Not applicable.
None.
The present invention is directed generally to electrical power supply and more particularly to an improved generator fuel tank module for diesel fuel supply to multiple or single generators coordinated together as a unit for back-up power generation to provide power needs in case of an electrical utility power failure, grid power shortages, grid low voltage and grid reactive power needs.
Power production from the conversion of mechanical energy to electrical energy is well known and utilized to meet a variety of power load demands. In today's expanding use of cloud computing, data storage and in other areas such as hospital and emergency facilities it is critical that electrical power be provided at a constant voltage and consistency regardless of weather, power grid load or other extenuating circumstances.
One problem with the use of redundant generators is the inefficient fuel demand and fuel supply. Currently, there is considerable expense and unnecessary fuel consumption required to operate redundant generators. Furthermore, operating multiple large hydrocarbon powered engines to produce electrical energy produces considerable toxic fumes, including nitrogen dioxide and/or sulfur dioxide. This by-product of on-site energy production is limited by federal mandate and thus presents both safety and design concerns as well as environmental reporting requirements to state and federal authorities.
Another problem inherent in storing diesel fuel is fuel contamination that leads to costly service and repairs. Fuel contaminants include water, oxides, microorganisms, dust, dirt, and other natural contaminants found in all diesel fuel. Another source of contamination is algae. Approximately, 90% of generator failure is directly connected to the fuel used by the generator. Diesel fuel has an average storage life of about 6 months before microbiological contamination becomes a serious problem. Microorganisms, such as algae, bacteria, and fungus, feed on the oil and use the water collected in the fuel for their oxygen supply. The use of cracked diesel fuel has led to an increase in the amount of water collected in the tank while the use of low-sulfur diesel fuel typically produced in the United States from United States oil and natural gas deposits promotes the growth of algae. Reducing the sulfur in the fuel also reduces the aromatic content of the fuel. Microorganisms use these aromatics as a source of food, and a reduction in aromatics forces the microorganisms to turn to other food supplies. Microorganisms growing in a fuel supply can lead to significant dollar damage to a fuel tank and the generator(s) powered by the fuel tank as well as significant generator downtime. The spread of the problem is very serious considering that a clean system can be contaminated by using a fuel nozzle connected to a contaminated tank. Clean diesel fuel can also easily become contaminated during transportation and storage. As processed fuel is transferred from the refinery by rail or pipeline to the consumer, it may be stored in numerous different storage tanks of varying ages before reaching the final consumer. Contaminants should be removed immediately before the fuel enters the generator's filter system, so as not to damage the system. Generators demand very high quality fuel entering the cylinders in order to operate effectively and efficiently.
The contaminated fuel problem also results in a build-up of a sludge or slime in the bottom of a fuel tank. The build-up of sludge can lead to the clogging of fuel filters and fuel system components, such as fuel injectors and pumps. Water in a fuel tank can also lead to serious problems, and algae clinging to the inside of a fuel tank will hold onto the water inside of a tank, making it difficult to drain the water out of the tank. Water is continuously formed in a fuel tank as a result of condensation when a tank is not kept at full capacity. The process occurs both day and night. Water in a steel tank not only supplies the microorganisms with oxygen, but also may lead to rust problems and tank decay, causing further contamination problems.
The prior art has attempted to solve these problems but has been unable to provide a solution to same.
U.S. Pat. No. 4,275,382 issued Jun. 23, 1981 discloses an apparatus for determining the level of liquid in a storage tank using a plurality of sensors (read switches) at varying heights in the storage tank acting to indicate the presence of the liquid level at a given height. A microprocessor receives signals from the sensors and translates such signals into liquid level height. The microprocessor stores information from the controller for future use in memory and has a display system to receive signals from the sensors as to height and temperature and provide a visual display of the liquid level height and temperature. A further embodiment is disclosed in which the controller sends out signals to alter the status of one or more pumps, valves and the like.
