MERICAN SYSTEM Introduction-20170801

MERICANMERICAN SystemSystem

TheThe fiberglassfiberglass reliningrelining systemsystem toto upgradeupgrade

inin--serviceservice steelsteel fuelfuel tanktank inin gasolinegasoline stationstation

SinoSino PolymerPolymer Co.,Co., Ltd.Ltd.

Part 1: Brief introduction

Part 2: Construction flow chart

Part 3: Construction specification

CodeCode forfor constructionconstruction andand acceptanceacceptance ofof

constructionconstruction qualityquality ofof MERICANMERICAN SystemSystem

Part 3: Construction specification

Part 4: Code for acceptance of construction quality

Part 5: MERICAN SYSTEM-Raw materials list

Part 6: MERICAN SYSTEM-Equipment list

Part 7: MERICAN SYSTEM-Construction workers

Part 1: Brief introduction – MERICAN system

-Developed according the actual requirement in Shanghai, MERICAN System is in line with the

Shanghai Environmental Protection Regulation No.182 (2017) and Sino Polymer owns IPRs

-MERICAN System is a fiberglass lining system which fabricating a double wall FRP tank in the

inside surface of single wall steel fuel tanks. It owns same composite specification as a double

wall FRP tank : two corrosion resistant laminates with the interstitial space in the middle, wall FRP tank : two corrosion resistant laminates with the interstitial space in the middle,

total thickness is between 11-15mm.

-After structural strength calculation and lamination structure design, the double wall FRP lining

replace all the functions of original steel tanks which includes load bearing, storage of oil,

corrosion resistance.

-The MERICAN 9505 series resin used in MERICAN System was certified by UL 1316 and

UL1746, it also conforms with the requirement in the standard of GB/T 30040.7 and SH/T 3177.

The innovation points in MERICAN System:

1- MERICAN 9505-50 UV curing resin is developed by Sino Polymer and in line with GB/T 30040

and SH/T 3177. It is also approved by UL.

2- When the wall thickness of original steel tank is less than 3.2mm, the lamination structure

design and lamination thickness of double wall FRP lining will be determined by the original

fuel tank’s allowable value of various loads and composites.


3-The dry ice derusting method was used by MERICAN System which ensure there is no

secondary pollution and provide a more safety environment and no harm to health.

4- The pressure leak detection system was used is in line with the Shanghai Environmental

Protection Regulation No.182 (2017)

5- No need to dig a monitoring wells, no open hole in the top of the tank to reduce leakage points

and construction risk.

6, The interstitial space exists in the circumferential direction of the tank 360 °which ensure the

leakage detection has full coverage without dead ends.

Lining structure of

MERICAN System

Total

thickness:

11.5-15mm


Primer

Outer FRP laminates: 4.0mm

Interstitial space layer: 3.5mm

Inner FRP laminates: 4.0mm

Original steel tank wall + dry ice rush removal

11.5-15mm


Structure of

MERICAN System

MERICAN System is in line with the standard below

Nr. Standard No. Standard Name

1 GB 50156-2012

（2014 version）

Code for design and construction of automobile

gasoline and gas filling station

2 GB/T 30040-2013

( )

Lead detection systems

This standard is equals to BS EN 13160:2003


(BS EN 13160:2003) This standard is equals to BS EN 13160:2003

3 SH/T3177-2015 Technical specification for buried glass fiber reinforced

plastic double skin oil tanks in fuel filling station

4 UL 1316 Glass-Fiber-Reinforced Plastic Underground Storage

Tanks for Petroleum Products, Alcohols, and

Alcohol-Gasoline Mixtures.

5 UL 1746 External Corrosion Protection Systems for

Steel Underground Storage Tanks.

UL certificates for

MERICAN 9505


The approval tests on MERICAN 9505 done by UL experts

Process Hand lay-up

Spray up

Vacuum Infusion/RTM

Pre-preg

Compatible fiberglass

OCV: M123 450, M123 600（Chopped Strand Mat）


OCV: M123 450, M123 600（Chopped Strand Mat）

Jushi: EMC 450、EMC600（ Chopped Strand Mat ）

Jushi: ER13-2400-180（Spray roving）

OCV: OCV P209 2400TEX（ Spray roving ）

Taishan Fiberglass: ERS240-T132B（ Spray roving ）

Shangdong Fiberglass: ECR13-2400A-823P（ Spray roving）

CPIC: ER 10-2400（ Spray roving ）

Compared with integral tank change, MERICAN System owns advantages below:

No dig at site, simple approval procedures, after the filing then it can be implemented.

