EEMUA PUB NO 225-2017 Above ground plastic tanks A guide to their specification installation commissioning inspection maintenance repair and disposal (Edition 1).pdf

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1、THE ENGINEERING EQUIPMENT AND MATERIALS USERS ASSOCIATION This publication has been made available for release by IHS NOT FOR RESALE Any organisation that is a substantial user or substantial purchaser of engineering products may apply to become a member of EEMUA. EEMUA Copyright 2017 The Engineerin

2、g Equipment and Materials Users Association Above ground plastic tanks: A guide to their specication, installation, commissioning, inspection, maintenance, repair and disposal Publication 225 Edition 1 Copyright 2017 The Engineering Equipment and Materials Users Association A company limited by guar

3、antee. Registered in England. Company number 477838. ISBN 978-0-85931-199-1 Imprint reference 10-2017 Registered and Trading Address: EEMUA, Second Floor, 16 Black Friars Lane, London EC4V 6EB Telephone: +44 (0)20 7488 0801 Email: saleseemua.org Website: www.eemua.orgIV Above ground plastic tanks Pu

4、blication 225 EEMUA Copyright 2017 The Engineering Equipment and Materials Users Association About EEMUA The Engineering Equipment and Materials Users Association is usually known by its initials, EEMUA. EEMUA is governed by a Council of members. This Council is responsible for the policies, financi

5、ng, membership, and strategy of the Association. Any organisation that is a substantial user or purchaser of engineering products may apply to become a member of EEMUA. Membership is subject to the approval of Council. EEMUA Aims EEMUA aims to improve the safety, environmental and operating performa

6、nce of industrial facilities in the most cost-effective way, pursuing and promoting leadership in industrial asset management by sharing engineering experiences and expertise, and by the active, enlightened promotion of the distinct interests of users of engineering products. These aims are achieved

7、 by various means, including: Providing the organisation within which networking, information sharing and collaboration among users on non-competitive technical matters can take place. Influencing the way written regulations are interpreted and applied in practice. Promoting and presenting members v

8、iews, and encouraging the application of good sound engineering practices. Developing user guides, specifications, training and competency schemes. Facilitating members participation in national and international standards making. Influencing relevant national and European legislation and regulation

9、. The income and resources of EEMUA are applied solely towards the promotion of the aims of the Association. No profit is transferred by way of dividend, bonus or otherwise to members. The work of the Association is mainly carried out by members representatives on EEMUA Technical Committees, Working

10、 Groups, and Forums, supported by EEMUA staff. Incorporation, Membership and Other Information For the purposes of conducting its business, EEMUA is incorporated in England and Wales as a company, limited by guarantee, not having share capital. All usual aspects of company management and business ad

11、ministration are dealt with by the EEMUA Executive Director, including policy implementation and leadership of the Executive team (the staff). A list of EEMUA publications for sale is given at the end of this Publication. The full list is also on the Associations website, including details of on-lin

12、e shopping facilities. To enquire about corporate Membership, write to enquirieseemua.org or call +44 (0)20 7488 0801. Engineering Equipment and Materials Users AssociationV Above ground plastic tanks Publication 225 EEMUA Copyright 2017 The Engineering Equipment and Materials Users Association Lega

13、l Aspects All rights, title and interest in this Publication belong to EEMUA. All rights are reserved. No part of this Publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means: electronic, mechanical, photocopying, recording or other, without the expres

14、s prior written agreement of the EEMUA Executive Director. Infringement of copyright is illegal and also reduces the Associations income thereby jeopardising its ability to fund the production of future publications. It has been assumed in the preparation of this Publication that: the user ensures s

15、election of those parts of its contents appropriate to the intended application; and that such selection and application is correctly carried out by appropriately qualified and competent persons for whose guidance this Publication has been prepared. EEMUA and the individual members of the Work Group

16、 that prepared this EEMUA publication do not, and indeed cannot, make any representation or give any warranty or guarantee in connection with material contained herein. EEMUA and the individual members of the Work Group that prepared this EEMUA Publication expressly disclaim any liability or respons

17、ibility for damage or loss resulting from the use or reliance on this Publication. Any recommendations contained herein are based on the most authoritative information available at the time of writing and on current good engineering practice, but it is essential for the user to take account of perti

18、nent subsequent developments and/or legislation. Any person who encounters an inaccuracy or ambiguity when making use of this Publication is asked to notify EEMUA without delay so that the matter may be investigated and appropriate action taken. Consultation and Feedback EEMUA encourages constructiv

19、e comments on this Publication from both Members of the Association and others. Comments should be sent on the standard feedback form, a copy of which is provided towards the end of this Publication. An electronic version of the feedback form is available from EEMUA: e-mail your request for a copy t

20、o: enquirieseemua.org or telephone your request to: +44 (0)20 7488 0801 or download the form from the EEMUA website at: www.eemua.org. Submit comments by e-mail (preferred) or post. Comments are considered by the relevant EEMUA Technical Committees and may be incorporated in future editions of this

