Tank Roof Replacement & Repair
Addressing Severe Through-Wall Failure in a Fuel Oil Storage Tank
A fuel storage facility faced a significant challenge with a diesel fuel storage tank experiencing severe internal corrosion. Despite a previous repair using a protective CFRP coating, the tank continued to develop multiple leaks. A routine inspection revealed hundreds of small through-wall failures in the tank roof. Rather than opting for a costly and time-consuming full roof replacement, the plant engineer sought a cost-effective, high-performance solution—a fiber-reinforced polymer (FRP) composite repair.
Inspection and Preparation
A detailed inspection and preparation process ensured optimal adhesion and long-term durability:
Surface Preparation:
The surface was prepared using 5,000 PSI water pressure with grit infusion to remove contaminants and corrosion, creating an ideal profile for adhesion.
Material Selection:
CFES Style 1210 E-Glass Fiberglass Fabric: Chosen for its exceptional durability, flexibility, and ability to conform to complex geometries.
CFES Standard Saturant System: Ensured full fabric saturation, creating a strong, resilient bond with the substrate.
CFES S-Epoxy Topcoat: Applied as a protective barrier to enhance chemical resistance and prevent future corrosion.
Innovative Repair Methods
The repair methodology involved precise application techniques to restore structural integrity:
Heavyweight E-Glass Fiber Application:
Multiple layers of heavyweight E-Glass fiber were strategically applied over the damaged areas, reinforcing the structure and sealing perforations.
The composite layers were built up to achieve the necessary strength and waterproofing properties, ensuring a seamless, high-performance repair.
Epoxy Topcoat Application:
A high-strength epoxy topcoat was applied to encapsulate the FRP system, providing long-term protection against harsh environmental conditions and further degradation.
Key Outcomes
Restored Integrity: The feeders’ wall thickness was restored, ensuring safe operation under high pressure.
Continuous Operations: Repairs were executed without disrupting service, maintaining system reliability.
Cost Savings: The innovative CFRP system eliminated the need for costly and time-consuming barrel replacements.
Enhanced Durability: The repair provided long-term resilience, Long-term protection was achieved through the anti-corrosion wrap and the CFES S-epoxy topcoat.
