Renovation of the hexane tank roof: the GMA solution for a safe and reliable structure

The industrial sector is constantly evolving, and structural safety must be a top priority. In this context, GMA stands out for its ability to tackle complex problems with concrete and innovative solutions. Today, we will discuss a recent remediation project carried out on the fixed roof of the Esano storage tank at the petrochemical plant. We will explore the technical details of this project, highlighting the importance of prevention and maintenance in ensuring safety and operational efficiency.

THE CURRENT SITUATION

The fixed roof of the Esano storage tank showed signs of significant deterioration, with corrosion and water infiltration issues. These problems not only compromise the structural integrity of the tank, but can also lead to high costs resulting from plant downtime and potential contamination of the stored product. Our intervention focused on the application of an innovative reinforcement system, combining PRS (Structural Reinforcement Plan) technology with carbon fibre composite materials.

The Need for Corrective Action

During a preliminary analysis, areas of pitting and deep corrosion were found, some of which had reached the point of perforation. These defects can cause water infiltration, with the risk of contaminating the stored product, making corrective action urgent. In previous years, GMA had already carried out some sealing work on existing leaks. However, to ensure long-term durability and safety, it was necessary to implement a more robust corrosion protection system.

Intervention methodology

The restoration was carried out by applying epoxy metal and then completely reinforcing the structure using the PRS carbon fibre method. This method not only addresses corrosion issues, but also provides superior structural strength.

Project phases

Analysis and preparation: Before starting the work, a detailed analysis of the roof’s condition was carried out, with non-destructive testing to identify critical areas.
Application of epoxy metal: The damaged areas were treated with epoxy metal, creating a solid base for subsequent reinforcement.
Structural reinforcement: Carbon fibre laminate was applied to the entire roof surface, providing structural support that follows the natural deformations of the structure during operation.
Monitoring and inspections: Upon completion of the work, a two-year monitoring plan was recommended, including visual inspections and measurements of the hardness of the composite material.

Technical characteristics of the project

Material: FE 42C UNI5335 carbon steel sheets.
Tank diameter: 6,716 mm.
Tank height: 10,571 mm.
Tank capacity: 3,000 cubic metres.
Operating conditions: ambient temperature with atmospheric pressure.

The importance of preventive maintenance

Preventive maintenance is crucial to ensuring the safety and efficiency of industrial plants. A proactive approach, such as that adopted by GMA, reduces the risk of plant downtime and minimises operating costs.

Advantages of the GMA solution

Durability: the use of carbon fibre composite materials ensures a long service life.
Safety: by reducing the risk of infiltration, the stored product is protected, preventing contamination.
Cost-effectiveness: prevention is always more economical than repairing serious damage.

GMA tackles challenges with cutting-edge technical solutions

The restoration of the Esano tank roof is an example of how GMA tackles challenges with cutting-edge technical solutions. Our ability to solve complex problems quickly and effectively sets us apart in the industry. Through the use of innovative technologies and high-quality materials, we ensure that our customers can operate safely, minimising costs and maximising efficiency.
If you want to ensure the safety and reliability of your industrial facilities, contact GMA today!
For more information about our solutions and services, visit the CORROSION section and find out how we can help you protect and optimise your facilities.
Don’t wait for the problem to become an emergency; prevention is the key to ensuring production continuity.

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