System and Method for Repair of Leaking Storage Tanks Containing Fluids Which Contaminate Ground Water

Thousands of tanks are presently in service worldwide for storage of ground water contaminating fluids. Older varieties of these tanks fabricated of steel and unprotected cathodically are subject to internal and external corrosion which will eventually cause leaking of the stored fluid or admittance of ground water into the tank. The rate of corrosion depends on the corrosiveness of the tank support structure or the contained fluid and the tank surface protective coatings. Leakage of these fluids into the ground water constitutes an extreme hazard to the public and environment; and, leakage of ground water into the tank adversely affects the quality of the stored fluid.

Here-to-fore leaking tanks have been replaced with new tanks, repaired in place or abandoned. The cost of replacing all old tanks with new tanks at one time would impose such an economic burden on many operators that they could not remain in business; therefore, tanks are usually replaced only when leaks are detected and many times this detection is made only after considerable contamination has already taken place. Fiberglass epoxy lining materials have been rejected according to information received on rules of the current Uniform Fire Code. Additionally, this in-place repair method cannot be considered a permanent solution since the tank will continue to corrode and there is no positive means to determine that the coating has not developed leaks. Abandonment of leaking tanks results in loss of storage capacity which can only be considered where other adequate storage is available.

I have devised a system and method for repair of leaking storage tanks containing fluids which contaminate ground water. The tank is made ready for installing my system by first removing all appurtenances from the tank except its external vent system and by gas freeing the tank. Subsequent to gas freeing the tank it is fitted with a new combination manway and appurtenances access and all tank screwed openings which originally contained the appurtenances are plugged liquid tight. A flexible fluid light containment means formed to the tank interior shape is positioned in place with its opening edge forming a fluid tight gasket seal between the flange and cover of the tank's new access. A support cage is installed within the containment means in the space around the tank's new access to relieve the strain on the opening edge of the containment means when the contained fuel level is low and the containment means is not fully inflated. The support cage additionally keeps the containment means away from the space occupied by appurtenances which extend down inside the containment means directly under their new connection points within the tank's new access. A sampling means is installed between the containment means and the lowest inside tank surface for detection and removal of any ground water leaks into the tank and to detect possible leakage of contained fluid through the containment means.

The primary object of this invention is to provide an economical method for repair of leaking storage tanks in order that the public and environment may be readily protected from the hazards associated with leakage of many fluid types into the ground water and subsequent fluid evaporation into the atmosphere.

Additional benefits of this invention is the complete elimination of fluid vapor expulsion into the atmosphere and the complete elimination of atmosphere contact with the fluid/fluid vapor interface which can develop explosive fluid vapor atmospheric mixtures.

FIG. 1 is a side view of a typical tank with all appurtenances and the support structure removed for clarity;

FIG. 2 is an end view thereof;

FIG. 3 is an enlarged vertical cross-section taken through the tank center as indicated in FIG. 2;

FIG. 4 is a partial vertical cross-section taken at a right angle to the tanks' longitudinal axis as indicated in FIG. 3;

FIG. 5 is an enlarged view of the manway and appurtenances access as indicated in FIG. 1; and,

FIG. 6 is a section taken through the manway and appurtenances access as indicated in FIG. 5.

Referring to FIG. 1 and 2, tank 1 contains screw type openings 2 into which existing appurtenances are inserted such as fill tubes, submerged pumps, suction pipes for suction pumps, syphon lines, fluid level gauging systems, vapor return lines and venting systems. Utilizing my method for tank repairs all appurtenances except the venting system will be relocated and openings 2 will be closed fluid tight with plugs 3. The complete existing venting system installed external to the tank remains connected fluid tight to its existing opening 4. Any existing vapor return line connected into the existing tank venting system requires reconnection into the new tank vapor return lines under my method for tank repair. Support structure for tank 1 normally comprises surrounding backfill sand/gravel material up to a level approximately three feet above the tank top. Included in this three foot thickness there is usually an existing surface slab of asphalt or concrete into which framed openings with covers are cast for access to the appurtenances. Utilizing my method for tank repairs temporary sand/gravel retainer rings are required until appurtenances are removed, the tank is gas freed, tank openings are plugged and the under slab void is filled with sand. Then the temporary retainer ring can be removed, the surface opening can be closed and a permanent sand/gravel retainer ring will be required for installation of the new manway and appurtenances access 5. Other slab/fill removal/replacement may be required to reroute piping and electrical system due to relocation of appurtenances. Referring to FIG. 6, access 5 contains side walls 6 joined fluid tight with tank 1 and flange 7. Cover 8 is shaped to close over the entire manway and appurtenances access opening including flange 7. Contact areas common to flange 7 and cover 8 are to be machined smooth for maintaining a fluid tight seal when assembled. Multiple bolts, with washers 9 are inserted in multiple holes drilled through flange 7 and cover 8 for assembly. Referring to FIG. 3 and 6, flexible fluid tight containment means 10 is fabricated of material inert to the stored fluid and formed to the tank interior shape. Containment means 10 is available from Flexi-Liner Corporation, P.O. Box 767, Pasadena, Calif. 91101. Opening edge 11 fabricated of the same material as containment means 10 is formed to the interior of access 5 including a sealing flange 12 which acts as a gasket between flange 7 and cover 8 when sealing flange 12 is punched with holes aligning with bolts 9 and when flange 7, sealing flange 12 and cover 8 are assembled together with bolts, nuts with washers 9. All parts of containment means 10, opening edge 11 and sealing flange 12 are joined together fluid tight. Referring to FIG. 5 and 6, screw type openings 13 joined fluid tight with cover part 8a are utilized for relocated appurtenances. Cover part 8b, utilized for manway access without removal of appurtenances, is joined together fluid tight with cover part 8a by cover flange 8c and 8d, gaskets 8e and bolts/nuts/washers 8f. Referring to FIG. 4, corrugated material 14 is brought through access 5 in coils, cut to length to cover 120 degrees across the tank bottom, lapped at joints and secured to the tank bottom with no edges which would puncture containment means 10. Corrugated material 14 allows any leaking ground water penetration or leaking stored fluid to seek the lowest level within tank 1 where a sampling means 15 is positioned. Sampling means 15 is joined fluid tight with leaked fluid/ground water suction line 16 which is routed between tank 1 and containment means 10 for connecting to a threaded coupling 17 which is installed fluid tight through side wall 6. Outside end of coupling 17 is to be connected with a flexible hose and quick coupler in order to periodically extract samples from sampling means 15 or for removal of any ground water which has leaked into the tank. Since there may be some residual fluid within the sand/gravel around the tank due to past leaks or spills at the fill connection, samples may indicate a slight presence of fluid; therefore, the frequency of sample taking should consider any change in fluid concentration. A dramatic increase in fluid concentration with a fairly constant level in ground water table will indicate fluid leakage through containment means 10. Referring to FIG. 3, cage 18 is brought through access 5 disassembled. Cage 18 is assembled and adjusted to force containment means 10 tight against the inside of tank 1 whereby all stress is relieved on opening edge 11 when stored fluid level is low and containment means 10 is draped down from cage 18 as indicated. Cage 18 additionally prevents containment means 10 from entering the space 19 occupied by the relocated appurtenances. Cage 18 is fitted with latchable personnel access gates in each circular and face whereby personnel may inspect gas free containment means 10 and inspect its inside surface when any leak is detected.