S A M P L E R E... THE PROVISION OF IN SERVICE ABOVE GROUND TANK
SAMPLE REPORT THE PROVISION OF IN SERVICE ABOVE GROUND TANK INSPECTION USING PHONON DIAGNOSTIC METHOD SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) CONTENTS 1. REPORT SUMMARY.....………………………………………………..... 3 2. TANK PHONON DIAGNOSTICS…………..…………………………… 3 2.1. Basic data of the tank…………….…………………………………… 3 2.2. Analysis of tank operation data……………………………………… 7 2.3. Diagram of tank phonon diagnostic ………………………….……… 8 2.4. Developing phonon calibration – drawings of the tank……...……… 9 2.5. Phonon monitoring of tank………………………………………...… 10 2.6. Analysis of phonon diagnostics results……………………………… 11 2.7. Calculation of tank remaining life with due account of phonon diagnostics data………………..……………………………………… 15 2.8. Diagnostic of thickness…………..…………………………………… 17 2.9. Thermal phonon diagnostic……...…………………………………… 19 2.10. Stressed state diagnostic………...…………………………………… 20 3. TANK GEOMETRY DIAGNOSTICS…………………………………… 21 3.1. Geometry diagnostics scheme………………………………………… 21 3.2. Bottom settlement evaluation…………………………………………. 21 3.3. Calculation of deviations from tank bottom plane…………………… 24 3.4. Shell plumbness evaluation……...…………………………………… 26 3.5. Shell ovality evaluation………………..……………………………… 27 4. TABLE OF TANK DEFECTS……………………………………………. 28 5. EVALUATION OF DEFECTS IN ACCORDANCE WITH FFS REQUIREMENTS………………………………………………...……… 6. EVALUATION OF TANK REMAINING LIFE………………………… 29 30 7. CONCLUSION ON TECHNICAL STATE OF THE TANK.…………… 31 8. RECOMMENDATIONS ON FURTHER OPERATION AND REPAIR…………………………………………………………………… 32 2 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 1. REPORT SUMMARY The technical report on the tank contains the following: - Diagrams and results of phonon diagnostics of the technical condition of the tanks, defects, thicknesses, stressed state and remaining life of the tanks; - Tank geometry diagnostics results; - Table of defects and their classification; - Defect assessment in accordance with the requirements of FITNESSFOR-SERVICE (FFS); - Evaluation of remaining life in accordance with the FFS requirements; - Conclusion on tank technical state; - Recommendation on further tank operation. 2. TANK PHONON DIAGNOSTICS 2.1. Basic Data of the Tank 2.1.1. The tank has been constructed according to the standard API 620, 9th edition, Annex 2. The basic data of the tank is determined proceeding from the analysis of the drawings, operational data and from polling the operating personnel. On the basis of this data there have been developed tables of tank parameters (Tables 2.1-2.6), 2D data (Fig. 2.2), 3D computer construction for further calculations and visualization of phonon diagnostics data. Table 2.1 TANK PREHISTORY Number Location Serial number Date of construction Operating life Purpose Product Operating mode Breakdowns Repairs Previous inspections 3 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Fig. 2.1. General view of the tank Table 2.2 NOMINAL DIMENSIONS AND TANK DATA 3 Nominal volume, m Inner diameter (ID), mm Outer diameter (OD), mm Shell height, mm Height of ring , mm Design pressure, bar Design temperature, °C Corrosion allowance, mm Specific weight Filling level for hydrotesting, mm Maximum filling level, mm Normal filling level, mm External insulation Inner insulation 4 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Table 2.3 SHELL AND ROOF NOZZLES Elements Shell Roof Nozzle name Designation Temperature connection Manhole w/davit Manhole w/davit Level connection Foam chamber connection Drain w/dip pipe to sump Spare w/blind fl. Pump return w/mixing jet Liquid outlet Liquid inlet w/diffuser Overflow Level connection Center vent Circulating vent Circulating vent Circulating vent Circulating vent Circulating vent Circulating vent Circulating vent Manhole w/davit Orientation, degrees T M3 M1 L1 F E D C B A X L2 W V1 V2 V3 V4 V5 V6 V7 M2 115 315 315 170 60 100 15 90 0 225 170 0 270 315 0 45 90 180 225 135 Outside diameter, mm (in.) Shell thickness, mm 48.26(1 1/2) 609.6(24) 609.6(24) 48.261 1/2 114.3(4) 60.3(2) 141.3(6) 141.3(6) 141.3(6) 88.9(3) 141.3(6) 48.26(1 1/2) 323.8(12) 323.8(12) 323.8(12) 323.8(12) 323.8(12) 323.8(12) 323.8(12) 323.8(12) 609.6(24) 5.08 9.52 9.52 5.08 8.56 5.53 8.56 8.56 8.56 7.62 8.56 5.08 9.52 9.52 9.52 9.52 9.52 9.52 9.52 9.52 9.52 Table 2.4 MATERIALS AND THICKNESSES OF PLATES Component Number of plates, pcs. Course 1 Course 2 Course 3 Course 4 Course 5 Course 6 Course 7 Course 8 Course 9 Bottom Roof Material Thickness, mm 7.9 4 JIS G 3101 SS400 6.5 10 19 5.5 7.9 Table 2.5 MATERIAL DATA Part Material Yield point Y, MPa Break point T, MPa Maximum allowable stresses of courses 1 and 2/next courses S, MPa Efficiency factor Shell, bottom, roof JIS G 3101 SS400 245 400 172/189 1 5 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Table 2.6 CHEMICAL COMPOSITION OF WORKING MEDIUM No. 1 2 Medium N-Butanol Water Composition, % Specific weight Corrosiveness 99.925 0.03 0.8 low Roof Shell development Bottom Scheme – exploded view of tank with conventional symbols 6 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 2.2. Analysis of Tank Operation Data Legend product level 85% from working level average cycles Level, % Working level average Time, days Fig. 2.2. Histogram of tank loads and cycles After considering the results of operating modes analysis (in accordance with API 579-1/ASME FSS-1 2007 (FFS), Annex B1, B1.5.2, Table B1.8) it was established, that complete cycles N FT = 60, and incomplete cycles (by 15 % less than complete ones) N PO = 3. In accordance with the results of cyclic recurrence analysis the total number of cycles amounted to N FT+ N PO = 63. Thus, the tank operates in the cyclic mode. As for the date of this diagnosis it has run 400 cycles and does not need calculation for material fatigue. 7 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 2.3. Diagram of Tank Phonon Diagnostics 2.3.1 The tank phonon diagnostics has been carried out using eightchannel circuit diagram of phonon sensors (PFE) forming six groups. PFE fixation on the construction was performed by special-purpose magnetic holders. The diagram of phonon diagnostics is presented on Fig. 2.3. 2.3.1.1. The first group was installed in the area of the bottom and consisted of PFE No. 1 at 0, No. 2 at 90, No. 3 at 180, No. 4 at 270. 2.3.1.1.1. The second group was installed in the area of the roof and consisted of PFE No. 5 at 0, No. 6 at 90, No. 7 at 180, No. 8 at 270. 2.3.1.1.2. The third group diagnoses a quarter of the shell from 0– 90and consists of PFE No. 1 at 0, No. 4 at 90in the area of the bottom and No. 5 at 0, No. 8 at 90in the area of the roof. 2.3.1.1.3. The fourth group diagnoses a quarter of the shell from 90– 180and consists of PFE No. 4 at 90, No. 2 at 180in the area of the bottom and No. 8 at 90, No. 6 at 180in the area of the roof. 2.3.1.1.4. The fifth group diagnoses a quarter of the shell from 180– 270and consists of PFE No. 2 at 180, No. 3 at 270in the area of the bottom and No. 6 at 180, No. 7 at 270in the area of the roof. 2.3.1.1.5. The sixth group diagnoses a quarter of the shell from 270– 0and consists of PFE No. 3 at 270, No. 1 at 0in the area of the bottom and No. 7 at 270, No. 5 at 0in the area of the roof. 2.3.2 For phonon diagnostics there was used one system of phonon diagnostics (SFD) “PHONON-8K”. The system has eight data registration channels, is delivered with “FDT-8” software package for phonon diagnostics data analysis and is of explosion-proof version. In the area of the tank there was arranged the phonon diagnostics station equipped with a table for SFD installation, 8 cable routes of 100 m length for connection of 8 PFE, electrical cable 220 V equipped with industrial systems for hooking up, canvas for rain protection. 