GRP Lining / Intumescents / Passive Fire Protection / Chemical Resistant Linings
Ferrous Protection are widely recognised as one of the leading providers of specialist lining and industrial coating solutions in the UK and many countries across the world.
We have an extensive track record of installing highly complex, technically demanding lining systems or maintenance coatings to offer asset protection against the harshest and most hazardous of cargos and environments.
For many of our customers, they are experts in their relevant fields and knowing how to protect a bulk liquid storage asset from corrosion can be a difficult and daunting decision. Which tank lining system should we go for? How is the tank lining applied? What are the safety aspects of working in a confined space? What are the safety aspects of working with high pressure airless spray equipment? What are the environmental impacts of working with hazardous paint materials? Should we just buy a new tank? Etc Etc. This is where Ferrous Protection can offer value! We have the expertise to answer all of these questions and make the decision to re-line your bulk storage asset a simple one. From installing a belts & braces, "tank within a tank" fibreglass lining system to a chemical resistant lining, we have the right tank lining solution for you.
Case Study 1 - Installation of a GRP Lining in an 80m diameter oil tank in Trinidad (£1m)
Client: Global Oil & Gas Supermajor
Location: Trinidad, Caribbean
Contract Value: £1,000,000
Asset(s): 80m diameter external floating roof crude oil tank
Project Brief: Ferrous Protection were contracted to apply a highly effective GRP lining system into a new build 80m diameter storage tank in Trinidad. The climate, location and fact that the works were undertaken during the height of the Covid-19 pandemic presented significant challenges to overcome. A fully detailed HSQE plan was prepared addressing all aspects of the project from start to finish and our Contracts Manager was deployed on the project full time to deliver the works safely and to specification. The team consisted of 15no operatives including 3no working supervisors, a site manager, coatings inspector and 2no subject matter experts to oversee the blasting and GRP lining elements.
Engineering controls were implemented to maintain the required atmospheric conditions within the tank and works were carried out day & night from November 2021 through to January 2022 including over Christmas to deliver the works on schedule for the customer.
We reinforced the waterproof membrane around the floating roof seal to prevent ingress of water and low-pressure water jetted the internal substrates to bring the salt contamination level within acceptable parameters per the relevant specification.
We then abrasive blast cleaned all vertical and intricate surfaces using expendable, non-metallic blast media, including sweep blasting the underside of the floating roof, and captive blasted the floor plates using 2no 20E machines with recyclable steel shot and angular grit mix.
We then applied a technically complex GRP lining using a novolac epoxy phenolic resin. The annular weld was given a quarter cove finish using a resin and silica sand mix and all welds, edges and intricate areas were sufficient covered using a compatible caulking compound.
On completion of the GRP lining application, the work was inspected in accordance with the specification and snags marked up and repaired. A fully detailed QAQC project dossier was prepared and submitted to the customer and the team demobilised.
The project was completed successfully and the quality of the workmanship praised by the key stake holders.
Client Project Manager:
“Job well done Ferrous! Exceptional quality work done amid the constraints with the global COVID pandemic, changing site conditions amongst other constraints – a professional response and management of the job at no compromise to quality”
Case Study 2 - Fuel Infrastructure Upgrade of Greenland's biggest air transport hub ($1.4m)
Client: Global Oil & Gas Supermajor
Location: Greenland, USA
Contract Value: $1,400,000
Asset(s): 8no bullet tanks, 1no flat bottom tank, 1.4km pipeline
Project Brief: Ferrous Protection engaged in 2021 with the aviation division of one of the world’s largest Oil & Gas Supermajors to deliver the major fuel infrastructure upgrade of Greenland’s largest commercial airport and main air transport hub. The project included the corrosion repair, and application of a protective three-coat epoxy system to 1.4km of semi-buried fuel transfer pipeline, the washing of 8no bullet tanks and the re-lining of 6no bullet tanks and a flat bottom storage tank with a high performing novolac epoxy phenolic lining system.
Extensive planning and preparation were required to overcome the technical, logistical and climatic challenges of working in such an extreme and remote part of the world. We shipped 10no 20ft containers and hazardous goods cargo to the work area and flew out our Contracts Manager, working crew and subcontractors. We installed fixed scaffolding over 4no bullet tanks to provide a stable platform for a tripod & winch to allow a vertical emergency extraction from the confined space. We set up our laydown area and erected effective hazardous works signage, barriers and Heras fencing around our work area.
Engineering controls were implemented and atmospheric conditions were monitored within the tanks to ensure a safe working environment was achieved and the atmosphere was in specification. Firstly, we pumped the residual fuel out of the tanks and downgraded the contents to arctic diesel. We then high-pressure water jetted the internal surfaces of the tank and filtered the contaminated washings down to 3.5ppm in accordance with the local environmental regulations.
The internal surfaces were abrasive blast cleaned using an inert, naturally occurring and eco-friendly blast media and spent grit was removed using an automatic grit recovery system. The blasted areas were held under dehumidification until a two-component holding primer was applied by airless spray.
All steelwork defects were addressed and edgework, welds and intricate areas received a stripe coat by brush to ensure sufficient coverage to all areas. All pitted areas received a scrape coat to ensure the epoxy resin was effectively worked into the pits.
A full coat of two-component, solvent free novolac epoxy phenolic was applied to the internal surfaces by airless spray and inspected by our competent and experienced protective coatings inspector. D.F.T. Checks were taken, a visual inspection carried out and holiday detection done alongside a methyl ethyl ketone rub test to ensure compliance to the specification was achieved. All snags were marked up, repaired and re-tested.
The tanks were then boxed up, gaskets re-instated and soak test carried out.
On handover of the tank back to the customer, a fully detailed QAQC project dossier was submitted.
On completion of all works, we demobilised the containers and left just in time for the fjord to freeze back over.
The project was both a technically and logistically complex undertaking, however Ferrous Protection delivered the works successfully with no safety or environmental incidents, on budget and nearly a whole month ahead of programme. The customer reported to be very satisfied with the quality of execution and overall project management and complimented the team on their excellent attitude to quality and safety.
Client Project Manager:
“The Ferrous Protection and Qualitech partnership has shown the power of collaboration, it has combined the safety performance and know-how of tank cleaning from Qualitech along with the
expertise and knowledge of tank and pipework corrosion protection from Ferrous Protection. In addition, Ferrous Protection’s attention to detail and diligent planning has led to the project in Kangerlussuaq being executed to perfection, which is a rare achievement in the project environment. Air BP will be looking to build a stronger and longer term partnership with this company going forward, given the breadth of their offer and the professionalism of their delivery.”
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