The Importance of Fuel Tank Inspections in Maintaining NFPA 110 Compliance for Emergency Backup Power Systems

Maintaining compliance with NFPA 110 (National Fire Protection Association Standard for Emergency and Standby Power Systems) is crucial to guaranteeing that your emergency backup power system is ready when needed. One key aspect of this standard is fuel system maintenance, which includes regular fuel tank inspections. To ensure its reliability, regular inspections and maintenance are required, particularly of the fuel tank that powers the generator.

What is NFPA 110?

NFPA 110 outlines the performance requirements for emergency and standby power systems, particularly those that are powered by fuel. It specifies the installation, maintenance, operation, and testing of these systems to ensure they are capable of providing backup power in the event of an outage.

NFPA 110 is structured to ensure safety, functionality, and reliability, especially for systems that must function during emergencies. Failure to comply with NFPA 110 can lead to generator malfunctions, environmental hazards, and significant fines from regulatory bodies.

A critical aspect of NFPA 110 compliance is maintaining the fuel supply system, particularly the storage tanks, to ensure they are safe, functional, and free from contaminants. This is where regular fuel tank inspections play a significant role.

The Importance of Fuel Tank Inspections

Fuel tank inspections are essential for ensuring the reliability and functionality of emergency backup power systems. Over time, fuel tanks are subject to various risks such as corrosion, sediment build-up, microbial contamination, and fuel degradation. These factors can directly impact the quality and efficiency of the fuel, potentially leading to system failures during emergencies.

Key Reasons Why Fuel Tank Inspections Are Important:

1. Prevent Fuel Degradation: Fuel stored over long periods is prone to degradation, leading to reduced combustion efficiency. This is especially true for diesel fuel, which can form sludge or sediment over time. A regular inspection ensures that the fuel remains in good condition.
2. Corrosion Control: Metal fuel tanks are vulnerable to corrosion. If left unchecked, corrosion can lead to leaks, which are both hazardous and non-compliant with NFPA 110. Inspections can detect early signs of corrosion, allowing for preventive measures to be taken before a leak occurs. AST (Above-ground Storage Tank) inspections have fewer strict regulations than USTs (Underground Storage Tanks), which adhere to section 49CFR. These requirements include pressure testing of primary and annular sections of the tank to verify integrity, hydrostatic testing of the spill buckets (SB989), and Monitor Testing and Certification.
   
3. Detect Microbial Growth: Moisture in the fuel tank creates an ideal environment for microbial growth. Bacteria, fungi, and other microorganisms can thrive in fuel, particularly diesel, leading to clogged fuel filters and injectors. Regular inspections identify microbial contamination and allow for cleaning and fuel polishing.
4. Ensure Tank Integrity: Cracks, weak points, or leaks in the fuel tank can cause fuel loss, environmental hazards, and non-compliance with regulatory standards. A visual inspection of the tank regularly ensures that it is structurally sound and free from leaks.
5. Environmental and Regulatory Compliance: Leaking fuel tanks pose significant environmental hazards. NFPA 110 has strict regulations regarding the containment and integrity of fuel systems. Regular inspections help detect leaks early, ensuring compliance with environmental and safety regulations.

What is Done During a Fuel Tank Inspection?

Fuel tank inspections involve a series of checks to ensure the tank’s integrity, cleanliness, and safety. The specific procedures can vary depending on the type of tank (Day Tank, Base Tank or larger-volume above-ground tanks) and the fuel being stored, but typical steps include:

1. Visual Inspection

   – Inspect the exterior of the tank for visible signs of damage, corrosion, or leaks. This includes checking for any cracks, dents, or rust spots on the tank’s surface.
   – Inspect the fuel lines, fittings, and connections for leaks, cracks, or other damage.
   – Verify that all safety features, such as pressure relief valves and overfill protection systems, are functioning correctly.
   – Ensure that the tank’s labeling and identification plates are clear and legible, and that emergency shut-off devices are accessible.

2. Fuel Sampling and Testing

   – A sample of fuel is taken from the tank bottom for visual assessment of the tank environment, and a second is taken from “off-bottom” and tested for quality. The sample is analyzed for signs of fuel degradation, water contamination, or microbial growth.
   – If contamination is detected, the fuel may need to be polished (filtered and cleaned) or replaced.

