Regan Brown
Fuel tank lining is a solution for ageing tanks to extend their lifespan. Tank lining systems are used to prevent leaks and increase resilience, providing an additional layer of protection within the tank. The materials used for fuel tank lining vary, including resin and fibreglass combinations, epoxy coatings, and polyurea lining systems. Proper preparation and application are crucial to ensure the lining adheres correctly and functions effectively. Fuel tank lining services offer a cost-effective alternative to full tank replacement, providing peace of mind for several years.
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What You'll Learn
Fuel tank lining options
For aboveground tanks, AmTech's DuraChem® 500 series Polylining System is a popular choice. It is designed to store petroleum products such as diesel, kerosene, and fuel oil. This system is a high-temperature, high-pressure spray-up application that bonds to steel or concrete and can withstand the forces of expansion and contraction caused by temperature changes.
Another option for aboveground tanks is the use of epoxy coatings, which are typically applied at a thin mil thickness. However, these coatings may not have the flexibility to remain adhered to the tank, leading to potential issues.
For underground fuel storage tanks, there are several lining options available:
- Fastliner: This is a bladder liner system that can be installed with or without human entry into the tank. It is a quick solution, often installed in a single day, and can transform a single-skin tank into a double-skin tank.
- Lifeliner: This is a retrofit double-skin lining system that uses the same specifications as a composite tank. It is strong enough to be monitored with a Class 1 pressure system and comes with a 30-year warranty.
- Refibra: This system uses layers of resin and fibreglass to create a double wall and an interstitial chamber with an in-built leak detection system. It provides three layers of protection for the fuel and is accredited and guaranteed for up to 10-20 years.
Additionally, there are fuel tank sealers and coatings available, such as POR-15 Fuel Tank Sealer, which can act as a liner and help prevent rust, corrosion, and small fuel leaks. These sealers are typically applied to metal tanks after thorough cleaning and preparation.
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Lining installation methods
Fuel tank linings are made of various materials, including rubber, epoxy, polyurethane, and polyurea. Linings are installed to protect the tank from corrosion and leaks, extend its lifespan, and improve its structural strength.
Now, let's discuss the lining installation methods in detail:
- Preparation: Before installing a new lining, the existing fuel must be removed, and the tank must undergo a degassing process. It is crucial to ensure that the tank is free from contaminants, structurally sound, and free from plastic parts. If there are any signs of degradation, such as rust or old sealers, these should be addressed. A thorough cleaning process is essential to ensure the best conditions for the new lining to adhere properly. This involves using a cleaner degreaser and metal prep products to remove any residue, varnish, or rust.
- Application of the Lining: The specific application method will depend on the lining material being used. For example, rubber linings are commonly used to protect tanks from corrosive chemicals and their vapors. Epoxy linings, on the other hand, are often self-priming and applied to steel surfaces, offering excellent chemical resistance. Polyurea linings are sprayed onto the tank at high temperatures and pressures, bonding to steel or concrete with strong adhesion. The DuraChem 500 Series, a polyurea lining system, is a popular choice for aboveground and underground fuel tank linings.
- Curing and Drying: After the lining is applied, it needs time to cure and dry. The curing cycle can vary depending on the product; for instance, the DuraChem 500 Series has a quick curing cycle of just minutes.
- Inspection and Quality Control: Once the lining is installed, it is essential to perform inspections to ensure the lining's integrity and proper installation. This includes visual inspections, non-destructive testing methods, and physical measurements.
- Maintenance and Repair: Regular inspections of the tank lining are crucial to identify any signs of wear, corrosion, or damage. Detecting issues early can extend the lifespan of the liner and prevent more costly repairs or replacements. Proper maintenance may involve using fuel preservation and stabilizer solutions to maintain the fuel system's optimal performance and avoid problems like "stale gas."
- Warranty and Guarantee: Steel tank linings are typically guaranteed after installation, with warranties covering issues like adhesion failure, cracking, or peeling under normal operating conditions. The specifics of the warranty will depend on the manufacturer, lining material, and the tank's intended use.
The installation process may vary slightly depending on the lining manufacturer and the specific requirements of the tank. It is important to follow the manufacturer's instructions and guidelines for the best results.
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Benefits of fuel tank lining
Fuel tank lining is a solution for ageing tanks that extends their lifespan. It is a cost-effective and less disruptive alternative to a full tank replacement. The process involves applying layers of resin and fibreglass to create a double wall with an interstitial chamber, which also houses an in-built leak detection system.
Extends Tank Lifespan
Fuel tank lining can extend the lifespan of storage tanks. The process involves turning single-skin tanks into double-wall tanks with in-built leak detection. This increases the tank's resilience, reducing the risk of leaks and providing additional layers of protection.
