Franklin Fueling Systems for Mission Critical Applications

Guide to Franklin Fuel Systems for Mission Critical Generator Applications

Franklin Fuel Systems (FFS) is the leading provider of tank gauges and submersible Turbine Pumps globally. The new EVO controllers have integrated control logic for generator fuel applications. This capability makes them ideal for mission critical generator applications.

We partner with Franklin Fuel Systems for critical systems because they are supported globally by over 200 distributers all with highly skilled and trained certifications. Long term operation support is fundamental reliable performance.

To purchase these Franklin Fuel Products and Systems you can lookup your local distributer here.

Franklin Fuel Systems Advantages for Mission Critical Generators

Precise Fuel Level Measurement. The FFS magnestrictive level probes are the most precise fuel level instruments available. His allows for precise inventory control throughout the system in bulk tanks, day tanks, and generator sub-base tanks.

Network Capability. The FFS-EVO controllers have network capability built-in with wired or wireless connection. Native modbus allows integration to building and industrial control networks.

Control Logic. The FFS-EVO controllers have a built-in Conditions capability which allows for basic PLC-like control for alarms, pumps, and valves.

Sensors for Environmental Protection. FFS has a variety of leak sensors to apply to tanks, piping, and equipment areas. Importantly the sensors have an integral integrity check to assure they are always ready. High level sensors and alarms are applied to provent otank overfill risks.

Submersible Pump Technology. FFS Submersible Turbine Pumps (STP) are in reliable fuel service every day. In mission critical applications, the STP has a distinct advantage over standard pump systems in avoiding suction line problems. Loss of Prime is a common source of failure in suction type pumping systems. In addition suction side problems can lead to cavitation and excessive wear that causes pre-mature failure in suction pump systems.

Pump Monitoring Technology. The FFS Guardian pump controllers have continuous monitoring of pump performance characteristics. This allows facilities to identify ootential pump issues long before actual performance is affected.

STPs for Fuel Polishing and Water Catch. The FFS STPs have an auxiliary induction feature that allows tank bottom water to be removed while bypassing the turbine. This is important because water passing through a pump along with fuel creates an emulsification that makes the water very difficult to remove in standard filter systems.

Water collects in the bottom of steel tanks. This is a problem for corrosion which shortens the life of the steel tank. More importantly it creates a water-fuel interface that promotes bacterial growth contaminating fuel supplies and producing an acidic condition that promotes accelerated corrosion. For these reasons all steel tanks carry a warning label requires monitoring and removal of tank bottom water. This problem is especially severe for the generator sub-base tanks commonly used in generator applications, because of their very large bottom plate profiles.

A second advantage of STPs for Fuel Polishing is their robust flow rates compared to other pump types. Generator sub-base tanks are difficult to fuel polish because of their long wide configuration and internal baffles. Smaller suction style often short-circuit flow with a local low-flow loop that excludes most of the tank volume. Franklin STPs offer a high flow rate that engages the full volume of the tank to be cleaned and polished.

Here are Data Sheets for the Key Franklin Products:

Generator: Generators by Caterpillar, Cummins, MTU, Kohler, and Generac within a weatherproof enclosure, examlpe Robinson Enclosures.
Sub-Base Diesel Fuel Tank can be UL142 or UL2085 Fire-Rated. Designed to support the generator load, example United Alloy.
Franklin EVO Tank Gauge within Earthsafe E51 Enclosure. The enclosure allows the EVO to operate in mission critical environments providing -20 to +120 F temperature range, NEMA 4 water protection, Input power surge suppression and output electrical isolation.
EVO Guardian Pump Controller within Earthsafe E52 Enclosure. Monitors pump status and performance and integrates that information to the EVO controller.
Earthsafe M5 Dual High Flow Fill Station for Diesel and DEF. Weatherproof enclosure 2 containmnet compartments with tight-fill connections for delivery hoses. Integral High Level Stop actuated valves for overfill protection.
Earthsafe M3 Fuel Polisher and Water Catch. Duplex Filters are fed from the submersible pump with water induction accessory. This allows for efficient tank bottom water removal without emulsifying the water allowing removal in the coalescing filter from the fuel flow. The 25 GPM flow rate assure throughput of the sub-base tank contents to avoid short circuiting that defeats polishing effectiveness.
The FFS-PRO Display within Earthsafe M53 Enclosure is a graphic interface for all generator tanks in a grouping, and it is an interface to in-building control rooms and other building systems. The important function is to allow operators to manage onsite fuel logistics – “how much fuel is needed and where is it needed first”.
The FFS Submersible Turbine Pump (STP) transfers fuel at high flow to the M3 fuel polisher / water catch module. The STP has 2 important accessories:
(a) The Earthsafe M1-STP10 Kit allows for STP extended run in shallow tanks, of large tanks at low fuel level. The Kit uses a small amount of the fuel flow to cool the turbine components. And
(b) The Earthsafe M1-STP11 Kit uses an eductor at the pump discharge to lift water from the tank bottom surface and direct it to the fuel polisher / water catch with emulsification in the turbine pump fuel flow.
FFS-EVO Tank Level Probe, Leak Sensor, and High Level Sensor. The EVO level probe is a high precision magnetostrive probe that provides fuel levels and temperatures to the EVO controller. Leak Sensors for tanks, piping, and equipment modules are continuously monitored for integrity. The high level sensor provides an independent redundant signal for overflow protection.
Earthsafe UM5 DEF Storage Tank Insulated and Heated. DEF storage is typically 10% of diesel fuel storage and usually requires insulation and heat tracing to prevent freezing and at high temperatures to prevent degradation. The M5 is available ia a variety of configurations to fit in and around the generator.
FFS-EVO DEF Tank Level Probe, Leak Sensor and High Level Sensor. The EVO level probe is a high precision magnetostrive probe that provides fuel levels and temperatures to the EVO controller. Leak Sensors for tanks, piping, and equipment modules are continuously monitored for integrity. The high level sensor provides an independent redundant signal for overflow protection.

