18 waren Emrsnng 8 Nengomar + Ay 2900 7 N hemicals can be severely cor- ( rosive to above-ground metal N storage tanks, resulting in pos- sible leaks. The average corrosion rate of some carbon-steel storage tanks in certain services at ambient temperatures is more than 1 mil per year, with leaks developing in as few as five years. These leaks result in costs for both tank repair and possible environmental penalties Tank corrosion sometimes increases when a layer of water containing soluble salts and chlorides setdles to the bottom. These compounds are highly corrosive in themselves, and they can generate a strong: re-read Sera e How Strong Are Tho? electrolyte that further promotes corrosion from within. There can be a problem with external tank corrosion as well. The bot- toms of above-ground storage tanks are susceptible to corrosion, especially if the tanks are close to salt water or subject to stray electrical currents inthe soil. fan above-ground tank bottom is cor- roding, it must either be replaced or coated with a thick-film, fiberglass reinforced plastic (FRP) lining with a 60 to 65 mil dry film thickness. Since replacing a tank bottom can be costly and time-consum- ing, FRP linings have become a popular altemative for tank bottom repair. inc FRP Lining Installation ‘The recent trend has municip shifting away from replacing tank bottn and toward the application of FRP Fring ystems where recommended. Installing Tining system means applying a primey Putty, catalyzed resin with a glass mat a a sealcoat. The tank must be dry and d surface properly prepared. ‘The ent process is quicker and less expensive d replacing an entire tank bottom. Thick-film FRP linings are considers secondary bottoms that are bonded ly to the storage tank. When pro selected and applied, they prevent worw.waterinfocenter.comLE Ne eats due to intemal corrosion for 10 to 20 years. If the supporting steel bottom is perforated, these linings also can help minimize the problem of exterior como- sion by providing enough strength to bridge small perforations. Even if severe corrosion is present on the outside, it is possible to apply a double layer of the lam- inate for a total thickness of 110 to 120 mils. (Linings of less than 20 mils dry film thickness will not protect against leakage from outside corrosion. They are recom- mended only for relatively new tanks with no internal pitting and underside corro- sion.) FRP Development Introduced in the mid-1950s, the first FRP laminates were orthophthalic poly- esters that bridged gaps caused by under- side corrosion and were thought to provide protection ffom internal corrosion 4s well. However, in the early 1960s, it was found that isophthalic polyester resins were better able to withstand aguressive conditions, Vinyl ester resins were intro- duced in the middle 1960s and performed very well, but their expense meant that they were used only when high pecfor- ‘mance was needed. Today, many FRP lin- ings consist of epoxy novolac residents in ‘avinyl ester backbone. ‘As with any repair method, FRP lin- ings have advantages and disadvantages. Advantages + ERP systems can bridge holes up to 8” diameter, with double laminates swithstanding 82 psi and single lami- nates 37 psi. FRP linings with vinyl ester resin sys- tems can resist numerous corrosive car- ‘goes at elevated temperatures FRP linings cost less than replacing existing steel tank bottoms, Since FRP linings can be installed more quickly, they minimize down time, so the tank can be placed back into service much sooner than it could with con- ventional tank linings or bottom replacement with new sted + Tn many installations, FRP linings have 4 35-plus year history of service Disadvantages * When pigmented gel coats are used, it is not possible to see the steel bottom to determine the existence or extent of bottom-side corrosion. However, new technology and high power magnets ‘ean now let operators scan the thick laminates to gather accurate informa- tion about corrosion taking place beneath the steel bortom. ‘Applicators must be aware of proper installation procedures and the importance of clean, contaminant- face substrates before application. While cyclic loading may affect the fong-term ability of FRP linings to bridge a large, clear opening, the extent of its effect is not yet filly known. Standing Up to Pressure There have been many articles written about FRP laminates that discuss the pros and cons of their use as an alternative to steel tank bottom replacement. One case history described a leaky 211-foot-diame- ter tank that had an PRP laminate installed in 1985. In mid-1995, a leak developed in its sump area, caused by bot tomside corrosion. Two holes had been created, each approximately one foot in diameter. However, it was determined that the FRP laminate had not filed. In fact, it ‘was only the FRP laminate that had been containing the contents of the tank and it did so until hydraulic pressure finally caused the laminate to rupture. How much hydraulic pressure can FRP laminate systems withstand? One physical pressure test took place in a water- filled chamber that could be steam heated through a pipe loop until it reached 140° F. ight plates of 12” x 1A" x 4" steel were fabricated, with a set of holes cut fiom the middle of each of four plates to represent corrosion pits. The holes (*A", 144", 4” and 8” in diameter) were filled with melted wax, with an isophthalic polyester resin laminate installed on top. A single lami- ‘Installing a lining system oneans applying prime, puty, catalyzed resin with glass mat and sel coat, pe See ae WWW Wa