Cost-Effective
Tank lining is a cost-effective alternative to tank replacement, especially for below-ground tanks that require excavation. The price of tank lining depends on the tank's size, condition, location, and accessibility.
Less Disruptive
Tank lining can be applied in situ, without the need for permits or building works. This means there is no lengthy permit application process or expensive building works, and disruption is minimised.
Prevents Leaks and Contamination
A two-wall system increases the tank's resilience and reduces the risk of leaks. The interstitial chamber contains an in-built and permanent leak detection system that alerts you to breaches and fuel loss. This helps to prevent contamination and potential environmental hazards.
Stops Rust and Corrosion
Fuel tank coatings can act as a liner and stop rust and corrosion. Before applying the coating, the tank must be free from loose rust, old sealers, and contamination. The coating process involves cleaning and etching the tank for better adhesion of the sealer.
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Preparation for fuel tank lining
If the tank is rusty, there are different methods to address this, depending on the severity of the rust. For loose, flaky rust, adding stones, nuts, or bolts to the tank and agitating it can help remove the rust. For more severe rust, a rust remover that also etches metal should be used, such as an acid-based product. This step may need to be repeated until all rust is removed. After using an acid-based product, it is crucial to rinse the tank with water to remove any residual acid and then use a solvent like acetone to ensure the tank is thoroughly cleaned.
Once the tank is clean and dry, the next step is to apply the liner. The specific application process may vary depending on the product used, so it is important to follow the manufacturer's instructions. However, the general process involves pouring the liner into the tank and coating the entire inner surface by slowly rotating the tank. It is important to ensure that all surfaces are adequately coated and that there is a generous excess of the liner. The tank should then be drained of any excess liner and left to air dry for an extended period, typically at least 12 hours.
For extra protection, some products recommend repeating the coating process after the first coat has dried for a certain period, usually around 6 hours. It is crucial to follow the specific instructions for the product you are using to ensure proper preparation and application of the fuel tank liner.
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Fuel tank lining maintenance
Preparation
Before applying a new lining or repairing an existing one, it is essential to prepare the fuel tank thoroughly. The tank must be free from any contaminants, plastic parts, old sealers, or loose rust. A thorough cleaning process should be undertaken, and specific products like degreasers and metal prep solutions can be used to ensure the tank is ready for the new lining. This preparation stage is crucial, as improper preparation can lead to the failure of the lining material to adhere correctly.
Application
When applying a new fuel tank lining, it is important to follow the manufacturer's instructions carefully. For example, the POR-15 Fuel Tank Sealer is a popular product that requires users to mix the sealer with hot water, pour it into the cleaned tank, and then drain and rinse the tank after coating. Another example is the DuraChem 500 Series, a polyurea lining system with a high-temperature, high-pressure spray-up application, which bonds to steel or concrete with strong adhesion.
Curing and Drying
After applying the new lining, it is crucial to allow adequate cure time between coats to prevent issues like solvent entrapment. Proper ventilation and following post-cure procedures are also essential to ensure the lining dries correctly. The curing cycle can vary depending on the product used; for example, the DuraChem 500 Series has a quick curing cycle of just minutes.
Leak Detection
It is essential to consider a lining system with an in-built leak detection mechanism. Systems like the Speedy Fuels tank lining and Lifeliner include leak detection features that alert you to breaches and fuel loss. This added layer of protection ensures that any potential issues are promptly identified, minimising the risk of contamination and environmental hazards.
Regular Inspections
Even with proper maintenance and lining applications, regular inspections of fuel tanks are necessary. Over time, factors like temperature fluctuations and chemical corrosion can affect the integrity of the tank and its lining. Regular inspections can identify any signs of degradation or potential failures, allowing for proactive maintenance and repairs.
Re-lining and Repairs
If a fuel tank lining fails or becomes damaged, it is crucial to address the issue promptly. Re-lining the tank with newer, more advanced materials can restore its integrity and protect against corrosion and leaks. Repairs should be undertaken by experienced professionals who can identify weak spots, fix failures, and ensure the tank's safe return to operation.
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Frequently asked questions
The materials used for fuel tank lining vary. Some common materials used include resin and fibreglass, epoxy, and polyurea. Factors such as the type of fuel, tank construction, and environmental conditions influence the choice of lining material.
Resin and fibreglass linings create a monolithic structure, providing excellent protection against leaks and contamination. The absence of forces or stresses between the layers enhances the integrity of the tank.
The choice of lining material significantly affects fuel tank maintenance. Traditional thin epoxy linings may not adequately adhere to the tank, leading to blistering and flaking, and oxidation. More advanced materials, such as the DuraChem 500 Series, offer better flexibility and adhesion, reducing the risk of lining failure and extending the lifespan of the tank.
