Trends with Shop-Fabricated Storage Tanks

Report
Wayne Geyer
Steel Tank Institute
November 18, 2013
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
2012 Annual Product Awards:
Steel Fabricated Products
www.steeltank.com
Steel Fact Sheets
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
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
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
Education, Research, & Advocacy
STI Certification Programs
• 927 Certified SP001 Aboveground
Storage Tank Inspectors
• 484 Certified Cathodic Protection
Testers
• Over 130,000 sti-P3 tanks tested for
cathodic protection through
WatchDog program
• NEW: On Line Learning Program
• T*I*M Tank Integrity Management
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
35,000
1988
T
a 30,000
n
k
sti-P3 Tank
Installations
25,000
U
n 20,000
i
t 15,000
s
B
u
i
l
t
1998
10,000
1971
5,000
2008
0
1
2
3
4
5
6
7
8
9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41
Years in Number after 1970
Coatings Provide Corrosion
Protection
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
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
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
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
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.
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
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.
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.
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.
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 Events
Biofuels
• 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
Ultra Low Sulfur Diesel Issues
• 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
Inspection and Maintenance
of the Tank System
Inspection and
Maintenance
STI R111
Storage Tank Maintenance
STI SP001 AST Inspection
Aboveground Storage Tanks
•Cylindrical
•Rectangular
•Vertical
•Horizontal
•Double Wall
•Diked
•Fire-protected
•Gen-Base
•FieldErected
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
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.
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
AST’s with 2-Hr Fire Test Ratings
31
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
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
Facilities with a mix of tanks
require one type of inspector
Release Prevention
Barrier (RPB)
 Liquid containment
barrier
 Under the AST
 Diverts leaks toward
the perimeter of the
AST where they can
be easily detected
Risk Matrix Concept – SP001
More Risk
Tank Size
More Risk
Shop
built
tanks
Category 1
Category 2
Category 3
0 - 1100
P
P
P, E&L(10)
1101 5,000
P
P, E&L(10)
[P, E&L(5), I(10)]
or
[P, E(5) & L(2)]
5,001 30,000
P, E(20)
[P, E(10)& I(20)]
or
[P, E(5) & L(10)]
[P, E&L(5), I(10)]
or
[P, E(5) & L(1)]
30,001 50,000
P, E(20)
P, E&L(5), I(15)
P, E&L(5), I(10)
P, E(5), I(10)
P, E(5), I(10)
P, E(5), I(10)
P
P
P **
Field erected
Portable
containers
Category 1 – Secondary
Containment and CRDM
Double-wall Tank
with Overfill Prevention
Tank in a
Concrete Dike
Wayne Geyer
WGeyer @ steeltank.com
847-438-8265
www.steeltank.com

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