Petrochemical Storage Tank PU Insulation in Russia

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Project reference basis. Figures and configuration details are reported in the supplied project brief. They are reference values for the stated application, rather than verified acceptance results or a guarantee for another installation. Confirm the source records, material, tooling, operating schedule and test method when assessing a comparable project.

Haifeng successfully engineered and deployed a heavy-duty storage tank spray polyurethane foam insulation system for a premier petrochemical refinery in Russia, slashing heating steam consumption by 45% across multiple 20,000 m³ crude oil storage tanks with corrosion-under-insulation control requiring substrate preparation, moisture management and inspection. The turnkey delivery encompassed an explosion-proof hydraulic proportioning machine, 90 meters of heated high-pressure delivery hose line, automated magnetic crawler integration, and heavy pneumatic drum transfer pumps.

Prior to commissioning, the refinery experienced severe operational hazards with conventional mineral wool cladding on its heated oil tanks (maintained at 65°C). Snowmelt and driving rain penetrated gaps in the outer metal jackets, soaking the mineral wool and accelerating acidic corrosion against the carbon steel tank shell, reducing wall thickness by 25%. The client required an industrial chemical spraying platform capable of atomizing high-temperature rigid polyurethane directly onto grit-blasted steel walls, locking the stoichiometric ratio at 1:1, and creating a continuous 80mm closed-cell thermal envelope that bonds permanently without air gaps.

Operating around the clock on a two-shift daily schedule using automated spray crawlers, the contractor completed an entire 20,000 m³ tank in just 12 operational days. By deploying Haifeng's closed-loop Ratio Lock flow controls and high-temperature fluid lines, the contractor applied an continuous thermal insulation layer for the stated thermal-insulation application; ongoing corrosion control remains subject to coating condition, sealing and inspection.

Project Technical Specification Matrix:

Haifeng deployed an industrial high-pressure spray platform engineered for explosion-proof refinery tank environments:

1. ATEX-Compliant Hydraulic Proportioning: Ex-proof proportioning drives pump chemicals at 170 bar, maintaining stoichiometric balance under fluctuating outdoor temperatures.
2. Extended 90m Heated Delivery Hoses: Multi-zone insulated delivery lines ensure precursor chemical temperatures remain at 54°C (±0.8°C) from ground skids to the top of 18m tall tanks.
3. Automated Magnetic Spray Crawler: Integrated crawler robot tracks vertically along steel shells, depositing smooth, uniform 20mm passes up to 80mm total thickness.
4. Protective Polyurea Coating: A spray-applied elastomeric polyurea coating was applied over the foam to protect against foot traffic, diesel splashes, and UV degradation.

Installation and commissioning: 15 days. Operator training: 4 days. Machine warranty: 1 year. Long-term spare parts and remote equipment support are available.