Sylvie Willis
Fuel oil tanks can rust from the inside, and this internal corrosion is not visible by exterior examination. It is caused by a build-up of condensation and water, which occurs when tanks are not filled to the top. This can lead to equipment failure and leaks, which can be costly to fix. To prevent internal rusting, tanks must be checked and dewatered every six months to stop water build-up and subsequent corrosion. Underground tanks are thicker than aboveground tanks due to a more corrosive environment, and there are also various coatings and materials that can be used to protect against corrosion.
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What You'll Learn
- Fuel oil tanks can rust from the inside due to moisture and condensation
- Underground tanks are thicker than aboveground tanks, but both can corrode
- Tanks under concrete and asphalt last longer as they are sheltered from rain
- Regular internal testing and cleaning can prevent and address corrosion
- Corrosion-resistant finishes and coatings can protect tanks from rust
Fuel oil tanks can rust from the inside due to moisture and condensation
The presence of water or moisture inside a fuel oil tank creates an environment conducive to corrosion and rust formation. This can occur due to several factors, including incomplete filling, condensation, and external exposure. When a fuel oil tank is not filled to the top, it can collect moisture, leading to rust formation over time. Condensation can also build up, especially when the oil cools, resulting in water accumulation at the bottom of the tank. Additionally, external exposure, such as rainwater seeping into the tank or exposure to the elements, can introduce moisture and accelerate rusting.
To combat these issues, regular maintenance and proactive measures are essential. Homeowners and businesses should consider regular inspections and testing to detect corrosion early on. This includes internal testing by experts who are trained to ensure safe entry into confined spaces. Dewatering the tank at outlet pipes can also help detect and remove water, preventing its buildup and subsequent corrosion.
Furthermore, protective coatings and finishes can be applied to fuel oil tanks to repel water and prevent rust formation. These include epoxy coatings and corrosion-resistant finishes like Hammerite Direct to Rust Metal Paint. Additionally, underground tanks made of fiberglass or steel with fiberglass or plastic coatings offer enhanced protection against corrosion. Regular cleaning and maintenance of fuel oil tanks can also help remove sediment, grit, and rust buildup, ensuring the tank remains in good condition.
By implementing these measures, homeowners and businesses can effectively mitigate the risk of rust and corrosion in fuel oil tanks. Regular maintenance, proactive inspections, and the use of protective coatings can significantly extend the lifespan of fuel oil tanks, preventing costly leaks and failures.
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Underground tanks are thicker than aboveground tanks, but both can corrode
Fuel oil tanks can rust from the inside, especially if they are not filled to the top, as they collect moisture when left exposed. Generally, smaller tanks are made of thinner gauge metal than larger tanks, so they will get holes faster once they start to rust and degrade. Aboveground tanks usually come in single-wall steel and are painted or coated. However, the outward appearance of your tank is not an indication of its inside condition. These aboveground tanks start to degrade at the bottom first and do so from the inside out. Heating oil is dirty and forms sludge at the bottom, which holds moisture. Since water is heavier than oil, it will sink to the bottom.
To prevent leaks in underground tanks, you can purchase a tank made of fiberglass, which offers inherent corrosion resistance. Steel tanks with a fiberglass coating or a special plastic-type coating are also available, along with cathodic protected tanks that include an anode bag to help prevent corrosion. Aboveground tanks can be made more durable with high-performance coatings like epoxy.
The choice between aboveground and underground tanks depends on various factors, including local regulations and resale considerations. Some states require the removal of underground tanks if they are no longer in use, regardless of leakage. Realtors often advise clients to remove underground tanks before listing their homes as most buyers are reluctant to take on the risk. Additionally, banks may be hesitant to offer mortgages for properties with underground tanks.
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Tanks under concrete and asphalt last longer as they are sheltered from rain
Fuel oil tanks can rust from the inside, and this is not visible by exterior examination. This internal rusting occurs when the tank is not filled to the top, causing moisture to collect inside. The use of low-sulphur fuel in heating oil tanks can also cause microbial growth, leading to the production of corrosive acids. To prevent this, tanks should be dewatered every six months to stop water build-up, and the fuel should be regularly checked for contamination.
Tanks under concrete and asphalt last longer as they are sheltered from the rain, which can cause corrosion and reduce the tank's lifespan. A concrete basement floor provides a strong, stable, and solid base for the tank, reducing the risk of leaks. Indoor tanks are also less likely to be subjected to freezing temperatures, which can cause issues with the product supply lines. Additionally, indoor tanks are protected from other environmental factors such as snow and corrosion, reducing maintenance costs and the risk of oil leaks.
To further protect against corrosion, a bund (secondary containment) made of concrete or brick is legally required to contain and prevent spillages. However, these bunds can fill up with rainwater, which can cause oil to escape. Therefore, measures such as valves must be implemented to extract rainwater from exposed bunds.