8 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) phonon emission sensors channel number cable routes phonon diagnostics station Fig. 2.3. Diagram of phonon diagnostics for the tank 2.4. Developing Phonon Calibrations – Drawings of the Tank 2.4.1. Phonon calibrations–drawings are precise developments of diagnosed tank components, including welds of plates, nozzles, manholes. Separately calibrated are the bottom, roof, and tank shell. The shell is divided into four sections of 90 degrees in a clockwise direction. The results of phonon calibrations are presented on Fig. 2.4. 9 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Channel Channel Results of phonon calibration for tank roof R622.CLB Results of phonon calibration for tank bottom B-622.CLB Channel Channel Results of phonon calibration for tank shell 0-90 S1-622.CLB Results of phonon calibration for tank shell 90-180 S2-622.CLB Channel Channel Results of phonon calibration for tank shell 180-270 S3-622.CLB Results of phonon calibration for tank shell 270-0 S4-622.CLB Fig. 2.4 Phonon calibration results 2.5. Phonon Monitoring of Tank 2.5.1. Phonon monitoring of all tank components was carried out simultaneously in real time, by recording data on a hard disk. The results and duration of phonon monitoring are presented in Table 2.7. 10 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Table 2.7 RESULTS AND DURATION OF PHONON MONITORING Mode Phonon diagnostics results file 1 bottom B-622.CLB B-622.RES 2 Shell 0-90 S1-622.CLB S1-622.RES 3 Shell 90-180 4 Shell 180-270 S3-622.CLB S3-622.RES 5 Shell 270-360 S4-622.CLB S4-622.RES 6 Roof R-622.CLB R-622.RES 26.04.09 Duration Phonon diagnostics data file Component Plane Data Phonon calibration file # 11 hr 7 min S2-622.CLB Test262.dta S2-622.RES 2.5.2. In the course of phonon calibration, phonon energy emission (radiation) areas – phonon active areas (FAA) are plotted in real time by the means of software on phonon calibrations – drawings in the places of their origination. Active areas of phonon emission correspond to such defects as general and local metal loss, pitting corrosion, crack-like defects, laminations, etc. By the location of these areas on phonon calibration – drawing it is possible to localize spatially and fix the places of defect formation. 2.6. Analysis of Phonon Diagnostics Results 2.6.1. The results of phonon diagnostics are presented in Table 2.8. The development of the tank with the results of phonon diagnostics is presented on Fig. 2.5. 2.6.2. The coordinates of the Defect on the tank shell are specified relative to the nearest weld crossing. Defect coordinates for the roof and bottom are specified relative to the center. 11 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Table 2.8 MAPS AND TABLES OF PHONON DIAGNOSTICS RESULTS Maps of phonon diagnostics Defect table Map and table of phonon diagnostics results for the bottom Defect FAA number number Number of acts FAA energy concentra tion Activity coeff, KFFA FAA hazard level Defect type FAA area mm2 Channel FAA coordinates, mm X Y D9d 1 0.3 98 1.59 ND Local metal 113205 loss -153 117 D10d 2 0.2 184 1.93 ND Local metal 113105 loss 376 108 D11d 3 0.6 115 1.61 ND Local metal 113205 loss 407 196 Graph of energy distribution in FAA Map and table of phonon diagnostics results for the roof FAA Defect numbe r number D8k Number of acts 1 0.6 FAA energy concentra tion 102 Activity coeff, KFFA 1.25 FAA hazard level ND Defect type FAA area mm2 Local metal 174114 loss FAA coordinates, mm X Y 73 31 Graph of energy distribution in FAA Channel Map and table of phonon diagnostics results for the shell 0-90 FAA Defect numbe number r D4s 1 Number of acts 0.1 Channel 12 FAA energy concentra tion 64 Activity coeff, KFFA FAA hazard level 0.77 ND Defect type FAA area mm2 FAA coordinates, mm X Local metal 235451 -2111 loss Y 463 Graph of energy distribution in FAA SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Maps of phonon diagnostics Defect table Map and table of phonon diagnostics results for the shell 90-180 FAA Defect numbe number r D5s 1 Number of acts 0.2 FAA energy concentra tion 53 