Generator Diesel Fuel Tank Problems

Common Generator Diesel Fuel Tank Problems

Generator diesel fuel tanks play a crucial role in ensuring reliable power, but they’re not immune to problems. Over time, a variety of issues can develop that affect performance, safety, and compliance. Here are the most common issues:

1. Water Contamination

Condensation can build up inside the tank, especially with changes in temperature, leading to water settling at the bottom. This creates several problems:

• Promotes microbial growth (diesel bugs)
• Causes fuel degradation
• Risks rust and corrosion inside the tank
• Can damage the fuel system or engine

2. Microbial Growth

Bacteria, fungi, and algae thrive in the interface between water and diesel. This microbial sludge can:

• Clog fuel filters
• Damage injectors
• Lead to operational failures during critical moments

3. Fuel Degradation

Diesel fuel naturally degrades over time—especially if the tank isn’t used frequently. Oxidation and contamination lead to:

• Gum and sediment formation
• Reduced fuel efficiency
• Poor combustion and engine performance

4. Corrosion

Corrosion weakens the tank structure and can lead to leaks or sediment buildup. Internal tank corrosion can result from:

• Water contamination
• Sulfur content in diesel
• Aging metal tanks

5. Tank Leaks

Older tanks, especially underground ones, are susceptible to leaking due to corrosion or physical damage. This poses:

• Environmental hazards
• Risk of fire
• Costly cleanup and regulatory penalties

6. Improper Venting or Pressure Build-Up

Blocked vents or improper tank venting can cause:

• Overpressure or vacuum conditions
• Structural damage to the tank
• Fuel delivery issues

7. Clogged Fuel Lines or Filters

Sediment, microbial growth, or degraded fuel can clog lines and filters, leading to:

• Engine starting failures
• Reduced generator performance
• Increased wear on the fuel system

8. Fuel Theft or Tampering

Above-ground tanks may be targeted for fuel theft, especially during power emergencies or fuel price spikes. Without proper locks or monitoring:

• Fuel loss goes unnoticed
• Emergency power reliability is compromised

9. Regulatory Non-Compliance

Fuel tanks are subject to strict regulations, especially underground tanks. Issues include:

• Outdated or missing permits
• Lack of spill containment systems
• Infrequent inspections

10. Poor Tank Maintenance Practices

Neglecting regular tank inspections, fuel polishing, and water drainage can allow all of the above issues to develop unchecked.

These are the biggest things that can damage your engine and its injectors, as well as stop the generator from running if you do not maintain the fuel and the tank properly.

Preventive Tips for Proactive Diesel Fuel Tank Maintenance

• Inspect and test fuel regularly
• Use water separators and fuel polishing services
• Keep tanks full to reduce condensation
• Schedule professional tank cleaning and maintenance
• Ensure tanks meet local environmental regulations

For more information on common generator diesel fuel tank problems, request a quote or give us a call at 1-800-899-3931.