Coating and Lining Failure in Tanks: Root Causes and Corrective Actions
| 23 – 27 Mar. 2026, Cairo | 20 – 24 July 2026, Abu Dhabi |
COURSE OVERVIEW:
The structural integrity of industrial storage tanks is heavily dependent on the performance of internal linings and external coatings, which serve as the primary barrier against aggressive chemical environments. This course provides an in-depth technical analysis of why these barrier systems fail, moving beyond surface-level observations to identify the underlying electrochemical and mechanical triggers. Participants will examine the complex relationship between substrate preparation, coating formulation, and the operational stressors that lead to premature degradation and catastrophic containment loss.
The scope of this training encompasses a wide array of failure modes specifically encountered in tank environments, including osmotic blistering, cathodic disbondment, and chemical permeation. By investigating the root causes—ranging from improper environmental conditions during application to latent defects in the coating material—attendees will learn to differentiate between application-related errors and service-induced failures. The curriculum emphasizes the physics of adhesion and the impact of internal tank temperatures and pressure fluctuations on lining longevity.
Coverage includes a structured approach to forensic investigation and the development of robust corrective action plans. Participants will be guided through the selection of repair methodologies, from localized spot repairs to full system replacement, ensuring that chosen solutions are compatible with existing materials and future service requirements. Through detailed case studies and technical evaluations, this course equips professionals with the expertise to minimize downtime and extend the lifecycle of critical storage assets through effective failure analysis and remediation.
COURSE OBJECTIVES:
After completion of this course, the participants will be able to:
- Identify and categorize common and complex coating and lining failure modes in petroleum and chemical storage tanks.
- Execute a systematic root cause analysis (RCA) to determine the primary drivers of coating degradation.
- Evaluate the impact of surface profile and non-visible contaminants, such as chlorides and sulfates, on lining adhesion.
- Analyze the role of environmental conditions, including dew point and relative humidity, during the failure-prone application phase.
- Distinguish between osmotic and non-osmotic blistering mechanisms within immersion service environments.
- Assess the effects of "cold wall" phenomena and temperature gradients on the permeability of internal linings.
- Utilize specialized forensic tools, such as Tooke gauges, holiday detectors, and analytical spectroscopy, for failure investigation.
- Develop detailed repair specifications that address both the symptoms and the root causes of the identified failure.
- Determine the compatibility of various generic coating types when performing maintenance and overcoating operations.
- Calculate the economic impact of lining failures versus the cost of high-performance material upgrades.
- Implement quality assurance and quality control (QA/QC) protocols to prevent the recurrence of identified failure modes.
- Prepare comprehensive technical reports for stakeholders detailing findings, risks, and justified corrective actions.
TARGET AUDIENCE:
This course is designed for tank integrity engineers, coating inspectors, maintenance managers, facility owners, and technical specialists involved in the specification, application, and inspection of protective systems for storage tanks.
TRAINING COURSE METHODOLOGY:
A highly interactive combination of lectures, discussion sessions, and case studies will be employed to maximize the transfer of information, knowledge, and experience. The course will be intensive, practical, and highly interactive. The sessions will start by raising the most relevant questions and motivating everybody to find the right answers. The attendants will also be encouraged to raise more of their questions and to share in developing the right answers using their analysis and experience. There will also be some indoor experiential activities to enhance the learning experience. Course material will be provided in PowerPoint, with necessary animations, learning videos, and general discussions.
The course participants shall be evaluated before, during, and at the end of the course.
COURSE CERTIFICATE:
The National Consultant Centre for Training LLC (NCC) will issue an Attendance Certificate to all participants who complete a minimum of 80% of the total attendance time requirement.