Franklin Fuel Systems at the Tank Farms

Data Centers, Hospitals, and other critical facilities often include Bulk Fuel (and DEF) Tank Farms to supplement the fuel stored directly at the generator in a sub-base or day tank. Here is how Franklin is deployed at the tank farm.

Bulk Storage Tank: UL 142 or UL 2085 Fire-Rated Tanks from Modern Welding. Up to 50,000 Gallon capacity
Duplex FFS Submersible Turbine Pump (STP) with Earthsafe M1-STP10 transfers fuel to the generator locations upon demand. The pumps are monitored for flow and other performance characteristics by the Guardian Pump Controller. The STP has 1 important accessory:
(a) The Earthsafe M1-STP10 Kit allows for STP extended run in shallow tanks, of large tanks at low fuel level. The Kit uses a small amount of the fuel flow to cool the turbine components.
Franklin EVO Tank Gauge within Earthsafe E51 Enclosure. The enclosure allows the EVO to operate in mission critical environments providing -20 to +120 F temperature range, NEMA 4 water protection, Input power surge suppression and output electrical isolation.
EVO Guardian Pump Controller within Earthsafe E52 Enclosure. Monitors pump status and performance and integrates that information to the EVO controller.
Earthsafe M5 Dual High Flow Fill Station for Diesel and DEF. Weatherproof enclosure 2 containmnet compartments with tight-fill connections for delivery hoses. Integral High Level Stop actuated valves for overfill protection.
Earthsafe M3 Fuel Polisher and Water Catch. Duplex Filters are fed from the submersible pump with water induction accessory. This allows for efficient tank bottom water removal without emulsifying the water allowing removal in the coalescing filter from the fuel flow. The 25 GPM flow rate assure throughput of the sub-base tank contents to avoid short circuiting that defeats polishing effectiveness.
The FFS-PRO Display within Earthsafe M53 Enclosure is a graphic interface for all fuel and DEF tanks in a grouping, and it is an interface to in-building control rooms and other building systems. The important function is to allow operators to manage onsite fuel logistics – “how much fuel is needed and where is it needed first”.
The Polishing FFS Submersible Turbine Pump (STP) transfers fuel at high flow to the M3 fuel polisher / water catch module. The STP has 2 important accessories:
(a) The Earthsafe M1-STP10 Kit allows for STP extended run in shallow tanks, of large tanks at low fuel level. The Kit uses a small amount of the fuel flow to cool the turbine components. And
(b) The Earthsafe M1-STP11 Kit uses an eductor at the pump discharge to lift water from the tank bottom surface and direct it to the fuel polisher / water catch with emulsification in the turbine pump fuel flow.
9. FFS-EVO Tank Level Probe, Leak Sensor, and High Level Sensor. The EVO level probe is a high precision magnetostrive probe that provides fuel levels and temperatures to the EVO controller. Leak Sensors for tanks, piping, and equipment modules are continuously monitored for integrity. The high level sensor provides an independent redundant signal for overflow protection.

Using Franklin EVO System for Mission Critical Applications

Earthsafe Systems can integrate Franklin equipment to operate in mission critical applications by using some PLC-like capabilities of the Franklin EVO controllers called TS-CON. These applications include:

Day Tank or Generator Sub-base Tank Automatic Refill
Fuel Tank Filling Stations for 1, 2 or Multiple Fuel Storage Tanks
Duplex Pump Systems and Mult-Tank Selection
Fuel Polishing and Tank Bottom Corrosion Control
DEF Tank Heating, Pumping, and Level Control

Here is Franklin's Information about its TS-CON Control Conditions Software

"The TS-CON Control Conditions Software Option is an available software option that enables an EVO™ Series Automatic Tank Gauge (ATG) to be configured to perform advanced customized control and monitoring functions. “Control Conditions” use combinations of discrete and analog inputs with various logic operations allowing customers to create custom events and applications as well as control relays and submersible pumps.

The power and flexibility of the TS-CON Control Conditions software makes it suitable for installations requiring specific control capabilities not normally associated with typical tank monitoring systems. This functionality makes the software ideal for emergency power and generator systems. This is all accomplished while the EVO™ Series ATG continues to provide standard FMS functionality.

The individual(s) responsible for programming the setup configuration of the FMS must have a solid understanding of PLC programming and ladder logic.

The logic programming should include integrated fail-safe protection to guard against fuel tank overfills, fuel spill occurrences, fuel pump failures and similar issues.
FFS recommends completing a “Failure Mode Effects Analysis” exercise to insure proper system operation.
A full system commissioning must be done prior to full site operation."

Fuel Systems for Hospitals, Life Safety, and Critical Apps

So far we have focused on Data Center Application. Now lets look at using the Franklin equipment for Hospitals, Building Life Safety, and Other Critical Facilities

Generator fuel systems are configured in a wide variety of systems to suit safety, compliance, and operational requirements in and around buildings. Most often they are designed and built, or cobbled together, using independent fuel gauges, pumps, day tanks, and other components that are difficult to commission and operate as an integrated system. The Franklin Evo has a heritage of integrating fuel tank level gauging, leak detection, and pump control—and an unmatched global network of certified technicians.

Utilize Standard Petroleum Equipment to Maximum Extent

The design intent is to utilize standard petroleum equipment to the maximum extent possible.

There are several benefits to this approach.