U.S. Pat. No. 9,506,795 issued Nov. 29, 2016 discloses a tank level monitoring system with wireless transmission capability. The monitoring system includes a wireless tank monitor for level sensing connected to one or more float level sensors. The system regularly measures the level of fluid in a tank, but may change the measurement rate based upon signals from the float switch. This system actively monitors conditions of a tank and alerts a user when conditions exceed a predetermined parameter.
U.S. Patent Application Publication Number 2013/0181829 published on Jul. 18, 2013 discloses a system for measuring and reporting changing levels of liquids in a storage tank and includes a sensing device having a fluid level sensor, an accelerometer, a wireless transceiver, and a microcontroller for detecting the volume of liquid in the storage tank and sending an alert message if the volume of liquid in the storage tank has changed from a previous volume by a threshold amount. The system also includes a central tracking computer having a tracking database and is interfaced to the Internet, and a master control unit attached to the storage tank.
U.S. Patent Application Publication Number 2013/0293388 published on Nov. 7, 2013 discloses a system, apparatus and method for monitoring the status and use of an LP fuel tank using cellular communication technology. The system includes a sensor unit communicatively connected to a storage tank, the sensor unit measuring the level of fluid in the storage tank and transmitting fluid level data externally via a cellular data communication link. A remote host unit is disposed remotely from the storage tank, the host unit receiving fluid level data from the sensor unit via the cellular data communication link, and a base unit is disposed in the vicinity of the storage tank by a user, the base unit receiving fluid level data from the sensor unit.
U.S. Pat. No. 9,371,774 issued Jun. 21, 2016 discloses a fully automated emergency generator fuel oil system with plurality of emergency generator fuel oil system components. The system has a plurality of sensors continuously monitoring the physical status of the system components, and a master control panel is in operative communication with the plurality of sensors to interpret signals received from the plurality of sensors to determine if an event has occurred, namely, an event indicating the physical status of one or more of the system components, and when such event has occurred, the master control panel issues one or more instructions responsive to the event that control the function of one or more of the system components.
U.S. Pat. No. 9,321,467 issued Apr. 26, 2016 discloses a fuel assembly and a method of providing fuel to generators for the electric traction motors of a locomotive. The fuel assembly includes a frame, a first fuel storage tank sized to fit within the frame having fuel contained therein and an electronic fuel control assembly configured to regulate delivery of the gaseous fuel in the fuel storage tank to an external power unit. The fuel control assembly includes a microprocessor and a first fuel assembly electronic memory module having stored thereon identifying information by the interchangeable fuel assembly.
U.S. Patent Application Publication Number 2008/0128029 published Jun. 5, 2008 discloses a method directed toward ensuring backup generator fuel availability. The method includes, receiving natural gas at a local backup power generation site via a pipeline, compressing the natural gas and then containing the natural gas in compressed form until needed by the generator pursuant to a power outage or reduction.
U.S. Pat. No. 6,520,124 issued Feb. 18, 2003 is directed toward a double-walled tank for a generator set including an integral mounting assembly. The tank is formed of an outer basin having an open top, a bottom wall and a number of side walls that define an interior within the basin and form the exterior of the tank. An enclosed inner member having a top panel, a bottom panel and a number of side walls connecting the top and bottom panels is attached within the interior of the basin and provides a double-walled construction that serves to retain fuel within the tank when the external walls of the tank are damaged. An integral mounting assembly is attached to and extends across the basin over the inner member between the side walls of the basin and is configured to receive and support a generator, engine, and radiator to form a complete generator set.
What is needed in the industry is a fuel supply system and method that eliminates the need and cost of toxic biocide treatments, costly tank cleanings, exposure to and accidents from hazardous biocides, fuel starvation due to algae and bacteria growth, and equipment malfunction.
Also there is current need for a system and diesel fuel treatment method that reduces maintenance costs and downtime and protects machine components.
What is also needed is a system and diesel fuel treatment that reverses or precludes the process of sludge build-up, improves generator combustion, saves fuel, reduces carbon deposits, and reduces harmful emissions.