In accordance with the requirements of the national standard：After upgrade, the steel

fuel tank will have a complete double FRP wall structure which meet the requirement of

GB/T30040-2013 Leak Detection System and GB 50156-2012 Code for design and

construction of automobile gasoline and gas filling station

Part 1: Advantage of MERICAN system

Stable & reliable leak detection system：Real time detection of tank system status

Short construction cycle:

For uninterrupted operation, it only takes 3 weeks to upgrading four 30m3 steel tank

Low overall cost：MERICAN system provide a much lower overall cost compared with

the overall tank change solution,

Very small tank capacity change：

After upgrading, the tank capacity is 97% of the original tank capacity.

Compared with the existed lining upgrade systems introduced from international market, the

MERICAN System is more suitable with Chinese national conditions with advantages below:

The main raw materials used in the system were approve by international authority third

party certification, the quality can be guaranteed. The resin was produced by Sino Polymer

which greatly reduce the cost of lining project.

The dry ice derusting process reduce the risk of explosion during construction and the risk of

Part 1: Advantage of MERICAN system

construction environmental pollution, reduce the health risks of construction workers.

The UV curing equipment owns characteristics of small size, light weight, long life, easy

moving which is in line with the single manhole of in-service steel fuel tank in Shanghai.

The operating voltage of UV curing equipment is low (12V) which is in line with limited space

voltage requirements, safe and efficient, ensure complete curing.

No need cut off the triangular steel support inside the in-service steel fuel tank to avoid

security risks

Compatible fiberglass is in full range

Site preparation,

Safety protection

Tank cleaning &

decontamination Dry ice derustingCut off the bottom

steel support

Inner wall repair,

apply the primer

Installation of Leak

Gas burst

testGas burst

test

Visual inspection,

Thickness

measurement

Part 2: MERICAN SYSTEM: Construction flow chart

Thickness

measurement

Out FRP

laminates

Interstitial

space layer

Installation of Leak

detection

prefabricated parts

Inner FRP

laminatesInstallation of Leak

detection system

Installation of

Electrostatic

discharge device

Interstitial

space test

Intermediate layer

pressure test

(Positive & Negative

pressure)

Thickness measurement,

appearance inspection,

barcol hardness test,

spark test

Thickness measurement,

appearance inspection,

barcol hardness test

Completion

acceptance

Grounding

resistance

1-Initial preparation work

1.1 Communicate with the owners,

investigate the working environment,

sign the security responsibility agreement,

confirm the construction considerations.

Part 3: MERICAN SYSTEM:

Construction Specification

confirm the construction considerations.

1.2 Equipment approach, commissioning:

Assembly and commissioning lighting, ventilation, spraying, light curing

equipment to ensure that the equipment is in good condition.

1.3 Personnel safety training.

1.4 Security protection settings.

1.5 Tank gas test.

2 Forced ventilation

The forced ventilation has to be done when the cleaning up of the oil in steel

tank was finished. The ventilation time should be at least 2 hours or more.



3 Dry ice derusting

3.1 After the ventilation was qualified, cleaning the welding slag, burr, rust, oil, dust and

other floating objects in the steel tank and ensure the tank surface is flat.

3.2 Check the dry ice derusting equipment, inspect the compressed air flow and pressure of

the air compressor.

3.3 Dry ice derusting: -78 dry ice particles in the cleaning machine was driven by

compressed air impact on the tank surface with a high-speed to achieve the purpose of rust.

Part 3: Construction Specification

3.4 To ensure the safety, the whole dry ice derusting process should be monitored.

After dry ice derustingBefore dry ice

derusting

4 Correction on single steel wall tank

4.1 When the second tank cleaning and derusting was finished, and tank

flammable gas test was qualified, then cut off the bottom of the tank steel

support in about 500 ~ 600mm width.



4.2 Cutting detection opening on reinforcement rib plate in the two sides tank

head, so that the tank head and the cylinder sandwich has good conduction

performance.

4.3 Using 9505TP resin putty in the tank flat head, inner wall reinforcement ribs,

welding seam to make transition section to ensure the smooth transition .

4.4 ESD device installation work.



4.4 ESD device installation work.

5 Inspection and repair work on steel tank wall

5.1 Inspect the the steel single wall tank’s thickness, corrosion, crack

and deformation, etc.