21、Publication. New editions are publicised on the EEMUA website. Cover photographs reproduced with kind permission of Chem Resist Group Ltd., Forbes Group and Plasticon UK About this PublicationVI Above ground plastic tanks Publication 225 EEMUA Copyright 2017 The Engineering Equipment and Materials U

22、sers Association Plastic tanks used in industrial heavy engineering applications have been typically regarded as “fit and forget” items, with lifetime based purely on manufacturers recommendations for nominal operating conditions. This often does not take into account the specific conditions of tank

23、 usage, leading both to tank failure in service, and the unnecessary scrapping of serviceable tanks. EEMUA Publication 159 “Users Guide to the Inspection, Maintenance, and Repair of Above Ground Vertical Cylindrical Steel Storage Tanks” has become the de facto standard for stakeholders in such equip

24、ment, worldwide, but there was no comparable guidance for users of plastic tanks. EEMUA formed a work group to produce EEMUA Publication 225, addressing the management of plastic tanks, from cradle to grave, including specification, inspection and maintenance, giving practical, pragmatic guidance fo

25、r owners and operators of plastic tanks which will help reduce the risk of failure in service and enable the extension of service life where appropriate. This will also improve the image of plastic tanks, too often thought of as the “low cost, low quality” option, when the true issue has been the qu

26、ality of the in-service care, rather than the quality of the equipment. The work group comprised experts from the user community, manufacturers, and wider industry, brought together and supported by EEMUA. PrefaceVII Above ground plastic tanks Publication 225 EEMUA Copyright 2017 The Engineering Equ

27、ipment and Materials Users Association Contents 1 Scope .1 1.1 What is included? 1 1.2 Standards for thermopastic tanks 1 1.3 Standards for Glass Reinforced Plastic (GRP) tanks .3 1.4 What is not included?5 2 Materials .7 2.1 Group 1, Thermoplastics7 2.2 Group 2, Glass Reinforced Plastic (GRP) 7 3 D

28、esign issues 9 3.1 Information to be provided to the manufacturer .9 3.2 Tank procurement: selecting a manufacturer 10 3.3 Requirements for discussion/information to be exchanged between the end userand manufacturer . 10 3.4 Information to be provided to the end user by the manufacturer 17 3.4.1 Inf

29、ormation to be provided for thermoplastic tanks . 18 3.4.2 Information to be provided for GRP tanks . 20 3.5 Tanks with secondary containment .23 3.5.1 Bunded tanks .23 3.5.2 Close bunded tanks 23 3.5.3 Tanks with low-level nozzles .24 3.5.4 Tanks with “over the top” discharge systems 24 3.5.5 Integ

30、rally bunded tank .24 3.5.6 Thermal insulation. 25 3.6 Vents 25 4 Nameplates, data book, and management of change .27 4.1 Tank nameplates . 27 4.2 Tank data book . 27 4.3 Management of change . 28 5 Installation, commissioning, and operation within the design window 29 5.1 Pre-delivery/Factory accep

31、tance testing (FAT) 29 5.2 Transport and delivery . 30VIII Above ground plastic tanks Publication 225 EEMUA Copyright 2017 The Engineering Equipment and Materials Users Association 5.3 Offloading and installation 31 5.3.1 Vertical tanks. 31 5.3.2 Horizontal tanks 34 5.4 Commissioning 36 5.5 Operatio

32、n 37 5.6 Modification . 37 5.7 Reuse, re-siting . 38 6 Degradation mechanisms and failure modes .39 6.1 Degradation and failure modes of thermoplastics and thermoplastic-lined GRP 39 6.1.1 General .39 6.1.2 Chemical degradation 39 6.1.3 Thermal degradation .41 6.1.4 Weathering 41 6.1.5 Mechanical de

33、gradation 42 6.1.6 Failure modes 43 6.2 Degradation and failure modes of glass fibre reinforced plastic (GRP) tanks 44 6.2.1 General . 44 6.2.2 Chemical degradation 45 6.2.3 Thermal degradation .48 6.2.4 Weathering 48 6.2.5 Mechanical degradation 49 6.2.6 Failure modes 49 7 Inspection methods and ND

34、T techniques .53 7.1 The purpose of inspections 53 7.2 Safety and preliminary considerations for inspections . 53 7.3 Type and frequency of inspection 53 7.4 What to inspect . 54 7.4.1 Tank bases and supports .54 7.4.2 Tank shell/body. 54 7.4.3 Tank bottom .55 7.4.4 Tank roofs .55 7.4.5 Paintwork 55

35、 7.4.6 In-tank measurement and sampling devices 55 7.4.7 Connections and nozzles 55 7.4.8 Stairway, ladder, handrail system, walkways or platforms 56 7.4.9 Associated equipment/items .56 7.5 Inspection techniques . 56 7.5.1 Visual inspection 56 7.5.2 Remote visual inspection 57IX Above ground plasti

