Replaceable Fuel Bladder Assembly for Low-Downtime Generator Tanks
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Solution Overview
Problem
Large industrial diesel generators require frequent replacement of corrosive diesel fuel tanks, which involves costly downtime as the entire tank must be removed and replaced.
Innovation Solution
A fuel tank assembly with a removable and replaceable internal bladder, allowing for quick and inexpensive replacement of the bladder without needing to remove the entire tank, thereby minimizing generator downtime.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If the entire fuel tank is removed and replaced, then the fuel tank can be fully renewed, but the generator downtime increases and replacement cost increases
Solution Approach 1:
The fuel tank system is divided into two separable components: a permanent outer tank and a removable inner bladder. This segmentation allows the bladder (which degrades from fuel corrosion) to be replaced independently without removing the entire tank assembly, thus reducing generator downtime while achieving full renewal of the fuel-containing component
Solution Approach 2:
The inner bladder is designed as a extractable component that can be removed from the outer tank through an access opening. This extraction capability enables replacement of only the degraded bladder portion while leaving the permanent outer tank in place, solving the contradiction between complete renewal and minimal downtime
2Reliability
If the entire fuel tank is removed and replaced, then the fuel tank can be fully renewed, but the replacement cost increases
Solution Approach 1:
By segmenting the fuel tank into a permanent outer shell and a replaceable inner bladder, the system allows replacement of only the degraded component (bladder) rather than the entire tank assembly. This reduces material costs and labor expenses associated with full tank replacement while ensuring complete renewal of the fuel-contacting surface
Solution Approach 2:
The inner bladder is designed as a consumable component that can be replaced more economically than the entire tank. The bladder, being the part exposed to corrosive diesel fuel, has a limited service life and is replaced periodically at lower cost, while the expensive outer tank structure is retained and reused
3Strength
If a rigid outer tank is used, then structural support is provided, but corrosion from diesel fuel degrades the tank over time
Solution Approach 1:
The system separates the structural function (outer tank) from the fuel containment function (inner bladder). The rigid outer tank provides necessary structural support and protection, while the inner bladder serves as the primary fuel-containing barrier that can be replaced when corroded, thus maintaining both strength and corrosion resistance
Solution Approach 2:
The inner bladder acts as an intermediary barrier between the diesel fuel and the outer tank wall. This intermediate layer protects the outer tank from direct contact with corrosive fuel, extending the tank's service life while the bladder itself can be replaced when degraded
Data Source
AI summary
A fuel tank for a generator or the like, wherein the fuel tank includes a rigid outer fuel tank structure and an inner bladder. The outer fuel tank structure includes a longitudinal channel for receiving the inner bladder. End caps are disposed on either end of the outer fuel tank structure, so that the internal bladder may be pulled therein with cables or the like. When the internal bladder needs to be replaced due to damage or corrosion, the end caps are removed and cables may be attached to one end of the damaged internal bladder for pulling it from the outer fuel tank structure. Additionally, a replacement bladder may be attached via cables to the other end of the damaged bladder, so that the replacement bladder is pulled into one end of the outer fuel tank structure while the damaged bladder is being pulled out the other end thereof.