Alexei Volkov
Plastic resin tanks are used to store a variety of hazardous chemicals, including hydrochloric acid and sodium hydroxide. The resin layer protects the tank shell from corrosion or chemical attacks, but over time, the resin can degrade, leading to leaks and environmental damage. Therefore, regular inspections are necessary to ensure the integrity of the tank and the safety of people and the environment. This includes checking for defects, chemical permeations, degraded areas, thin coverage areas, and tank thickness. One method of inspection is to perform an internal inspection by sending a camera into the tank. Another method is ultrasonic thickness testing (UTT), which can assess the liner thickness and changed in liner Barcol hardness.
| Characteristics | Values |
|---|---|
| Plastic resin tank type | Fiberglass-reinforced plastic (FRP) tanks |
| Use | Storage of hazardous chemicals, fuels, and industrial liquids |
| Advantages | High corrosion resistance, lightweight, customizable, UV resistant, non-conductive |
| Inspection techniques | Ultrasonic testing, Barcol hardness testing, acoustic emission, strain gauge measurement, pressure testing, internal inspection |
| Cleaning techniques | Use plastic/silicone scraper, wipe with tissue/microfiber towels, clean with IPA, inspect for damage |
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What You'll Learn
Inspecting fiberglass-reinforced plastic (FRP) tanks
Inspection Frequency and Guidelines
As per state or tank owner guidelines, a comprehensive inspection of both the interior and exterior surfaces of FRP tanks is typically required every five years. However, it is recommended to conduct visual inspections at least twice a year to check for holes, corrosion, leaks, and other signs of wear and tear. Regular inspections help identify potential issues early on and ensure the safety of people and the environment.
Safety Precautions
Inspector safety is of utmost importance, especially during internal inspections. Prior to any inspection, proper safety measures must be followed to ensure the tank is clean, free from chemicals, and has acceptable air quality. Access to the tank's interior is usually through a ground-level or roof manhole.
Inspection Focus Areas
During inspections, special attention should be given to tank penetrations, including erosion, corrosion, mechanical damage, and environmental deterioration. Acoustic emission testing, using water or product filling, helps identify active flaws through acoustic emission sensors. Infrared (IR) cameras can also detect thermal gradients during filling, indicating potential delaminations or repairs. Other assessments may include scanning for chemical permeations, degraded areas, thin coverage, tank thickness, and overlapping of corrosion barrier resin.
Maintenance and Repair
Proper maintenance of FRP tanks is crucial to prevent costly repairs and safety issues. While FRP tanks offer high corrosion resistance and durability, they can still experience damage over time. Regular cleaning is essential to remove dirt and debris that can cause long-term damage. Additionally, specialised services are available for repairs, modifications, exterior coatings, and interior re-lining to address any identified issues and ensure the tank's integrity.
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Liner assessment methods
The most effective way to evaluate the corrosion protection liner of a fiberglass-reinforced plastic (FRP) tank is to perform an internal inspection. However, this requires the tank to be emptied, cleaned, and vented for inspector entry, which can be costly and time-consuming. FRP tanks are often used to store hazardous chemicals, and in high-purity processes, it is impossible to remove the tank from service for inspection. Therefore, an in-service FRP tank inspection solution is required.
Ultrasonic thickness testing (UTT) is a commonly used method for assessing the condition of tanks. UTT can be used to assess liner thickness accurately and detect changes in liner Barcol hardness. However, the transition from the inner layer to the structural layer in an FRP tank is generally not detectable with UTT. Acoustic emission, strain gauge measurement, and pressure testing can provide quantitative information on the tank's structural condition, but they cannot provide data on the FRP liner thickness or if it has deteriorated over time.
Barcol hardness testing is another non-destructive testing (NDT) process that provides direct information on the current condition of the liner. An increase in FRP liner Barcol hardness may indicate that the liner has become brittle and prone to cracking, while a decrease in hardness may indicate that the liner is more susceptible to chemical attack.
Other methods for assessing the condition of FRP tank liners include acoustic emission testing, strain gauge measurement, and pressure testing. These methods can provide quantitative information on the tank's structural condition but may not provide data on liner thickness or deterioration over time. Additionally, FRP laminates are known to exhibit high permeability to gases, particularly hydrogen, due to its small molecular diameter and high kinematic viscosity. This has limited linerless pressure vessels to low-pressure operation and cryogenic storage.
