Mercedes Mullins
Fuel tank corrosion is a serious issue that can lead to costly repairs and safety hazards. It is caused by the presence of water, microbial contamination, and low MW acids in the tank, which result in metal corrosion. This is a common problem in steel tanks, which are prone to corrosion from weather conditions like heat, condensation, and UV light. Diesel fuel storage tanks, in particular, are susceptible to corrosion due to the presence of biofuels like ethanol and biodiesel, which microbes feed on. Regular inspections and water level checks are crucial for preventing corrosion, as recommended by the EPA. Additionally, fuel tank corrosion forms from the inside, making internal testing by experts necessary. Proactive measures such as routine filtering of fuel and regular maintenance can help prevent corrosion and maintain fuel quality.
| Characteristics | Values |
|---|---|
| Cause | Microbial growth, water, condensation, UV light, heat, bacterial microbial contamination, low MW acids, ethanol, biofuel, steel tanks, scratches, new fuel chemistry |
| Prevention | Regular water level checks, routine inspections, water removal, quality filters, proactive approach, corrosion-resistant finish, bund (secondary containment), fuel polishing, tank cleaning |
| Effects | Fuel leaks, contamination of surroundings, plugging of dispenser filters, equipment failure, risk to tank integrity, liability risk for tank owners, health risks |
| Solutions | Monitoring and curing microbial build-ups, fuel filtering, use of high-grade filters, keeping tanks full, double skin on tank |
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What You'll Learn
Microbial contamination
The introduction of biofuels and modern refining techniques has decreased the shelf life of diesel fuel, making it more susceptible to contamination and corrosion. Water, the most common contaminant in fuel systems, provides the ideal environment for microbial growth. When water mixes with jet fuel, for instance, it creates the perfect conditions for microbes to thrive, leading to microbial fuel infestation.
As microbes multiply, they form biomass and biofilms, which can damage fuel system components. The presence of water also accelerates corrosion, as it settles at the bottom of the tank, leading to pitting corrosion and structural instability. This is especially problematic in aircraft fuel tanks, where corrosion can compromise flight safety and result in costly repairs and downtime.
To prevent microbial contamination, regular inspections and water level checks are crucial. The EPA recommends filtering fuel for water and particulates to maintain fuel quality and prevent corrosion. Additionally, the use of corrosion-resistant finishes, such as Hammerite Direct to Rust Metal Paint, can protect tanks by repelling water and preventing rust formation.
In cases of heavy microbial contamination, a multi-stepped approach is necessary. This includes treating the problem with biocides, cleaning the tank, and implementing a fuel quality management (FQM) program. By proactively addressing microbial contamination, fuel tank operators can avoid costly repairs, environmental hazards, and potential health risks associated with fuel leaks and corrosion.
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Water ingress
One of the main ways water enters fuel tanks is through condensation. As tanks with high turnover rates pull in outside air, humidity is pulled into the tank, which then condenses. This is especially common in warmer months, when heat gain and evaporation cause water to form in the tank. Additionally, as fuel is delivered at higher temperatures, it is placed into a cooler underground environment, and the water sheds as the saturation point lowers.
Leaky seals are another common source of water ingress. A high water table can impact seals, allowing water ingress, and any seal has the potential to be a point of water ingress. Water can also enter the fill pipe through loose caps, and from unkept spill buckets.
The presence of water in a fuel tank increases the rate of microbial contamination, which in turn raises the acidity level of the fuel. This higher acidity level is strongly correlated with an increased rate of corrosion within the tank. Therefore, it is crucial to establish a regular schedule for water level checks and to take immediate steps to remove water if detected.
To prevent water ingress, it is important to ensure that riser pipes and fittings are installed appropriately and that all fittings, cord grips, manway caps, gaskets, and electrical conduits are watertight. Additionally, robust measures should be implemented to extract rainwater from exposed bunds, as rainwater can build up and cause oil to escape.
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Steel tanks
The degree of corrosion in steel tanks depends on the stored product and the tank's environment. Corrosion occurs due to a combination of sulfurous gases, moisture (including salt water), and oxygen within the tank. Acid salts, hydrogen sulfide, and other sulfur compounds can cause corrosion, particularly in areas covered by the stored liquid. Additionally, contaminated water accumulating at the bottom of the tank, known as bottom sediment and water (BS&W), can lead to internal steel issues.
To prevent and control corrosion in steel tanks, several methods can be employed:
- Coatings: Applying anticorrosive coatings is the most widely used method. Epoxy coatings and carbon nano polymers are recommended for their high-temperature resistance and excellent chemical resistance.
- Cathodic protection: This method involves using a sacrificial metal to protect the steel tank from corrosion.