Activity coeff, KFFA FAA hazard level 0.82 ND Defect type Local metal loss FAA coordinates, mm FAA area mm2 X 548221 Graph of energy distribution in FAA Y 1842 553 Channel Map and table of phonon diagnostics results for the shell 180-270 FAA energy concentra tion Activity coeff, KFFA FAA hazard level 1.1 312 2.98 ND Internal defect 2 1 99 2.74 ND 3 0.2 401 1.32 ND FAA Defect numbe number r Number of acts D1s 1 D2s D1s Defect type FAA coordinates, mm FAA area mm2 X Y 0.4 -186 0 Internal defect 0.24 0 343 Local metal loss 548222 -2073 588 Graph of energy distribution in FAA Channel Map and table of phonon diagnostics results for the shell 270-0 Defect number FAA numbe r Number of acts FAA energy concentr ation Activity coeff, KFFA FAA hazard level Defect type Internal defect D3s 1 0.9 799 2.61 ND D7s 2 0.5 2064 1.55 ND Channel 13 FAA area mm2 0.4 Local metal 235451 loss FAA coordinates, mm X Y -2623 0 -2270 722 Graph of energy distribution in FAA SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) shell development diagram roof shell development course 9 course 8 course 7 course 6 course 5 course 4 course 3 course 2 course 1 LEGEND - bottom weld number - roof weld number - vertical weld number - circular weld number - defect number bottom Fig. 2.7. Results of tank phonon diagnostics 14 - defect SCALE SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Table 2.8 SUMMARY TABLE OF DEFECTS ACCORDING TO THE RESULTS OF TANK PHONON DIAGNOSTICS Tank Section name Section element Course 1 shell Defect ratio, KFFA Defect dimensional specifications, mm mm Scaling factor kT coeff, T К FFA X Y Width, c Area m2 Dfect type Hazard level Length, s Depth, d Weld C1 D1s 2,99 0,11 3,09 -186 0 0.5 0.8 0.8 0.4*10-7 Weld defect unhazardous Weld L1-3 D2s 2,75 0,11 2,85 0 343 0.4 0.6 0.7 2.4*10-7 Weld defect unhazardous Weld C1 D3s 2,61 0,11 2,72 -2623 0 0.5 0.8 0.7 0.4*10-7 Weld defect unhazardous Plate P 1-5 D4s 0,77 0,11 0,88 -2151 463 620 495 0.2 0.235 Local metal loss unhazardous Plate P 1-5 D5s 0,83 0,11 0,93 -1842 553 1450 487 0.2 0.548 Local metal loss unhazardous Plate P 1-5 D6s 1,33 0,11 1,43 -2073 588 1400 518 0.3 0.548 Local metal loss unhazardous Plate P 1-5 D7s 1,55 0,11 1,66 -2270 722 609 485 0.4 0.235 Local metal loss unhazardous D8k 1,26 0,11 1,36 31 539 428 0.3 0.174 Local metal loss unhazardous D9d 1,59 0,11 1,70 -153 117 436 345 0.4 0.113 Local metal loss unhazardous D10d 1,93 0,11 2,04 376 108 436 345 0.5 0.113 Local metal loss unhazardous D11d 1,61 0,11 1,72 407 196 436 345 0.4 0.113 Local metal loss unhazardous Course 5 Roof Bottom Plate P8-R Plate P6-B 73 2.7. Calculation of Tank Remaining Life with Due Account of Phonon Diagnostics Data 2.7.1. Tank remaining life with due account of the data of phonon diagnostics is estimated for each defect and calculated according to the formula: i (P n P ) r (t ФД 2 u min h Д ) R y c T ФД T h Д K FFA h ФД – defect depth according to phonon diagnostics data; T K FFA – defect activity coefficient, with account for equipment operating life; T – period of service; Pu – excess pressure in the space under the tank roof; 15 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) r – radius of tank shell course median surface (since the thickness of tank shell is negligible in comparison to the radius, for calculation one takes tank outer radius), c – service factor: for the condition of product storage c=0,7 for course 1 and c=0,8 for other courses; Ry – design material strength according to yield point; P – hydrostatic pressure at the level of defect location; t imin – minimal shell thickness according to diagnostics data; 2.7.2. The results of remaining life calculation are presented in Table 2.10. Table 2.10 RESULTS OF REMAINING LIFE CALCULATION FOR TANK WITH ACCOUNT FOR PHONON DIAGNOSTICS DATA Coordinate, mm Defect number Activity coefficient, T К FFA X Y Defect depth z, distance from the bottom to the level of defect location, m P, hydrostatic pressure, kgf/mm2 Remaining life, years D1s 2.99 -186 0 0.8 0 0.0097 11.1 D2s 2.75 0 343 0.7 1.843 0.0083 14.2 D3s 2.61 -2623 0 0.7 0 0.0097 14.9 D4s 0.77 -2151 463 0.2 7.963 0.0034 161.1 D5s 0.83 -1842 553 0.2 8.053 0.0033 152.4 D6s 1.33 -2073 588 0.3 8.088 0.0033 64.0 D7s 1.55 -2270 722 0.4 8.222 0.0032 40.0 D8k 1.26 73 31 0.3 12.869 0 45.2 D9d 1.59 -153 117 0.4 0 0.0097 47.0 D10d 1.93 376 108 0.5 0 0.0097 30.4 D11d 1.61 407 196 0.4 0 0.0097 46.4 2.7.3. According to the data of calculation the remaining life of the tank with due account of phonon diagnostics data is 11 years. 