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6430 S. 39 W. Ave.
Tulsa, OK 74132
Ph: 918-584-2220
Fax: 918-584-2221
www.cittech.com

Introduction

Application: Synthetic Fertilizer Tank (UAN)
Temperature: Up to 150 F (66 C)
Diameter: 150
Defect Type: Cracked welds and general corrosion

A synthetic fertilizer plant has UAN (Urea-Ammonia-Nitrate) tanks that have experienced
cracking in the vertical welds. Nitrate embrittlement combined with improper welding practice is
suspected as being the cause of the Stress Corrosion Cracking, or SCC. The cracks run horizontally,
originating in the vertical welds and extending up to a few inches in length. Some have traversed out
past the heat-affected zone.

Various patches of worm holing have been observed on the floor of the tank, as well as
general wall loss on the floor. The foundation appears to have settled, thereby allowing the floor
plates for flex up and down. Several inches of displacement can be observed in some locations. The
floor plates all settle into location when the tank is put back into operation and filled.

Work Completed
1. Vertical weld patches, interior
Citadel Technologies applied a tapered 3-ply repair over each of the cracking vertical welds.
This repair tapered from 3 plies directly over the weld, down to 2 plies and out to 1 ply. This would
protect a width of up to 16 inches on each side of the weld, for a total repair width of 32 inches. The
goal of these repairs was to isolate the welds from the corrosion mechanism (UAN), and reinforce the
repaired area. The reinforcement from the DiamondWrap is expected to decrease the stress
concentrations found in the crack, and assist in crack arrest.

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6430 S. 39 W. Ave.
Tulsa, OK 74132
Ph: 918-584-2220
Fax: 918-584-2221
www.cittech.com

2. Vertical weld patches, exterior
A 4-ply tapered repair over each of the through-wall cracked welds was installed for the
external cracks on the West UAN tank. These repairs will not isolate the welds from the corrosion
mechanism. The layup would be similar to the 3-ply repairs proposed for the inside of the tank, with
the addition of an extra layer over the center. These repairs are not expected to stop the crack
propagation. The welds will still be in contact with the UAN. Also, the carbon fiber will distribute less
of the loading being applied to the outside of the tank. However, the DiamondWrap is still expected
to contain the UAN as a nand aid-type patch. This will be a suitable short-term solution to contain the
UAN in the tank until it can be taken out of service for an internal repair.

3. Floor patch
A 2-ply DiamondWrap repair was installed for the general underside corrosion
experienced on the floor of the tank. The floor test patch was a 50% overlap, 1-pass repair, covering
an area of 20x50.

4. Chime weld
A 10 long section of chime weld was installed with 2 plies of DiamondWrap. The section
chosen had a steel plate welded on to support the failing floor. Significant worm-hole corrosion was
present in this area. This repair was installed with repair extending about 2 up the sidewall and 2
into the tank on the floor.