5.2 Tank wall repair：

For the inner tank wall area where their is defects and the local wall thickness less



For the inner tank wall area where their is defects and the local wall thickness less

than 3.2mm, the chopped strand mat and special resin should be used to repair to

to ensure the pressure capacity of the tank.

5.3 When the whole steel tank thickness is less than 3.2mm , then integrally

reinforcement is required. The design and thickness of the reinforced lamination

structure and thickness should follow mechanical strength calculation.

6 Apply the primer

6.1 Clean the dust and debris in the tank, then apply MERICAN 110 primer resin in

the steel tank inner surface within 4 hours after derusting. Surface inspection

should be done during coating. The surface should be smooth, smooth, uniform,

and no un-coating area, sticky, peeling, bubbles and spots and other defects exist,

if there is defect coating, it should be repaired at once.

6.2 After the completion of the construction, the pull test should be done. Bonding



6.2 After the completion of the construction, the pull test should be done. Bonding

strength of 5.5MPa or more is qualified.

8 Outer wall glass fiber reinforced plastic (FRP) construction

8.1 Lay the trimmed fiberglass on the tank wall, soak with the UV curing resin, two

wove roving/mat’s overlap width should be at least 50mm on the same layer;

continue to lay the second piece of fiberglass mat, until reaching the design

thickness; roll out the bubble; resin brushing uniform, no missing part, resin dripping,

bubbles or burrs; resin content control at 70 ± 5%.



bubbles or burrs; resin content control at 70 ± 5%.

8.2 After each unit is finished, cure them with a UV lamp. After curing, the outer wall

is subjected to the barcol hardness test, and the minimum barcol hardness value is

≥30.

8.3 After the outer glass fiber reinforced plastic is finished, the thickness detection,

visual inspection and EDM test are carried out with ultrasonic thickness detector.

If the thickness of a region does not meet the design requirements, or the



If the thickness of a region does not meet the design requirements, or the

appearance inspection does not meet the requirements, you need to add resin

coating in the region, and re-testing it until achieve the thickness requirements.

9 Interstitial construction

Using MERICAN 9505-50 UV curing resin and 3D fabric to fabricate the middle gap

layer, cured with UV lamp. After the intermediate gap layer is finished, the visual

inspection and the curing degree test are carried out.



10 Leak detection system install

Install the leak detection system in accordance with the construction plan.

11 Inner wall glass fiber reinforced plastic (FRP) construction

11.1 Lay the trimmed fiberglass on the outer FRP wall, soak with the UV curing resin,

two wove roving/mat’s overlap width should be at least 50mm on the same layer;

continue to lay the second piece of fiberglass mat, until reaching the design thickness;

roll out the bubble; resin brushing uniform, no missing part, resin dripping, bubbles or

burrs; resin content control at 70 ± 5%.



burrs; resin content control at 70 ± 5%.

11.2 After each unit is finished, cure them with a UV lamp. After curing, the outer wall

is subjected to the barcol hardness test, the minimum barcol hardness value is ≥40.

11.3 After the inner glass fiber reinforced plastic is finished, carry out the thickness

detection and visual inspection. If the thickness of a region does not meet the design

requirements, or the appearance inspection does not meet the requirements, you

need to add resin coating in the region, and re-testing it until achieve the thickness

requirements.

11.4 Polish and repair the burrs, bulge and blistering part on the inner surface.



11.4 Polish and repair the burrs, bulge and blistering part on the inner surface.

12 Stiffeners wrapping (2nd time)

After the completion of the construction of the inner wall, use 9505-50 and 4 layers of

CSM to wrap the stiffeners again. Polish and repair the uneven part, to achieve flat,

burr-free surface, no missing coating area.

13 Gap connect test

Inject the identifying liquid into the middle gap layer, using the specialized lamp to

.



check inside the tank for its connection situation.

14 Interstitial pressure test

14.1 To test middle gap layer for gas pressure, test pressure=35KPa, pressure

rate=5KPa/min, holding pressure for 30min. No pressure drop, no leakage can be

considered as qualified.

14.2 To test middle gap layer for liquid pressure, test pressure=18KPa, holding

pressure for 30 min. No pressure drop, no leakage can be considered as qualified.



pressure for 30 min. No pressure drop, no leakage can be considered as qualified.

15 Leak detection system install

Connect the embedded part of inspection hole with one end of metallic bend pipe,

and connect the other end with metallic connecting pipe, connect it with manhole

outlet pipe and attach to the pressure gauge outside the tank.