For underground tanks, homeowners can choose from various materials and coatings to prevent corrosion. Fiberglass tanks or steel tanks with a fiberglass or plastic coating can be purchased. Cathodic protected tanks with an anode bag are another option to prevent corrosion. These tanks will help extend the life of the tank.
Above-ground tanks usually have single-wall steel construction and are painted or coated. They typically start to degrade at the bottom first and do so from the inside out due to sludge formation. To prevent corrosion, above-ground tanks can be upgraded with high-performance coatings such as epoxy. When installing above-ground tanks, it is important to ensure proper centring and support to prevent movement or falling over.
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Regular internal testing and cleaning can prevent and address corrosion
Fuel oil tanks can rust from the inside, and regular internal testing and cleaning are essential to prevent and address this issue. Internal corrosion can occur due to moisture build-up, condensation, or bacterial growth, leading to potential leaks and equipment failure. Here are some measures to consider for effective tank maintenance:
Regular Internal Testing:
It is recommended to have fuel and tanks checked at least every six months to detect any early signs of corrosion or contamination. Internal testing by experts with confined space entry training is necessary as external examinations cannot reveal internal corrosion. They employ methods like fuel uplift, pressure jetting, and Non-Destructive Testing (NDT) to assess the tank's internal condition and metal thickness.
Dewatering and Spill Prevention:
Dewatering outlet pipes every six months is crucial to prevent water build-up, which can lead to corrosion. Techniques like tank dewatering and the use of bunds (secondary containment) can help detect liquid interfaces between oil and water and prevent spills or leaks. Bunds should be made of concrete or brick and have the capacity to hold 110% of the tank's contents to ensure safe containment.
Cleaning and Maintenance:
Internal cleaning is essential to remove sludge, dirt, and corrosion build-up. Pressure jetting or manual cleaning can be employed to expose pitted or rusted areas. After cleaning, consider using a corrosion-resistant finish, such as Hammerite Direct to Rust Metal Paint, to repel water and prevent rust. Additionally, tank sealers and liquid tank liners are available to seal and protect the tank's interior after cleaning.
Tank Replacement and Upgrades:
In some cases, if significant corrosion is detected during internal testing or cleaning, it may be necessary to replace the fuel tank entirely. Upgrading to steel tanks with fibreglass or special coatings can enhance protection against degradation and corrosion. Underground tanks generally offer better protection against corrosion than aboveground tanks due to their thicker construction and less corrosive environment.
By implementing these measures, homeowners can proactively maintain their fuel oil tanks, preventing corrosion, addressing any issues early on, and extending the lifespan of their tanks. Regular internal testing and cleaning are key factors in achieving this goal.
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Corrosion-resistant finishes and coatings can protect tanks from rust
Fuel oil tanks can rust from the inside, especially if they are not filled to the top, as they collect moisture and are left exposed. This can lead to detrimental consequences if not properly addressed. Corrosion-resistant finishes and coatings can protect tanks from rusting.
For outdoor tanks, Cortec® recommends priming tank exteriors with VpCI®-396 corrosion-inhibiting primer followed by VpCI®-384 2K corrosion-inhibiting topcoat. Using two coatings of VpCI®-396 primer instead of just one will add greater longevity to the system. The 2K epoxy coating brings corrosion inhibitors close to the metal surface and is good for immersion conditions. It can also be used as its own topcoat for extra durability since tank internals are not usually exposed to UV light.
For tanks that hold strong chemicals, a strong chemical-resistant system such as VpCI®-395 and VpCI®-2026 may be required. The VpCI®-2026 coating can also be applied over VpCI®-395 on the tank bottom for better impact resistance.
For underground tanks, you can purchase a tank made of fibreglass. There are also steel tanks with a fibreglass coating or a special plastic-type coating, as well as cathodically protected tanks that come with an anode bag to help prevent corrosion.
Additionally, aboveground tanks usually come with single-wall steel and are painted or coated. These tanks can be upgraded to include high-performance coatings such as epoxy.
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Frequently asked questions
Yes, fuel oil tanks can rust from the inside. This is often due to moisture build-up, which can be caused by condensation or water vapour in the oil.
You may notice an oil leak or a strong oil smell. You can also use an inspection camera to look inside the tank.
To prevent rust, you should ensure that your tank is filled to the top to avoid moisture build-up. You can also use a corrosion-resistant finish, such as Hammerite Direct to Rust Metal Paint, or a tank liner.
If your fuel oil tank is rusting, you should clean it and treat the rust. You can use a rust remover or a rust converter, and then seal the tank with a product like KBS Gold Standard Fuel Tank Sealer.
Underground tanks are generally thicker than above-ground tanks and thus less likely to rust. However, they are more challenging to access for maintenance and repairs.
