Insulation Tank Chime Spacer’s Inject VCI and Leakage Corrosion Monitoring and Control System

This integrated system is specifically designed for storage tank chimes (the critical joint where the tank bottom meets the shell wall) to provide continuous physical support, prevent water accumulation, distribute volatile corrosion inhibitors (VCIs), and actively monitor for chemical leakage and corrosion rates.

The system utilizes specialized segments configured in a ring array along the tank chime, combining chemical protection with real-time electronic diagnostics.

1. Mechanical Support & Fluid Management

• Chime Spacer Blocks (Orange Modules): Structured segments configured into a ring array. The top surface features a wavy profile to provide weight distribution and ventilation, while the internal channels isolate the pipes and sheets.
• Stainless Collect Drainage Sheet: A curved metallic channel nested under the piping to catch condensation or fluid ingress, routing it safely to the drainage tube to prevent water trapping at the chime joint.
• Inject VCI Perforated PTFE Tube: A micro-porous/perforated polytetrafluoroethylene (Teflon) pipe running through the core of the spacer blocks. It allows the controlled injection and slow, uniform evaporation of Volatile Corrosion Inhibitors (VCIs) to chemically protect the steel from oxidation.

2. Embedded Electronic Sensors

According to the technical drawing, each spacer block has predefined pathways to host two distinct sensor elements:

• Leak Detect Wire: Embedded within the upper V-shaped drainage channel. It utilizes a continuous sensing rope (as shown in the yellow braided cable image) to immediately detect the presence of leaking fluids or moisture across the entire circumference.
• Corrosion Rate Sensor Wire: Positioned in the lower groove to host localized probes or continuous linear sensors for tracking real-time material degradation.

3. Data Acquisition & Wireless Telemetry

The physical sensors connect directly to an intelligent hardware node consisting of:

• Flexible Corrosion Sensors (ASTM G96 aligned): Thin, polyimide (PI) or silicone-backed flexible circuits featuring a serpentine copper/metal grid element. One side is protected by an organic coating or tape to mimic tank coating performance or act as a control baseline.
• WIFI / Wireless Data Model: A dedicated printed circuit board (PCB) equipped with an onboard wireless microprocessor and antenna to broadcast real-time leakage, sensor impedance, and corrosion metrics to a central control room.
• Power Module: Integrated system power supply supporting long-term field deployment.

⚙️ Working Principle & Control Mechanism

[Fluid Ingress / Leak] ──> [Drainage Channel & Sheet] ──> [Leak Detect Cable Triggers] ──> [Wireless Alarm]
                                                                                               │
[Corrosion Risk Detected] ◄── [VCI Vapor Protective Layer] ◄── [Inject VCI Perforated PTFE] ◄───┘

1. Passive Mitigation: The spacer blocks lift the tank structure away from stagnant moisture, while the stainless drainage sheet channels external water away.
2. Active Chemical Protection: VCIs are pumped into the perforated PTFE tube. The inhibitor vaporizes, escapes through the micro-perforations, and forms a molecular protective layer on the surrounding carbon steel tank chime.
3. Early-Warning Monitoring: If the tank contents leak or moisture breaks through, the Leak Detect Wire immediately registers a change in electrical impedance. Concurrently, the Flexible Corrosion Sensors track structural degradation rates according to ASTM G96 standards.
4. Edge Telemetry: The system transmits data wirelessly, allowing operators to adjust VCI injection frequencies or schedule targeted maintenance before catastrophic failure occurs.