The highest

monitoring point

Transmissible

pressure gauge

Stainless steel flexible pipe

Hand rolling

pressure testing

pump Stainless steel vessel



Middle gap layer volume & pressure test

The lowest

monitoring point

Copper tube

16 Electrostatic installation

A stainless steel plate with a total surface area of not less than 0.04 * V m2 (V: total

tank volume) is attached to the bottom of the tank, and the stainless steel plate is

connected to the pre-embedded conductive screw with a copper mesh braided

strap. Lightning anti-static grounding should meet GB50156 requirements.

压力值导出管人孔盖板Pressure value export tube Manhole cover



Electrostatic Export Illustration

油罐筒体钢板

转换接头

外层玻璃钢

压力值导出管

内层玻璃钢

2#压力值检测点

静电导出板

间隔层

1#压力值检测点

压力值导出管

静电跨接线

δ≥3.2mm

δ=4mm

δ=4mm

Pressure value export tube

1# Pressure value test point

Interstitial layer

Convert joint

Tank steel wall

Outer FRP wall

Pressure value export tube

Inner FRP wall

Electrostatic export board

2# Pressure value test point

17 Inner wall FRP surface treatment

17.1 After passing the inspection, polish and seal the inner FRP surface.

17.2 Brush coating the inner FRP surface with UV curing conductive resin,

rich resin layer ≥ 0.2mm, requiring flat and smooth surface, no tacky.



Operation room (2nd meter)Transmissible pressure gauge (1st meter)

4-20 mA direct current signal



Double wall tank pass-through layer leakage detection principle

The highest monitoring point

The lowest

monitoring point

No. Acceptance check items Test standards and methods Acceptance standard Using table type Remarks

1 Dry ice derustingUltrasonic thickness gauge Wall thickness ≥3.2mm Attached table 2 accuracy

Pulling force tester ≥5.5MPa Attached table 1Electric spark leak detector 2KV leak detection qualified Attached table 3

2 Outer FRP wall

Fixed size template checking Surface bubble less then 2 /Each bubble’s

maximumthickness≤

Ultrasonic thickness gauge FRP≥4mm Attached table 2 accuracy0.01mm

Electric spark leak detector 15KV leak detection qualified Attached table 3 Tank wall temperature

minusEnvironmental

dew point >GB/T 3854-2005 ＞30 Attached table 4


Environmental dew point >

3 Inner FRP wall

Fixed size template checking Surface bubble less then 2 /Each bubble’s

maximumthickness≤

Ultrasonic thickness gauge FRP≥4mm Attached table 2 accuracy0.01mm

GB/T 3854-2005 ＞40 Attached table 4

4 Middle interstitial layer

35Kpa gas pressure test No pressure drop, no leakage Attached table 6

Connectivity performance testing V=（0.002～0.02）Vt Attached table 5

18Kpa liquid pressure test No pressure drop, no leakage Attached table 6

5 Electrostatic Export device megohmmeter measuring R≤10Ω Attached table 7

6Middle interstitial layer

leakage detection system

Visual inspection 1st and 2nd meter confirm and normal /

1. Visual inspection

1.1 After outer/inner FRP construction finished, visual inspect the appearance

with specialized lamp; the surface should be flat and smooth, no

impurities/exposed fiber/cracking/scratching/ flaw/whitening or severe inequality

of the color;

1.2 In any 300mm×300mm size, bubble number should no more than 2 (each


1.2 In any 300mm×300mm size, bubble number should no more than 2 (each

bubble’s maximum diameter=3mm) , the maximum dept of the bubble should not

exceed 1/5 of outer(inner) wall thickness and less than 1mm.

1.3 After the middle interstitial layer construction finished, visual inspect the

appearance with specialized lamp; 3D fabric should be evenly soaked with resin,

no bubble, no whitening on inner side.

2. Thickness inspection2.1 After outer/inner FRP construction finished, the thickness should be

inspected, actual measured thickness should no less than design thickness.

2.2 Use Ultrasonic thickness gauge (accuracy = 0.01mm)

2.3 Each tank should test 32 spots evenly distributed, if the test failed, the outer

wall should be thickened.

2.4 If the failed area exceed than 5%, then the relevant area should be double

checked; If it still exceed than 5%, then the outer wall should be constructed one

more layer and test the thickness until reach the requirement.


more layer and test the thickness until reach the requirement.

3. Barcol hardness test3.1 After outer/inner FRP construction finished, test the barcol hardness

according to GB/T 3854-2005; outer wall min. hardness=30, inner wall min.

hardness=40

3.2 Testing spot should be distributed evenly

on the external surface of the inspected part.

