Repairing a storage tank to prevent corrosion, maintain the integrity of the tank, and to prevent leaks is an important part of storage tank maintenance. In the event that you need to repair a storage tank, the API recommends several specific steps. Storage tanks frequently have issues with erosion and corrosion. Tank deterioration can result in leaks, environmental damage, and operational shutdowns.
The Necessary Steps
The API recommends a five-step process in the event of storage tank repairs:
- Inspection of the tank is necessary
- Conventional repairs
- Modern alternatives to repairs
- Primary steps for alterations or repairs to a storage tank
- Tank reconstruction
Inspection of the Tank Is Necessary
Corrosion typically happens in the parts of storage tanks hidden from normal view. That means the corrosion can get larger before it is noticed, and a lot of damage can result from that. Tank parts under insulation or inside the tank are hidden enough that corrosion can get to a rather advanced level before it is detected, and by then the tank can be vulnerable. Interior corrosion can expedite the risk timeline any tank faces.
Conventional Repairs
There are many conventional repair and refurbishing techniques for tanks. They can work on both thin and thick walls. However, they also involve hot work that is hard to do, takes time, and will shut down operations. Hot work also involves the potential for flammability and even explosions while the repairs are going on.
All this adds up to the hot work of any impacted storage tank shutting down production. Before that, the tank has to be emptied out and cleaned. Productivity obviously suffers greatly, and high costs are bound to happen. Space restrictions can also impede hot work, as can current operating conditions and how available any replacement parts are.
Modern Alternatives to Repairs
A more recent alternative, and one that is quite plausible, is using cold-curing compounds for Belzoni repairing. These compounds help offer robust repairs that stand the test of time in cases of corrosion. The timeline for this process if much faster, and there’s usually no downtime involved. You won’t have to watch your productivity suffer, nor will extra repair or maintenance expenses hit your budget. This process usually only takes a day or two to get your tanks back to a totally functional form. Cost-management, in the long run, is improved by extending the practical lifetime of your storage tank.
Primary Steps for Alterations or Repairs to a Storage Tank
Carrying out effective repairs on a storage tank involve four main steps that you need to take in order:
- Any part of the tank contributing to the structure’s integrity need to be removed. This will include the bottom, the roof, and parts of the shell. This is going to facilitate any cold-curing or welding you do in the impacted area.
- The impacted tank roof, bottom, or she’ll need to get jacked and then relevelled for improved access and actual work.
- Reinforce the shell opening with more plates to improve support and labor efficiency.
- Follow this up with the tearing down and grinding of any corroded areas before using cold-curing or hot-work welding to your preference.
Tank Reconstruction
The API recommends specific steps to happen in the reconstruction or repairs of storage tanks. Read API-653 Section 7 for the particular requirements for alterations and repairs in storage tanks. Adhere to the primary guidelines of:
- Removing of shell plate material
- Repairing any defects in shell plate materials
- Changing the shell height
- Repairing defective welding
- Repairing shell penetration
- Adding, replacing, or altering shell penetrations
- Repairing the bottom of the tank
- Repairing or fixing the roof
- Repairing perimeter seals
Failing to Do Repairs Right or Right Away Is a Mistake
In the event of a storage tank failure, you need to identify the problem quickly and then deal with it as expediently as you can. While you might be tempted to gloss over it rather than shut down operations, letting something linger will only get more expensive to cover later on. Also, the potential disruption to your operations would magnify the longer you leave an issue in place. Routine storage tank inspections and repairs are crucial to keeping your operations running as smoothly and continuously as possible.
Think of repairs and inspections as an investment in your continued operations. You’ll also keep your storage tanks operating for as long as they can, and that will save you more money in the long run than you will spend on maintenance matters.
Perhaps the biggest thing is environmental considerations. If any storage tank leaks into the local environment, you automatically waste whatever you were storing in the tank. On top of that, the environmental damage does the world no good. You’ll possibly get hit with major fines for the cleaning up involved or regulation violations.
Worse yet, the publicity hit in a society increasingly concerned with environmental matters could doom your business. Consumers, clients, and even other businesses might choose to avoid doing business with you.
Key Takeaways
If you remember anything else from all this, then it needs to be this:
- Storage tanks are susceptible to corrosion and other damage over time.
- The worst corrosion is often in places that are hidden or hard to inspect on a regular basis.
- Storage tank leaks can shut down your operations, and repairs can also do that.
- Cold-curing compounds might be a quicker fix than hot-work welding.
- Environmental damage is a big no-no in today’s world.
Take care of your storage tanks, and they’ll take care of your business.
