How to Weld Fuel Tanks
Welding gas or diesel tanks is extremely hazardous. In addition to the risk of setting fuel vapors on fire, MIG or TIG welding inside fuel storage tanks can result in argon gas suffocation for the welder and anyone attempting a rescue.
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Things You'll Need
- Approved flammable liquids container
- Clean, warm soapy water
- Air hose
- Chemical test kit
- Welding equipment
- Welding safety equipment
- Fuel
Instructions
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1
"Disconnect the battery and remove or turn off ignition sources before draining the tank," according to the Canadian Centre for Occupational Health and Safety. This reduces the chance that a spark might set off fuel residue.
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2
Drain fuel tank completely into an approved container for use with flammable liquids. CCOSH recommends, "Do not drain gasoline tanks over or near inspection pits."
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3
Remove fuel tank (if for a vehicle). Open access point if welding a storage tank. Take appropriate safety measures, including donning breathing apparatus and any necessary monitoring equipment. Arrange an observation, evaluation, rescue and evacuation plan that will not endanger rescue crew members according to OSHA regulations for hot work/welding.
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4
Rinse tanks thoroughly several times with warm, soapy water. Drain into approved containers for flammable liquids.
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5
Evacuate fuel fumes from the tank with an air hose for a minimum of one hour or until fuel smell from filter is not detectable. Conduct chemical tests to determine whether all fuel fumes have been removed and whether the tank is now safe to weld.
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6
Weld tank according to contract specifications, following all applicable laws, regulations, safety standards and best welding practices. Allow tank to cool to within 5 to 10 degrees of 70 degrees Fahrenheit.
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Once tank has cooled, put a small amount of fuel in the tank and test for leaks. If tank does not leak, reinstall it according to manufacturer's specifications.
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Tips & Warnings
According to Thermo Fisher Scientific at Harrisphq.com, "the first test is for presence of oxygen. Fresh air contains 20.9 percent oxygen with a balance of mostly nitrogen. Fuel cell entry is not permitted if the oxygen level is greater than 23.5% or less than 19.5% by volume, according to OSHA's standard for confined spaces, Title 29 Code of Federal Regulations (CFR) part 1910.146."
Next, test the presence or absence of "explosive atmospheres, generally measured in percent LEL. Levels of flammable vapors greater than 10 percent LEL are considered not 'fire-safe' and no entry is allowed."