Testing spots should be no less than 10 in

shell cover&tank body, and should be no less

than 5 in reinforced parts.

4. Middle interstitial layer pressure test4.1 To test middle gap layer for gas pressure, test pressure=35KPa, pressure rate=5KPa/min, holding pressure for 30min. No pressure drop, no leakage can be considered as qualified.4.2 To test middle gap layer for liquid pressure, test pressure=18KPa, holding pressure for 30 min. No pressure drop, no leakage can be considered as qualified.4.3 Overpressure is strictly prohibited, observe the pressure value at any moment during the test.5. Spark test :Conduct the spark test according to HG/T 4090 standard. If the spark test failed, the


Conduct the spark test according to HG/T 4090 standard. If the spark test failed, the area should be marked, cutoff the FRP layer, clean the primer, polish the tank wall and scrubbing with acetone, then coat the primer, fabricate FRP outer wall, re-construction area should be twice of themarked area.

For a 120m3 petrol station (with four 30m3 oil storage tanks) :

Item Material Name Quantity Unit Application

1 MERICAN9505-50 Light Cured Resin 2500 kg Inner and outer FRP

2 MERICAN 9505TP Matrix Repair Resin 600 Kg

3 MERICAN 110 Prime Coat Resin 40 Kg Primer resin

4 EMC450-127 Chopped Strand Mat (alkali free) 1200 kg Inner and outer FRP

5 3D Fabric 260 m2 Middle gap layer

Part 5-MERICAN SYSTEM: Raw materials list

5 3D Fabric 260

6 Styrene 40 Kg Add curing agent to the resin

7 Photoinitiator 20 kg Resin curing

8 Acetone 80 kg

9 MEKP-9 20 kg

10 Talcum Powder 200 kg

11 Steel Plate 2 Piece

12 Stainless Steel Bolt 40 Set

Item Equipment Name Qty. Unit Application Remarks

1 UV light curing lamp 1 Set Resin curing

2 Adhesion tester 1 Piece Adhesion test for the primer layer

3 Gas tester 2 Piece Gas detection during tank operation5-in-1, with explosive

determination of organic matter

4 Thickness gauge 1 Piece Measure the thickness of FRP Range 20mm

5 Resin spray pump 1 Piece Spray resin A lot of types for choice

6 Resin gun 2 Set Spray resinOne set for use, the other

standby

7 Precision digital pressure gauge 1 Piece Middle layer test pressure Test pressure for middle layer

8 Dry ice derusting machine 1 Set De-rust the inner surface of steel tank Pipeline more than 15m

9 Manual hoist 2 Piece Lifting material, emergency equipment 1.5t electric hoist is usable

10 Explosion-proof axial flow fan 2 PieceForced ventilation for in-tank construction

work

Explosion-proof type,

3KW 64m3/h

Part 6: MERICAN SYSTEM - Equipment list

10 Explosion-proof axial flow fan 2 Piecework 3KW，64m3/h

11 Explosion-proof electrical box 2 Piece Power distribution facilitiesOne for sandblasting, the other

for spray resin

12 Explosion-proof lamp 4 Set In-tank lightingOne set for sandblasting, two

sets for lining

13 Gas welding machine 1 Set Repair tanks, weld conducting bolts Repair tank wall

14 Gas welding equipment 1 Set Cut stiffeners, open detection holesCut stiffeners, open detection

holes

15 Barcol Impressor 1 Piece Resin hardness test after curing

16 Labor protection products 1 Set Whole construction process

17 Supervisory equipment 1 Set Whole construction process

18 Communication equipment Several Set Whole construction process

Item Job title Number of People Remarks

1 Project Leader 1 Certified

2 Technician (part-time) 0 Technical information

3 Safety officer (part-time) 0 Certified

4 Electrician (part-time) 0 Certified

Part 7: MERICAN SYSTEM-Construction workers

4 Electrician (part-time) 0 Certified

5 Foreman 1 Be certified for anti-corrosion

6 Welder (part-time) 0Be certified for special construction

work permit

8 Anticorrosion worker 6Work in two shifts,

day shift and night shift, certified

Total 8 People

Thank you!Add：No. 130 Muhua Road, Shanghai

Zip code：201507

TEL：+86-21-64252619

FAX ：+86-21-64250084

E-mail： [email protected]

Website： www.sinopolymer.cn

www.hchp.com.cn

MERICAN SYSTEM Introduction-20170801

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