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Trends with Shop-Fabricated Storage Tanks

Trends with Shop-Fabricated Storage Tanks

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Trends with Shop-Fabricated Storage Tanks

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  1. Trends with Shop-Fabricated Storage Tanks Wayne Geyer Steel Tank Institute November 18, 2013

  2. Who and What is STI/SPFA? • Association of 180 fabricating and affiliate companies of steel construction products – shop-fab tanks, field erect tanks, pipe, pressure vessels and other special fabricated products • STI members account for nearly all of the total shop fabricated underground steel storage tank production capacity in North America

  3. 2012 Annual Product Awards:Steel Fabricated Products

  4. Steel Fact Sheets

  5. What does the Steel Tank Institute do? • UST and AST tank technologies • Industry standards and recommended practices • License manufacturers to build tanks to STI specifications • Quality control • Information resource • Certification 4 – 50,000 Gallon Permatanks Installed at Northwestern Univeristy

  6. STI Tank Registration • Every tank built with an STI labeled is inspected by tank fabricator to meet STI specification • Tank is “registered” with STI • STI maintains database with over 400,000 entries

  7. Tank Performance Evaluation • All STI labeled UST’s subject to 3rd party warranty • STICO Mutual has strong claims management program • STI gets feedback on quality and performance

  8. Education, Research, & Advocacy

  9. STI Certification Programs • 927 Certified SP001 Aboveground Storage Tank Inspectors • 484 Certified Cathodic Protection Testers • Over 130,000 sti-P3 tanks tested for cathodicprotection through WatchDog program • NEW: On Line Learning Program • T*I*M Tank Integrity Management

  10. STI Shop-Fabricated Tank Programs • > 100 tank shops licensed and inspected • 14 tank fabrication standards • 19 recommended practices for testing, installation and inspection • NEW: R111 Storage Tank Maintenance • Under Development: SP131- UST Inspection, Repair, & Modification

  11. Years in Number after 1970

  12. CoatingsProvide Corrosion Protection

  13. Underground Storage Tanks • Primarily used at service stations today • Tanks are getting larger • STI Database • Average capacity in 2013 for jacketed tank exceeds 15,000 gallons • 25 years ago, the typical UST at a service station was 8000 – 10,000 gallons

  14. Compartment Tanks • Compartment tanks have become very common for both UST’s and AST’s • Multiple fuel types can be stored within one tank unit • Provides user/owner versatility as more fuels develop

  15. Underground Storage Tanks • UL 58 is the principle standard for steel tank construction – single wall and double wall steel • UL 1746 is the principle standard for corrosion control and for jacketed (non-metallic outer wall) tank construction

  16. Underground Storage Tanks • Regulations require all tanks incorporate secondary containment • Today, jacketed tanks are favored by many buyers as outer containment provides a corrosion barrier and secondary containment • Other corrosion systems use two walls of steel

  17. Fabricating Steel Secondary Containment • After the primary tank is built and tested, the outer wall is fabricated atop the primary tank. • The second wall is intimately wrapped atop the primary tank wall.

  18. Testing the Interstice • Most fabricators will test the interstice by bleeding air from a 3-5 psi pressurized inner tank into the secondary tank. The volume of the interstice is very small and can get pressurized rapidly. • Access to the interstice can be fabricated in different ways

  19. Production Test to Verify Both Walls are Tight • Upon completion of production testing of the interstice with positive air pressure, and soap testing the welds of the secondary containment, all air is released. • Then a vacuum is pulled within the interstice and monitored by the fabricator for tightness over time.

  20. Preparing the Tank for Delivery • After ancillary equipment installed, coatings applied, etc. the tank is made ready for shipment. • Fabricators apply a vacuum into the interstice of secondary containment tanks.

  21. Interstitial Vacuum • After the vacuum is applied, the tank is held in storage until it is made ready for delivery • The vacuum remains on the tank during storage, delivery, and during much of the installation. • An easy view of the vacuum gauge to verify retention of the vacuum assures that both walls remain tight.

  22. Tank Compatibility - Biofuels • E10, E15, E85, B2, B20, B100 • Steel Tank Manufacturer Certification Statements • STI Web Site • Performance • Tanks are Cleaner – Sludge • Biodiesel Shelf Life • Water Concerns • Phase Separation - Ethanol

  23. Recent EventsBiofuels • Sumps • EPA ORD Research • NIST Research • Publications • “Compatibility of UST Systems with Biofuels,” • Published by ASTSWMO • Case Studies • Research and Work Groups • Underground tanks storing E85

  24. Corrosion of metal components within FRP tanks storing ULSD • Clean Diesel Fuel Alliance supported research from Battelle Labs - completed in 2012 • Further studies under consideration • STI Research • Tanknology hired to visually examine the insides of steel and FRP ULSD tanks • Fuel samples extracted and tested • Example – Las Vegas service station tanks under same owner • FRP tank vapor control fitting – top right photo • Steel tank vapor control fitting – bottom right photo Ultra Low Sulfur Diesel Issues

  25. Inspection and Maintenanceof the Tank System

  26. Inspection and Maintenance STI R111 Storage Tank Maintenance STI SP001 AST Inspection

  27. Cylindrical Rectangular Vertical Horizontal Double Wall Diked Fire-protected Gen-Base FieldErected Aboveground Storage Tanks

  28. Aboveground Storage Tanks • Most popular choice for shop-fabricated tanks for: • Fleet motor vehicle fueling applications • Fuel for emergency power generators • Bulk oil and chemical storage • Secondary containment

  29. Aboveground Storage Tanks • UL 142 is the principle standard for steel tank construction – single wall and double wall steel. • UL 2085 is the principle standard for two hour fire protected tank construction.

  30. Aboveground Storage Tanks • Secondary contained shop-fabricated steel tanks are preferred: • Serves as spill control to meet fire codes • Meets SPCC rules with proper use of overfill prevention equipment • Double wall construction preferred over diking

  31. AST’s with 2-Hr Fire Test Ratings

  32. Protected AST’s • Protected aboveground tanks preferred when: • Installed in close proximity to buildings & property lines • Dispenser mounted on tank • Minimize fire safety hazards • Meet codes for motor vehicle fuel dispensing

  33. SPCC – AST Inspections • EPA references STI SP001 standard for smaller tank inspection and integrity verification • Category 1 preferred • Double wall tanks can be easily tested with vacuum to prove containment integrity Category 3 – Higher Risk to Environment

  34. Facilities with a mix of tanksrequire one type of inspector

  35. Release Prevention Barrier (RPB) • Liquid containment barrier • Under the AST • Diverts leaks toward the perimeter of the AST where they can be easily detected

  36. Risk Matrix Concept – SP001 More Risk More Risk

  37. Category 1 – Secondary Containment and CRDM Double-wall Tank Tank in a with Overfill Prevention Concrete Dike

  38. Wayne Geyer WGeyer @ 847-438-8265