36、c tanks Publication 225 EEMUA Copyright 2017 The Engineering Equipment and Materials Users Association 7.5.3 Techniques for shell thickness measurement . 58 7.5.4 Techniques to assess structural flaws . 58 7.6 Reportong on inspections . 60 8 Deciding end-of-life, repairs, modication and recommission

37、ing .61 8.1 General considerations 61 8.2 Deciding end-of-life 61 8.3 Assessing whether to repair a tank 62 8.4 Modifying and repairing thermoplastic tanks 63 8.4.1 Types of damage 63 8.4.2 Planning for thermoplastic repairs 63 8.5 Modifying and repairing GRP and dual laminate tanks 64 8.5.1 Types o

38、f damage 64 8.5.2 Planning for GRP or dual laminate repairs . 64 8.5.3 Steps in the repair process for GRP tanks . 65 8.6 Recommissioning and returning tanks to service following repair . 66 9 Decommissioning, mothballing, reuse and disposal .67 9.1 Introduction . 67 9.2 Decommissioning 67 9.3 Re-si

39、ting and reuse 68 9.4 Disposal 68 Appendix 1: Example nameplates 69 Appendix 2: Example management of change form and checklist .71 Appendix 3: Recommended bolt tightening torques for flanges 79 Appendix 4: Example commissioning check list81 Appendix 5: Risk-based inspection frequencies for tanks co

40、ntaining potentiallyaggressive contents .85 Appendix 6: Example Inspection Record Form 89 Appendix 7: Detectable defects, applicable inspection techniques, and possible actions .103 Bibliography.107X Above ground plastic tanks Publication 225 EEMUA Copyright 2017 The Engineering Equipment and Materi

41、als Users Association List of Figures Figure 1: Installed polypropylene and high-density polyethylene tanks .2 Figure 2: Installed GRP tanks 4 Figure 3: GRP tank showing outlets 11 Figure 4: A tank being filled by discharge from a road tanker . 13 Figure 5: Bunded tanks. 14 Figure 6: Tank manway 15

42、Figure 7: Tank showing access ladders, platforms and circular hand railing 16 Figure 8: Illustration of spiral wound thermoplastic tank . 18 Figure 9: Illustration of sheet constructed thermoplastic tank . 18 Figure 10: GRP and lined-GRP flange sections 20 Figure 11: GRP pipe section . 21 Figure 12:

43、 Lined GRP pipe section 21 Figure 13: A thermoplastic tank insulated to 150mm above base level 24 Figure 14: Example of damage to tank as a result of incorrect transport 30 Figure 15: Tanks being offloaded 31 Figure 16: Typical vertical tank transport arrangement . 33 Figure 17: Vertical tank offloa

44、ding and installation 33 Figure 18: Vertical tank installation arrangement 34 Figure 19: Typical horizontal tank transport arrangement . 35 Figure 20: Horizontal tank offloading and installation . 35 Figure 21: Tank weathering 42 Figure 22: Mechanical damage to a thermoplastic tank caused by misalig

45、ned agitator . 42 Figure 23: Cracking of internal welds on a thermoplastic tank . 43 Figure 24: Cracking on a thermoplastic tank due to chemical degradation 44 Figure 25: Failure of an incorrectly specified GRP flange fitting due to attack by sodium hypochlorite . 46 Figure 26: Blistering on a GRP t

46、ank 47 Figure 27: Weathering on a GRP tank . 48 Figure 28: Corrosion on a GRP tank caused by chemical attack .49 Figure 29: Cracks on a GRP tank flange . 50 Figure 30: A pin-hole leak detected visually in the base of a tank using residual waterin the tank base 57 Figure 31: Flowchart to aid tank rep

47、air assessment .62XI Above ground plastic tanks Publication 225 EEMUA Copyright 2017 The Engineering Equipment and Materials Users Association List of Tables Table 1: EN13121 Group 2(a) resin types and characteristics 7 Table 2: EN13121 Group 2(b) thermoplastic lining (TPL) polymer types and charact

48、eristics .8 Table 3: Design information to be provided to manufacturer .9XII Above ground plastic tanks Publication 225 EEMUA Copyright 2017 The Engineering Equipment and Materials Users Association Acknowledgements This Publication was written by a work group made up of representatives from EEMUA m

49、ember companies, plastic tank manufacturers, and suppliers to those manufacturers, as well as EEMUA staff members and consultants. This work would not have been possible without the cooperation of the participants and their companies. Their help with, and enthusiasm for, the project is gratefully acknowledged.1 Above ground plastic tanks Publication 225 EEMUA Copyright 2017 The Engineering Equipment and Materials Users Association 1.1 What is included This Publication is aimed at owners and operators of above-ground plastic tanks, which are typ