However, due to the increased attention given to environmental concerns, particularly with respect to those industries utilizing highly hazardous materials such as the heavy hydrocarbon fuels utilized with generator sets which are used in cloud server facilities, the single-walled construction of most generator set tanks is not adequate to ensure that the fuels contained within these tanks will not leak excessively and cause serious environmental damage if the exterior of the tank is damaged.
Therefore, it is desirable to develop a generator fuel tank which can be immediately transported in its entirety and placed into service. The tank should include a double-walled construction that minimizes and/or eliminates any leakage of fuel from the tank due to damage caused to the exterior of the tank. The generator fuel tank should also include an integral mounting arrangement such that once the tank has been moved to the generator site, the respective components of the generator may be mounted directly to the tank.
There is also a need to monitor the fuel levels in the tank to enable ultimate fuel levels to be maintained cutting down bacteria growth and to monitor the fuel quality of new fuel being deported into the generator supply tank.
The present invention overcomes these problems and current problems and deficiencies are solved by this invention in the manner described below.
The present invention is directed to a diesel supply double walled skid mounted day tank assembly for use with generators. The inventive day tank is equipped with a redundant filtration and consumption monitoring system and is provided with a local microprocessor, controls and sensors to maintain preset day tank fuel levels and integrate with fuel transfer system. The fuel tank assembly microprocessor networks with a central control panel mounted on the tank allowing communication with the facility's building management system.
It is an object of this invention to provide local fuel storage and supply, redundant fuel filtration, fuel consumption monitoring and reporting of No. 2 diesel fuel including diesel fuels with bio-content blends.
It is another object of the invention to provide an automatic portable fuel day tank for a generator equipped with a redundant filtration and consumption monitoring system which can be drop shipped and added to existing installations or added to installations as additional generator power is needed.
It is yet another object of the invention to provide a portable day tank for a generator provided with double walls and a sloping floor to carry sludge and contaminants along the tank floor to a designated location in the tank for easy removal of the same.
It is still another object of the invention to utilize a microprocessor with a day tank to store fuel data, fuel quality data and fuel contamination data and generate usage and environmental reports.
These and other objects, advantages, and novel features of the present invention will become apparent when considered with the teachings contained in the detailed disclosure along with the accompanying drawings.
The present invention will be described with reference to the appended
The best mode and preferred embodiment of the fully automated generator fuel system invention is shown by
The tank side walls, front wall, and rear wall are spaced double walls which are constructed of carbon steel UL-142 listed, metal with a minimum thickness of 0.1345″ (10 ga.). The walls, top panel and bottom wall of the day tank 22 form a sealed chamber 36 having a preferred 150 US gallon nominal usable capacity (164.5 gallon total capacity) but can range from 100 to 1000 gallons for holding diesel fuel which is delivered to a generator (not shown). A half tank height forms the length of a stainless steel day tank fill tube 40 having an appropriate diameter extends into the chamber 36 along with an appropriately sized stainless steel engine supply drop tube 42 located at the rear of the chamber 36. Forward of drop tube 42, as shown in
A skid frame 50 is mounted to the day tank assembly 22 as shown in
A filter assembly 70 as shown in
The filters 72 and 74 have a single filter flow rate of 10 GPM and as previously noted, provide three stage filtration for solids, articulate, tars, coalescing and separation. A pleated filter is mounted in each filter unit 72 and 74 to remove 1-micron particulate and separate water with 12 PPM efficiency. The filters 72 and 74 are preferably operated separately and are redundant. Each filter may be shut off manually by turning the valve arm 77 to a perpendicular position with respect to the axis of the fuel pipe as shown by the letter A in
The day tank assembly 22 is designed for installation in weather protected environments and is provided with a microprocessor 100 and touch screen 102 interface for system status indications and operations. These operations include but are not limited to fuel level monitoring, maintaining preset fuel levels, activating fuel replenishment, control valve operation, filtration monitoring including redundant inlet filtration with status monitoring, consumption monitoring with temperature and pulsation correction and network integration. The network accessible information includes, clogged filter, full water sump, current tank fuel level, fill valve position, high fuel level, low fuel level, critical low fuel level and various consumption information.