- Corrosion inhibitors: In some cases, adding corrosion inhibitors to the tank can help prevent corrosion.
- Routine inspections: Regular checks for water, microbial contamination, and other issues are crucial for preventing corrosion and ensuring the longevity of the tank.
- Water removal: Water is a significant contributor to corrosion. Removing water and using water monitors can help mitigate corrosion.
- Fuel filtering: Filtering fuel for water and particulates before or shortly after delivery can reduce the risk of corrosion.
- Tank maintenance: Regular cleaning and maintenance, including pressure jetting to remove loose metal and expose corroded areas, can help identify and address corrosion early on.
By implementing these methods, operators can effectively manage corrosion in steel tanks, preventing equipment failures, reducing operational downtime, and minimising environmental risks.
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Regular inspections
It is important to establish a routine inspection schedule and document each inspection, noting any changes or concerns. If water is detected, immediate steps should be taken for its removal, and fuel should be filtered for water and particulates. High-grade filters designed for water and particulate removal should be used, with regular maintenance and timely replacement.
Beyond water, microbial growth in fuel tanks can cause corrosion and fuel leaks, contaminating the surroundings. Microbial bacteria enter the tank and fester, leading to accelerated fuel tank corrosion. Monitoring services are available to detect and remove microbial infestations.
Additionally, the introduction of bio and modern refining techniques has decreased diesel fuel's shelf life, increasing the likelihood of fuel contamination and tank corrosion. Regular inspections can identify these issues early and prevent costly repairs and environmental hazards.
For steel tanks, regular cleaning is essential as they are more prone to corrosion from weather conditions such as heat, condensation, and UV light. Internal testing by experts with confined space entry training is necessary to identify corrosion forming inside the tank, which is not visible through exterior examination.
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Corrosion-resistant finishes
Fuel tank corrosion is a common issue, especially with the recent changes in diesel fuel, such as the introduction of bio and modern refining techniques, which have resulted in a shorter shelf life. This has led to an increased demand for fuel tank cleaning and fuel polishing services.
To prevent corrosion and protect fuel tanks, several corrosion-resistant finishes are available:
Hammerite Direct to Rust Metal Paint
This paint finish is a corrosion-resistant coating that repels water and prevents rust from forming underneath the paint. By applying this paint, you can protect your fuel tank and prolong its life.
POR-15 Fuel Tank Sealer
POR-15 Fuel Tank Sealer is a highly effective coating that creates a strong, impervious barrier against rust, corrosion, and ethanol fuels. It is resistant to all types of fuels, including diesel, E10 ethanol, and high-alcohol content fuels. This sealer is known for its superior strength and fuel resistance, leaving a tough grey/silver finish. Before applying the sealer, ensure that the fuel tank is free from plastic parts, contamination, and structurally sound. It is also recommended to clean the tank with a suitable cleaner and degreaser and etch it with a metal prep solution for the best adhesion. After applying the sealer, it is crucial to drain the tank and let it cure for several days before putting fuel in the tank.
Double Skin on a Tank
Another way to enhance corrosion resistance is by implementing a double skin on the fuel tank. This provides an extra layer of protection from fluctuating temperatures and impact damage. The outer skin acts as a secondary containment, significantly reducing the risk of leaks and spills.
Regular Maintenance and Monitoring
While coating your fuel tank is essential, it is equally crucial to establish a regular maintenance and monitoring schedule. This includes routine water level checks, documentation of inspections, and immediate removal of water to prevent corrosion. Investing in high-quality filters designed for water and particulate removal is also recommended. By being proactive and consistent in your maintenance efforts, you can effectively prevent corrosion and ensure the longevity of your fuel tank.
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Frequently asked questions
Corrosion forms from the inside of a tank due to a combination of sulfurous gases, moisture, and oxygen. It is caused by acid salts, hydrogen sulfide, or other sulfur compounds, as well as contaminated water that accumulates at the bottom of the tank.
It is recommended to get fuel and tanks checked every six months. Regular checks are essential to prevent unforeseen issues and ensure the longevity of the tank.
To prevent corrosion, it is important to proactively address any issues found through regular checks and keep tanks full to avoid the risk of moisture. Using a corrosion-resistant finish, such as Hammerite Direct to Rust Metal Paint, will also help protect the tank. Additionally, coatings, cathodic protection, and in some cases, corrosion inhibitors can be used to control internal corrosion.
Internal corrosion in storage tanks can shorten their life cycle and cause dangerous leaks, leading to the release of hazardous materials into the environment. Corrosion can also affect the bottom line of a fuel site by reducing throughput due to clogged filters.
