider the Location
If you're installing a new tank or moving an existing one:
Sunlight: Place the tank in a location where it can get sunlight, as this natural heat can help keep the fuel warm.
Avoid Low Areas: Don't place tanks in low areas where water can accumulate, as this can increase the risk of freezing.
Adhering to these guidelines can significantly mitigate the risks associated with fuel storage during winter months. Remember, proactive measures can prevent costly and time-consuming issues later on.
Introducing a preventative maintenance plan for your pumps is a business-critical requirement to ensure mitigation of any safety risks, operational efficiency of the dispensing equipment as well as a competitive edge with a fully operational system. If you would like a professional service to prepare your fuel storage systems for winter, we would be happy to help. Our service inspections offer precise fuel testing for particulate, water content, and biological contaminants. We can also offer a complete service covering all equipment at your site including the tanks, automatic tank gauging, automatic vehicle identification, pipework and fuel management systems.
Part 3: DIY Winter Fuel Storage Preparation Checklist
If you would prefer to winterise your tanks yourself, here is a step-by-step guide to DIY inspections:
| Category | Action | Notes |
|---|---|---|
Preliminary Steps |
Safety First | Make sure to follow all safety protocols. Wear safety gear like gloves, safety goggles, and suitable footwear. |
Clear the Surrounding Area |
Remove any obstructions or debris around the tank to have unimpaired access to all components. |
|
Gather Tools and Materials |
Ensure you have all the necessary tools and materials, including a flashlight, inspection mirror, and checklist for keeping track of inspection points. |
|
Pump Steps |
||
Water Test at the Nozzle |
Check for Water Contamination |
a) Apply water finding paste to the nozzle and dispense a small amount of fuel to test. b) Look for a colour change in the paste to indicate water presence. |
Dispensing Speed and Pressure |
Measure Fuel Dispensing Speed |
Time the fuel dispensing process to ensure it matches the expected output rate. |
Check Dispensing Pressure |
Use a pressure gauge to verify that the fuel dispensing pressure is within specified limits. |
|
Possible Leak Sources |
Visual Leak Inspection |
Look over the pump body and connections for signs of leaks or dampness. |
Apply Leak Detection Solution |
Use leak detection fluid on connections and look for bubbling to identify leaks. |
|
Pump Cavitation |
Listen for Unusual Noises |
Operate the pump and listen for abnormal noises that could indicate cavitation. |
Inspection of Motor, Pulley, and Belts |
Visual Inspection of Motor and Pulley |
Examine these components for visible damage or wear. |
|
Check Belt Tension and Condition |
Use a tension gauge to measure belt tension and inspect for wear or damage. |
Filter and Seals Inspection |
Examine the Filter |
Remove and inspect the filter for dirt or damage; replace if necessary. |
|
Check Seals for Wear |
Look at seals for any signs of deterioration or cracking and replace them as needed. |
Tank Steps |
||
Inspect the Tank Exterior |
Check for Leaks | Look for visible signs of leaks like pools or puddles of fuel under the tank. |
|
Check for Dirt and Grime | Dirt and grime buildup can indicate slow leaks or seepage. Examine the tank for any such signs. |
|
Check for Rust and Corrosion | Examine the tank’s surface for areas of rust or corrosion, as this can weaken the tank's integrity. |
| Inspect Tank Seams and Welds | Pay close attention to the tank’s seams and welds for any signs of weakness or corrosion. | |
Inspect Fuel Delivery System |
Delivery Hose | Check the hose for cracks, bulges, or other signs of wear and tear. |
| Delivery Nozzle | Ensure that the nozzle is securely attached and look for any leaks. Operate the nozzle to make sure it works smoothly. | |
Inspect Valves |
Main Shutoff Valve | Open and close the valve to check its operation. Look for leaks or signs of wear. |
| Additional Valves | Similarly, inspect all other valves connected to the tank. | |
| Inspect Fuel/Water Separator | Check for Leaks | Inspect the housing and fittings of the fuel/water separator for leaks or cracks. |
| Check Petcock and Drain Plug | Make sure the petcock and drain plug are securely fitted and show no signs of wear or leakage. | |
| Inspect the Gauge System | Examine the fuel level gauge and any other monitoring systems to ensure they are functioning correctly. | |
| Examine Filter System | Spin-on Fuel Filter | Look at the old spin-on fuel filter for signs of clogs or damage. |
| Filter Gaskets | Inspect the gaskets for signs of wear or leakage. | |
| Concluding Steps | ||
| Take Notes | Document any anomalies or signs of wear and tear. Use this information for planned maintenance or repairs. | |
| Consult a Professional | For any issues beyond basic visual inspection, consult a professional for a comprehensive assessment. |