16 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 2.8. Diagnostics of thickness 2.8.1. Thickness map according to diagnostics results roof cross-section along minimal thicknesses of the roof shell development cross-section along minimal thicknesses of the shell course 9 course 8 course 7 course 6 course 5 course 4 course 3 course 2 course 1 thickness color scale, mm bottom cross-section along minimal thicknesses of the bottom Legend - thickness, mm - tank element minimal thickness Scale Fig. 2.8. Tank thickness map 17 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 2.8.2. Corrosive wear map of the tank roof Maximum corrosive wear of the roof 3,64% shell development Maximum 0°corrosive wear, % course 9 course 8 course 7 course 6 Maximum corrosive wear of the shell 4,62% course 5 course 4 course 3 course 2 course 1 bottom Maximum corrosive wear of the bottom 5,06% Legend 5,0 - corrosive wear, % 7,0 - maximum corrosive wear of tank element Scale Fig. 2.9. Corrosive wear map 18 corrosive wear scale SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 2.8.3. Thickness diagnostics results Table 2.10 GENERAL METALL LOSS EVALUATION RESULTS Tank component tmin, tam, COV, % FCA, mm t am - FCA Level 1 criteria tam - FCA ≥ tmin Bottom Shell course 1 Shell course 2 Shell course 3 Shell course 4 Shell course 5 Shell course 6 Shell course 7 Shell course 8 Shell course 9 Roof 2.84 2.84 2.50 2.50 2.50 2.50 2.50 2.50 2.50 2.50 2.50 7.95 7.85 7.85 6.65 6.65 6.65 6.65 6.65 6.65 6.76 5.65 0.50 0.43 0.41 0.48 0.48 0.66 0.48 0.48 0.48 0.93 0.62 1.5875 1.5875 1.5875 1.5875 1.5875 1.5875 1.5875 1.5875 1.5875 1.5875 1.5875 6.36 6.27 6.27 5.07 5.07 5.06 5.07 5.07 5.07 5.18 4.06 True True True True True True True True True True True The results of total corrosive wear evaluation for tank elements in accordance with Fitness - For - Service meets the criteria of FFS Part 4 Level 1. Coefficient of variation is less than 10% and does not exceed 0,9 %. 2.9. Thermal Phonon Diagnostics Shell top Liquid level Foundation Fig. 2.10. Tank shell temperature distribution map at the moment of performing diagnostics Temperature Density, % Liquid level Shell height, m Liquid Temperature, °C Fig. 2.11. Tank shell temperature distribution diagram Fig. 2.12. Tank shell temperature density distribution diagram 19 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 2.9.1. As per the Results of Thermal Phonon Diagnostics Operating temperature conditions of tank operation = 27÷30 ºC Maximum tank shell temperature density in the area of filling = 28 ºC Maximum tank shell temperature density in the remaining part of the tank = 29,5 ºC Product level at the moment of performing diagnostics = 9,9 m 2.10. Stressed state diagnostics zone 1 weld P1-1/P2-1 zone 2 weld P3-1/P4-1 Fig. 2.13. Scheme of stressed state diagnostics Table 2.11 STRESSED STATE DIAGNOSTICS RESULTS # Place of diagnostics Zone 1 – Weld P1-1/P2-1 Zone 2 – Weld P3-1/P4-1 Scale Map of stressed state Map of stress concentrators result Unsafe stresses not found Unsafe stresses not found 2.10.1. Stress State Diagnostics Results According to the results of stressed state diagnostics unsafe stresses were not found. 