After applying a traditional insulation system onto a storage tank, how long will it continue to perform as expected? What are the odds the aging system is maintaining its integrity? Unfortunately, the lack of sustainability and performance value can lead to larger problems as time passes; problems that may have significant structural, financial and potential environmental impacts. As these issues become increasingly important, so does the need to find a solution. We are now seeing an increase of tank owners specifying a new type of insulation system that comes in the form of a coating.
Thermal insulating coatings (TICs) are not reflective rooftop coatings, which solely reflect ultraviolet rays. TICs are typically acrylic resins filled with ceramics and silica, among other ingredients, creating a true, thermal barrier between two environments. Most TICs can be applied up to 5 millimeters total; however, the thickness depends on the internal temperature and the desired performance requirements. In many cases, TICs are able to effectively insulate and replace conventional insulation altogether. Today, there are countless applications in many different industries. They are not suitable for every tank application, but they are perfect for many.
Since large storage tanks are usually outdoors, they are constantly exposed to the elements. When jacketing is damaged by wind or mechanical reasons, moisture will likely make its way into the insulation below. These can cause decreased insulation abilities, corrosion under insulation (CUI) and other maintenance concerns. Tanks that hold product more than 320 F (160 C) may seem resistant to CUI, but that is only up to the fill line. Areas above that can still be subjected to corrosion.
In some instances, TICs can be applied only to certain areas that are more susceptible to corrosion. Five years ago, a terminal in Oregon installed a TIC on the bottom 4 feet of a tank because it had corrosion localized to that area, while the rest of the tank was covered in conventional insulation. By combining both types of insulation, the client had effectively insulated its tank while combatting corrosion. That application is still in service today with no corrosion issues.
When using conventional insulation, most tank roofs are left bare because personnel need access to the roof. Also, the many protrusions can ruin a perfect seal when using a paneling system. Since TICs are applied (just like paint) to the exterior of the tank, they adhere directly to the substrate or primer. This forms a seamless barrier rain and moisture cannot penetrate, effectively negating the possibility of CUI occurring. There aren’t any gaps like you would have with steel jacketing or panel systems. Their performance is not diminished by regular foot traffic and can also greatly reduce the effects of flash cooling due to a passing rainstorm.
Personnel protection is an important aspect in regards to workplace safety. Workers are susceptible to lost-time injuries stemming from storage tanks, whether it be burns, slip and fall accidents from condensation, or cuts and lacerations from sharp metal jacketing that has come apart. With TICs, the coating only needs to be applied to areas accessible by personnel. On the Gulf Coast in Texas, one company used a TIC only along the stairwell and the bottom 7 feet of the tank. This helped the company reduce installation costs and time. The rest of the tank was left insulated as they didn’t feel it necessary. Conventional insulation can be seen as a hindrance in areas like stairways and anything other than the sides of tanks as they require fabrication to provide adequate protection (while also promoting CUI).
All types of thermal insulation have their pros and cons. Though TICs have not been around as long as more conventional forms of insulation, it has become fairly clear where they are and are not successful. The benefits yielded on the successful applications make believers out of the most resistant skeptics. By working with an experienced company that can help guide you through best practices using an insulating coating, you are ensuring a sustainable system that will provide a return on your investment.
For more information, visit www.mascoat.com or call (800) 549-0043.