The front outer wall 24 of the tank 22 has a control panel assembly 110 and logic components mounted thereto as seen in
The rear outer wall 30 of the tank 22 as shown in
In operation diesel fuel is supplied to the tank container chamber 36 by an auxiliary fuel transfer system (not shown) which is fluidly connected to a main fuel tank. The supplied fuel is filtered by one of the three stage filter units 72 and 74, each being rated for 1 micron particulate removal and separation of both free and emulsified water with a 12 PPM efficiency. If the flow restriction in the active filter reaches a specified set point, the isolation valves 77 for the respective alternate filter should be manually opened as seen by letter B in
The day tank 22 will automatically maintain fuel level in the tank between 88% to 100% full. When the fuel level drops below 88% full, the continuous level float sensor causes the day tank control system to actuate its fill valve and allow fuel to flow through fill pipe 86 through the respective filter 72 or 74 into the day tank fuel chamber 36. When the chamber 36 is 100% full, a float level switch causes the control system to close the valve shutting off the fuel flow. The fuel position is transmitted to the customer via an internet network to communicate that the tank 22 is filling. A pre-set 88% fill start point can be adjusted programmatically as desired by the end user.
At 103% full, a high level switch causes the day tank control system to alarm and disable the fill valve 104 from opening. Overfilled fuel can return automatically through the overfill drain 106 or manually by the siphon drain valve. The alarm is terminated when the fuel level in the day tank drops to 100%.
When the day tank is 62% full, a low level float sensor switch causes the day tank control system to alarm to warn the operator in the event of the failure of the auxiliary fuel transfer system to maintain fuel level at a minimum of 88% full in the day tank.
When the day tank is 10% full a critical low level float switch causes the day tank control system to alarm and to provide a remote monitoring point for shut down of the systems supplied by the day tank to prevent the suction of air into those systems.
Fuel supplied to and returning from the generator is measured by two positive displacement, screw-type flow meters 99 having an accuracy up to within 0.1% for each meter. Local digital differential flow calculation uses evaluation algorithms to eliminate errors from liquid temperature differences and pulsations and outputs a highly accurate measure of fuel consumed by the engine. Additional customer required inputs and outputs may be monitored, controlled, and reported by the control system. These inputs and outputs can include engine run information, atmospheric conditions and component status.
As indicated above, sensors are positioned at various points throughout the system. The primary function of the network of sensors is to detect fuel leaks in any part of the system including secondary containment pipes, vaults, tanks, and mechanical slabs. The sensors also indicate possible over fill and under fill conditions, spillage during fueling, and breaks and broken connections in pipes and other equipment. The MCP 12 alarm and report program will identify the exact location of such a problem in real time as indicated by this sensor and alarm system.
It should be understood that, while the description of the invention herein discloses a system in which fuel oil is being circulated, the invention can be utilized for numerous other gas or liquid products for delivery to end user equipment on demand.
A fully automated emergency generator fuel oil system according to the invention operates faster and more accurately than manually operated systems, allows adjustments to system components in real time to achieve optimum operating performance, significantly reduces labor and operating costs, decreases system failures, increases system life, and improves system reliability. An added benefit is that by collecting critical and sensitive system components in seismically resistant cabinets, a system is created having significantly improved resistance to seismic events.
The principles, preferred embodiments and modes of operation of the present invention have been described in the foregoing specification. However, the invention should not be construed as limited to the particular embodiments which have been described above. Instead, the embodiments described here should be regarded as illustrative rather than restrictive. Variations and changes may be made by others without departing from the scope of the present invention as defined by the following claims:
This is a utility application claiming priority and the benefits of U.S. Provisional Patent Application No. 62/647,587 filed Mar. 23, 2018.
Number | Date | Country | |
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62647587 | Mar 2018 | US |