20 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 3. TANK GEOMETRY DIAGNOSTICS 3.1. Geometry Diagnostics Scheme Measurements of settlement, plumbness, ovality were carried out in the process of tank operation. The tank was filled to the level of 80%. The scheme for geometry diagnostics is presented on Fig. 3.14. Settlement measurements were performed at the points H1 – H12 in 30° steps, clockwise, total of 12 points. Measurements of plumbness, ovality were performed at the points V1 – V48, total of 48 points. - points of settlement measurement - points of plumbness and ovality measurement - horizontal generating line and distance from the bottom Fig. 3.14. Geometry diagnostics scheme 3.2. Bottom Settlement Evaluation Evaluation of bottom settlement was carried out in accordance with API Std 653, Annex B. The graph of results is presented on Fig. 3.15. The graph of data measured along the whole perimeter of the tank is represented by brown line, approximation curve – by blue line. Approximation with certainty R2=0.92 was carried out using polynomial method according to the formula y = 2,32E-15x4-1.37E-10x3+2.52E-06x2-0.01335+7028.234. 21 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 22 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 23 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Depth, mm Maximum inclination of the bottom LEGEND Measured points of bottom settlement Optimal polynomial curve Minimal inclination of the bottom Tank circumference, mm (deg) Fig. 3.15. Graph of tank bottom settlement (inclination) The tank bottom is inclined within the limits of design requirements. Inclination orientation from 60 (upper point) to 240 (lower point). Maximum bottom inclination according to the results of measurements is 47 mm at 240. 3.2.1. Bottom Settlement Evaluation Results Tank bottom settlement was not found. Sloping bottom of the tank corresponds to the design. 3.3. Calculation of Deviations from Tank Bottom Plane Depth, mm On the graph of Fig. 3.16, there are found deviations from the plane of tank bottom inclination. Legend deviation from bottom inclination plane above polynomial curve deviation from bottom inclination plane below polynomial curve Tank circumference, mm (deg) Fig. 3.16. Graph of deviations from bottom plane 24 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) To determine admissibility of inclination nonuniformity one performed calculations according to API 653 (4_EDITION), B.2.2.5. Table 3.12 CALCULATIONS OF DEVIATIONS FROM TANK BOTTOM PLANE # Distance along the perimeter, mm 1 2 3 4 5 6 7 8 9 10 11 12 13 1,00 2080,26 4160,52 6240,77 8321,03 10401,29 12481,55 14561,81 16642,06 18722,32 20802,58 22882,84 24963,10 Degrees along the perimeter, deg Measured values of inclination, mm Calculated values of inclination, mm 0 22 21 30 6 3 60 0 0 90 2 6 120 23 17 150 32 28 180 35 37 210 41 42 240 47 42 270 39 39 300 28 33 330 36 27 360 22 21 Maximum deviation from tank bottom plane- S max Maximum allowable deviation - S a Deviation from the plane S, mm U, mm -0,22 1,82 -1,16 -5,31 5,18 3,09 -2,87 -1,98 3,38 -1,17 -6,07 8,20 -0,22 -6,98 2,51 0,59 -7,32 6,29 1,93 -3,42 -2,24 4,96 0,18 -9,59 12,67 -6,98 12,67 mm 31 mm 3.3.1 Calculation Results for Deviations from the Plane Measured maximum deviation from tank bottom plane is 12,67 mm which is less than the allowable value of 31 mm. 3.4 Shell Plumbness Evaluation Measurement of shell deviations from the vertical plane has been performed on 12 vertical generating lines in 30° steps along the perimeter of tank clockwise. The results of measurements are presented on graphs in Fig. 3.17. Maximum allowable deviation from tank shell in the upper point is 128 mm. Roof Roof point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Bottom Roof point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Bottom point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Bottom Out-of-plumbness, mm Out-of-plumbness, mm Out-of-plumbness, mm Out-of-plumbness on generating line 0 Out-of-plumbness on generating line 30 Out-of-plumbness on generating line 60 25 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Roof Roof