3. Corrosion Testing

   – Metal tanks, especially underground ones, are prone to corrosion. An inspection includes testing the tank’s cathodic protection system (if available) to ensure it is working properly to prevent corrosion. As mentioned above, USTs are not covered under the STI, SP001 standard. They require compliance with 49CFR, which contains rules specific to underground tank compliance and testing.
   – In some cases, non-destructive testing methods such as ultrasonic thickness testing may be used to assess the thickness of the tank walls and detect internal corrosion.

4. Tank Cleaning

   – Over time, sediment and sludge can accumulate in the bottom of the fuel tank, reducing fuel quality and causing blockages in the fuel delivery system. If significant build-up is detected during an inspection, the tank will need to be cleaned.

5. Leak Detection

   – Advanced leak detection methods, such as pressure testing or hydrostatic testing, may be used to detect small leaks that are not visible to the naked eye. In underground tanks, these tests are particularly important, as leaks can be harder to detect.*
   *Note: This kind of leak detection is not covered under the SP001 standard as mentioned above. However, fuel inspections will inform UST owners of conditions that may precede a leak, and sometimes after a tank is cleaned of the sediment and sludge, a leak may be uncovered, avoiding an environmental emergency.

How Often Should Fuel Tank Maintenance Be Performed?

NFPA 110 mandates regular inspections and testing of fuel systems to ensure ongoing compliance and reliability. The frequency of these inspections depends on the specific system, but general guidelines include:

• • • Monthly Inspections: A visual check of the annular (secondary) should be performed monthly if the annular space is equipped with a viewable port or sight glass.
    • Annual Inspections: A more thorough inspection of the tank and fuel system should be conducted annually. This includes fuel testing, tank cleaning (if necessary), and checking for corrosion or other damage that could compromise the tank’s integrity.
    • Fuel Testing Every Six Months: NFPA 110 recommends that fuel quality be tested at least semi-annually to detect any contamination or degradation. This should be sampled from the bottom and lower level of the fuel, as this is the primary draw of fuel to the engine. If fuel problems are detected, additional maintenance may be required.
    • More Frequent Inspections in Harsh Environments: For systems located in harsh environments or where there is a higher risk of contamination (e.g., areas with high humidity), more frequent inspections may be necessary.

How Fuel Tank Inspections and Maintenance Relate to NFPA 110 Compliance

NFPA 110 places significant emphasis on maintaining the fuel system as part of the overall maintenance of emergency and standby power systems. Chapter 8 of NFPA 110 outlines the minimum requirements for routine maintenance and operational testing of these systems, including the fuel storage and delivery system.

Key NFPA 110 Compliance Requirements Related to Fuel Tanks:

1. Fuel Quality: NFPA 110 requires that fuel quality be maintained to ensure reliable generator performance. This includes regular fuel testing and corrective action (such as fuel polishing or replacement) if contamination or degradation is detected.
2. Leak Prevention: NFPA 110 requires that fuel systems be designed and maintained to prevent leaks. This includes regular inspections of tanks and fuel lines, as well as the installation of leak detection systems for underground tanks.
3. Corrosion Control: NFPA 110 mandates that metal tanks and piping be protected against corrosion. This typically involves the use of cathodic protection systems, which must be tested regularly to ensure they are functioning properly.
4. Record-Keeping: NFPA 110 requires that detailed records be kept of all inspections, tests, and maintenance activities related to the fuel system. These records must be available for review by authorities having jurisdiction (AHJs).

By conducting regular fuel tank inspections and maintaining detailed records, you not only ensure compliance with NFPA 110 but also protect your facility from the potential risks associated with fuel system failures.

Conclusion

Maintaining NFPA 110 compliance for your emergency backup power system involves more than just testing the generator – it requires ongoing fuel tank inspections and maintenance. By inspecting the fuel tank regularly, you can detect and address issues such as fuel degradation, corrosion, and leaks before they become major problems. This ensures that your backup power system will perform reliably when needed, protecting your facility and ensuring the safety of those who rely on it.

Regular inspections and maintenance of the fuel tank are a vital part of the comprehensive care that emergency power systems require to stay NFPA 110 compliant and fully operational in times of need.

Electro-Motion is here to help you by providing regular maintenance visits at an affordable cost. Regardless of your budget, give us a call at (650) 321-6169 or schedule a free consultation to help avoid costly downtime, protect your operations, and ensure the safety and reliability of your emergency power system.