Storage Tank Corrosion Mitigation
What is the Problem? • Leaks leading to: • Wastage • Lost resources • Environmental damage
What is the Problem? Corrosion is the main cause of these leaks. Other causes could be environmental damage or damage due to impact
Belzona Solutions for Storage Tanks
Tank Base Problem areas for Tanks Sealing Through-wall Defects 4 2 Corroded Hand Rails 3 Seam Defects 5 Internal Corrosion 1 Deteriorated Base
Tank Base Solutions for Tanks Sealing Plate Bonding for Through-wall Defects 4 2 Hand Rails Bonding 3 Composite Patch Repair 5 Internal Lining 1 Tank Base Sealing
Tank Base Problem Areas Sealing • Corrosion of tank wall and • Tank chine angle • Water / moisture ingress Wall under the tank base • Deterioration of seal through this joint, when the tank moves the capillary action squeezes • Corrosion of tank base the water under the base • Concrete or • Tank base Asphalt
Tank Base Sealing Traditional Repairs Mastics Steel Skirt Bonded Rubber
Tank Base Sealing 1 Tank Base Sealing
Tank Base Sealing: Belzona 3111
Tank Base Belzona Tank Base Sealing System Sealing Advantages of using a Belzona system? • Microporous • Flexible • Weather resistant • Excellent adhesion
Case studies – Tank Base Sealing Petrochemical Plant, UK (2010)
Case studies – Tank Base Sealing Refinery, West France (2004) 1. Failing System 2. Surface conditioned 4. Application – 13 years on 3. Testing the Annular Ring
Case studies – Tank Base Sealing International Petroleum company, China (2014) 1. Tank farm overview 2. Damaged tank base 3. Application of Belzona 3211 4. Completed application
Case studies – Tank Base Sealing Petrochemical Plant, Croatia, 2014
External External solutions for Tanks Protection External Corrosion Protection Problems – Corrosion - UV damage
External Protection Problem: • Corrosion • Environmental damage • Impact damage Conventional repair methods: • Hot work – Health and safety issues • Impractical as tank needs to be empty • Damaging to the internal lining in the process
External Belzona Solution: Protection Advantages: • High Zinc content • UV resistance • Cold applied • Durable • Spray applied
Plate Bonding Introduction
Tank roof repair 2006, Oil Distributor, England Deteriorated tank roofs Evident through-wall defects Belzona plate bonding permanent repair
External Tank Protection PEMEX Mexico, Tamaulipas field 1. External corrosion 2. Belzona 5111, 6111 and 5811 3. Completed application 4. 12 years later
External Tank Protection IVECO-Turin, Italy
External Tank Protection Chemical Plant, Poland
External Tank Protection Sugar Factory, France Coating of the silos Finished application
External Protection Petroleum plant, South Africa (2013)
Internal Internal Solutions for Tanks Protection 5 Internal Lining
Internal Protection Common Problems: • Corrosion • Erosion • Chemical attack • Maintenance/cleaning (steam out) Leads to: • Thin/through wall defects • Leaks • Delamination of existing coating
Internal Protection Conventional Repairs: • Welding • Standard paint systems Belzona Solution: • Cold applied • Resistant to a wide range of chemicals/temperatures • High adhesion • Long-term protection • In-situ repair
Internal Protection Oil company, Tunisia
Internal Protection International Oil company, Chad (2003)
Internal protection Tank, Pulp Factory, Germany (2007)
Internal Protection France, 2017
Belzona Solution Corrosion Protection of small bore nozzles Small bore nozzles are difficult to blast properly, difficult to apply coating and cannot inspect properly Same Belzona adhesive can be A cost effective alternative to used to form flange face CRA is to insert corrosion inert providing complete protection. sleeve and bond into place using suitable Belzona material
Nozzle Insert Technology
Nozzle Insert Technology
Flange Face Forming
Flange Face Forming Flange faces formed using Belzona materials to prevent corrosion and leaks
Belzona solutions – Storage Tanks Why Belzona? Application: Brush or spray Fast curing for Cold applied Solvent free applied minimal downtime No hot work no shrinkage In-service performance: High Resistance to a wide range of Long-term Maintainable adhesion chemicals and temperatures solution
CASE STUDY 1 Belzona seals tank shell to the concrete floor Romania April 2018
APPLICATION SITUATION A steel tank with a concrete floor used to store a mix of salt water and oil 12m 13m Volume: 1500m 3
PROBLEM There was a gap of up to 6 mm between the concrete floor and the steel shell. It had to be sealed to stop the tank from leaking.
SOLUTION 1. Enlarge the gap 2. Remove contaminated concrete 3. Clean and sandblast steel 4. Degrease the surface
SOLUTION 5. Insert NBR rubber cord into the gap 6. Close the gap with Belzona 4111 7. Apply Belzona 1321 for corrosion protection
OUTCOME No leaks after 1 year of operation 4 people completed this application in 5 days
CASE STUDY 2 Belzona restores tank wall and protects against corrosion Romania August 2018
APPLICATION SITUATION A steel tank used to store a mix of salt water and oil 9m 12.3m Volume: 980m 3
PROBLEM The tank suffered from an advanced internal corrosion.
SOLUTION 1. Clean, degrease and sandblast the area 2. Apply Belzona 1111 to restore the wall thickness 3. Bond steel plates over holes 4. Apply Belzona 5892 to protect the tank bottom and shell from corrosion
OUTCOME Fast and easy back to service Belzona was the only alternative due to the risk of sparks
CASE STUDY 3 Belzona repairs a crack and holes in a tank shell Romania May 2019
APPLICATION SITUATION A 20-year-old with significant mud deposits
PROBLEM - 80% wall thickness loss - Crack developed from the bottom of the tank
SOLUTION 1. Old plate removed 2. Nozzle bonded with Belzona 1212 to redirect the leak 3. Area sandblasted
SOLUTION 4. Belzona 1111 used to restore lost wall thickness 5. Specially designed metal plate bonded in place 6. Plug fitted and Belzona 3412 applied for corrosion protection
OUTCOME Belzona solution = Welding was the 2 days with no only alternative = 4 weeks downtime disruption
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