Trends with Shop-Fabricated Storage Tanks

Trends with Shop-Fabricated Storage TanksWayne GeyerSteel Tank InstituteNovember 18, 2013Who 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 productsSTI 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

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What does the Steel Tank Institute do?UST and AST tank technologiesIndustry standards and recommended practicesLicense manufacturers to build tanks to STI specificationsQuality controlInformation resourceCertification4 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 specificationTank is registered with STISTI maintains database with over 400,000 entriesTank Performance Evaluation

All STI labeled USTs subject to 3rd party warrantySTICO Mutual has strong claims management programSTI gets feedback on quality and performance

Education, Research, & Advocacy

STI Certification Programs927 Certified SP001 Aboveground Storage Tank Inspectors484 Certified Cathodic Protection TestersOver 130,000 sti-P3 tanks tested for cathodic protection through WatchDog programNEW: On Line Learning ProgramT*I*M Tank Integrity ManagementSTI Shop-Fabricated Tank Programs> 100 tank shops licensed and inspected14 tank fabrication standards19 recommended practices for testing, installation and inspectionNEW: R111 Storage Tank Maintenance Under Development: SP131- UST Inspection, Repair, & Modification

Years in Number after 197011Coatings Provide Corrosion Protection

Underground Storage TanksPrimarily used at service stations todayTanks are getting largerSTI DatabaseAverage capacity in 2013 for jacketed tank exceeds 15,000 gallons25 years ago, the typical UST at a service station was 8000 10,000 gallons

Compartment TanksCompartment tanks have become very common for both USTs and ASTsMultiple fuel types can be stored within one tank unitProvides user/owner versatility as more fuels develop

Underground Storage TanksUL 58 is the principle standard for steel tank construction single wall and double wall steelUL 1746 is the principle standard for corrosion control and for jacketed (non-metallic outer wall) tank construction

Underground Storage TanksRegulations require all tanks incorporate secondary containmentToday, jacketed tanks are favored by many buyers as outer containment provides a corrosion barrier and secondary containmentOther corrosion systems use two walls of steel

Fabricating Steel Secondary ContainmentAfter 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.

17Testing the IntersticeMost 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

18Production Test to Verify Both Walls are TightUpon 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.

19Preparing the Tank for DeliveryAfter ancillary equipment installed, coatings applied, etc. the tank is made ready for shipment.Fabricators apply a vacuum into the interstice of secondary containment tanks.

20Interstitial VacuumAfter the vacuum is applied, the tank is held in storage until it is made ready for deliveryThe 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.

21Tank Compatibility - Biofuels

E10, E15, E85, B2, B20, B100Steel Tank Manufacturer Certification StatementsSTI Web SitePerformanceTanks are Cleaner SludgeBiodiesel Shelf LifeWater ConcernsPhase Separation - Ethanol

Recent EventsBiofuels23Sumps EPA ORD ResearchNIST ResearchPublicationsCompatibility of UST Systems with Biofuels,Published by ASTSWMOCase StudiesResearch and Work GroupsUnderground tanks storing E85

Ultra Low Sulfur Diesel Issues24Corrosion of metal components within FRP tanks storing ULSDClean Diesel Fuel Alliance supported research from Battelle Labs - completed in 2012Further studies under considerationSTI ResearchTanknology hired to visually examine the insides of steel and FRP ULSD tanksFuel samples extracted and testedExample Las Vegas service station tanks under same ownerFRP tank vapor control fitting top right photoSteel tank vapor control fitting bottom right photo

Inspection and Maintenanceof the Tank System

Inspection and Maintenance

STI R111Storage Tank MaintenanceSTI SP001 AST Inspection

Aboveground Storage Tanks

CylindricalRectangularVerticalHorizontalDouble WallDikedFire-protectedGen-BaseFieldErected

27Aboveground Storage TanksMost popular choice for shop-fabricated tanks for:Fleet motor vehicle fueling applicationsFuel for emergency power generatorsBulk oil and chemical storageSecondary containment

Aboveground Storage TanksUL 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 TanksSecondary contained shop-fabricated steel tanks are preferred:Serves as spill control to meet fire codesMeets SPCC rules with proper use of overfill prevention equipmentDouble wall construction preferred over diking

31ASTs with 2-Hr Fire Test Ratings

Protected ASTsProtected aboveground tanks preferred when:Installed in close proximity to buildings & property linesDispenser mounted on tankMinimize fire safety hazards Meet codes for motor vehicle fuel dispensing

SPCC AST InspectionsEPA references STI SP001 standard for smaller tank inspection and integrity verificationCategory 1 preferredDouble wall tanks can be easily tested with vacuum to prove containment integrity

Category 3 Higher Risk to EnvironmentFacilities with a mix of tanksrequire one type of inspector

34Release Prevention Barrier (RPB)Liquid containment barrierUnder the AST

Diverts leaks toward the perimeter of the AST where they can be easily detected

Risk Matrix Concept SP001Tank SizeCategory 1Category 2Category 3Shop built tanks0 - 1100PPP, E&L(10)1101 - 5,000PP, E&L(10)[P, E&L(5), I(10)]or[P, E(5) & L(2)]5,001 - 30,000P, 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 - 50,000P, E(20)P, E&L(5), I(15)P, E&L(5), I(10)Field erected P, E(5), I(10)P, E(5), I(10)P, E(5), I(10)Portable containers PPP **More RiskMore Risk36Category 1 Secondary Containment and CRDM

Double-wall Tank Tank in a with Overfill Prevention Concrete Dike www.steeltank.com

Wayne GeyerWGeyer @ steeltank.com847-438-8265