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Cleaning resin vats
It is important to note that you should not clean the film on the inside of resin vats using alcohol, soap, or water. Instead, simply empty the resin into a cup and use a soft spatula to get the rest out. You can also use a plastic or metal scraper to empty the resin, or a deck of playing cards to gently clean the bottom and sides of the vat. After pouring the majority of the liquid resin into a UV/light-proof storage bottle, hold the playing card at a 45-60 degree angle to remove the remaining liquid resin.
After emptying the vat, wrap it with plastic wrap and store it somewhere dark. If you need to clean the vat completely, for example, when changing the film or resins, you can use high-purity isopropanol. However, some users have warned against using alcohol, as it can cause the acrylic to crack and resin to spill.
If you get a bad grow, strain your resin. You can use pec pads to wipe the vat if necessary, but avoid paper towels, as they can scratch the film. After washing out the vat, you may see spotting or staining, so it is recommended to wipe off the film with just water and pec pads.
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FRP tank safety measures
FRP, or fiberglass reinforced plastic, is a popular choice for businesses requiring reliable and cost-effective tank storage solutions. FRP tanks are highly durable, with a comparable strength to concrete, and can last for up to 40 years. They are also highly customizable, allowing for different combinations of glass fibres, resin, and designs to meet specific requirements.
Safety Measures
To ensure the safety of FRP tanks, it is important to conduct regular inspections and maintenance. Here are some key safety measures to consider:
- Regular Inspections: FRP tanks should be regularly inspected to identify any potential issues and maintain their integrity. A visual inspection should be conducted at least twice a year to check for holes, cracks, corrosion, and other signs of wear and tear. It is also important to look for any signs of leakage and ensure that all necessary seals are in place and up-to-date.
- Internal Inspections: For a more comprehensive evaluation, internal inspections may be required. This involves emptying, cleaning, and venting the tank for inspector entry. Special attention should be given to tank penetrations, examining erosion, corrosion, mechanical damage, and any deterioration caused by environmental factors.
- Additional Scanning and Tests: To ensure the integrity of the tank, additional scanning and tests may be necessary. These include assessments of chemical permeations, degraded areas, thin coverage areas, tank thickness, and overlapping of the corrosion barrier resin.
- Liner Assessment: The condition of the liner is critical to the performance of the tank. Ultrasonic testing technology can be used to assess the liner thickness and hardness accurately. An increase in liner hardness may indicate that it has become brittle and prone to cracking, while a decrease in hardness may indicate susceptibility to chemical attack.
- Cleaning and Maintenance: Physical cleaning of the tank is important to remove dirt and debris that can cause damage over time. Regular maintenance by a professional technician can also help to identify and address potential issues before they escalate into significant hazards.
- Safety During Inspection: Ensuring the safety of inspectors is of utmost importance, especially during internal inspections. Proper safety measures must be taken prior to inspection, including cleaning the tank and ensuring acceptable air quality.
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FRP tank customisation options
FRP, or Fiberglass-Reinforced Plastic, is a composite material made of glass fibres and epoxy resin. It is a popular choice for tanks due to its strength, durability, lightweight nature, and corrosion resistance.
The customisation options for FRP tanks are varied and depend on the specific requirements of the application. Here are some of the ways in which FRP tanks can be customised:
- Accessories: Accessories can be added to improve performance and suit changing requirements. For example, vents can be added or removed to regulate airflow, and manways can be enlarged for improved access and tank cleanout. Digital gauges can replace manual ones, and features like access panels, sights, level gauges, temperature, and pressure instrumentation can be included for dynamic storage conditions.
- Safety Features: For enclosed areas or when storing hazardous or slippery substances, safety accessories are crucial. FRP bolt-down tabs can be added to secure the tank and prevent movement due to wind or vibration. Ladders, walkways, and handrails provide safe access for monitoring and maintenance. An elevated platform can improve access and provide a non-skid surface.
- Refurbishment: The nature of FRP fabrication allows for customisation and refurbishment. Access ports can be added or removed, and nozzles can be switched out, allowing existing tanks to be refurbished for new uses instead of being replaced.
- Colour: Colour can be added to polyethylene tanks for aesthetics, branding, chemical identification, or to reduce the transmission of radiant heat through the plastic. Coloured resins can be used, or the exterior can be painted. Black resin, for example, is an effective UV inhibitor, while lighter colours may be preferable in warmer environments to deflect heat.
- Size and Shape: FRP tanks can be manufactured on-site to meet specific size and shape requirements, making them ideal for applications where large volumes of water need to be stored above ground level.
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