point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Roof point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Bottom point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Bottom Bottom Out-of-plumbness, mm Out-of-plumbness, mm Out-of-plumbness, mm Out-of-plumbness on generating line 90 Out-of-plumbness on generating line 120 Out-of-plumbness on generating line 150 Roof Roof point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Roof point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Bottom point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Bottom Bottom Out-of-plumbness, mm Out-of-plumbness, mm Out-of-plumbness, mm Out-of-plumbness on generating line 180 Out-of-plumbness on generating line 210 Out-of-plumbness on generating line 240 Roof Roof point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Roof point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Bottom point-by-point measurements Ideal vertical (-) – inward tank (+) – outward tank Bottom Bottom Out-of-plumbness, mm Out-of-plumbness, mm Out-of-plumbness, mm Out-of-plumbness on generating line 270 Out-of-plumbness on generating line 300 Out-of-plumbness on generating line 330 Fig. 3.17. Graphs of tank shell out-of-plumbness 26 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 3.4.1 Shell Plumbness Evaluation Results Maximum measured tank shell deviation is 10 mm inward of the tank, 6 mm outward of the tank and does not exceed maximum allowable value in the upper point which is equal to 128 mm. 3.5 Shell Ovality Evaluation Radius, mm Measurement of shell ovality has been performed by measuring tank radii on 4 horizontal generating lines 0 m, 4290 mm, 8580 mm, 12860 mm. There have been performed 12 measurements on each generating line in 30° steps along the tank perimeter in a clockwise manner. The results of measurements are presented on the graph of Fig. 3.18. Legend Horizontal generating line #1 – 12860 mm Horizontal generating line #2 – 8580 mm Horizontal generating line #3 – 4290 mm Horizontal generating line #4 – 0 mm Ideal generating line of tank shell Fig. 3.18. Graph of tank ovality According to the graph the determined total ovality with maximum diameter (Dmax) is equal to 8000 mm in the direction 60- 240, minimal diameter (Dmin) is equal to 7955 in the direction 150-330. The directional ovality agrees with bottom inclination. Table 3.13 CALCULATION OF DEVIATIONS FROM OVALITY DIAMETER 60- 240 # of generating line Radius 60, mm Radius 240, mm Mean radius, mm Diameter, mm Deviation 60 Deviation 240 1 2 3 4 4010 4011 4002 4005 3990 3987 3987 3989 3988 3989 3990 3991 8000 7998 7989 7994 22 22 12 14 2 -2 -3 -2 Table 3.14 CALCULATION OF DEVIATIONS FROM OVALITY DIAMETER 150- 330 # of generating line Radius 60, mm Radius 240, mm Mean radius, mm Diameter, mm Deviation 60 Deviation 240 1 2 3 4 3975 3979 3980 3982 3980 3980 3981 3984 3988 3989 3990 3991 7955 7959 7961 7966 -13 -10 -10 -9 -8 -9 -9 -7 27 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) Total ovality per radius from the side 60 is 22 mm. Maximum admissible ovality per radius for the tank of diameter less than 12 m is Tolmax=13 мм (FFS, Part 8, Table 8.7). Evaluation of tank ovality has been performed in accordance with FSS, Part 8, p. 8.4.3.3, level 2. Table 3.15 EVALUATION OF TANK OVALITY LEVEL 2 Dmax, mm 7955 Dmin, mm 8000 Dm, m m 7977 P, MPa 0.125 t c, mm 7.85 Sa, MPa 160 Rorb = 0.02 m, MPa 6.33 Hf Cs 1.5 0.5 0.28 Ey, MPa 210000 RSF = 1 Rb = 0.02 Rbs = -1 RSFa=0.9 Condition RSF>RSFa met. Ovality is acceptable according to retained strength condition. 3.5.1 Shell Ovality Estimation Results Ovality is admissible for further operation and does not cause hazardous secondary (additional) stresses, but may have an impact on operation of internal floating roof. 4. TABLE OF TANK DEFECTS Table 4.16 TABEL OF TANK DEFECTS ACCORDING TO PHONON DIAGNOSTICS RESULTS 28 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 4.2. Defect Analysis and Classification Results 4.2.1. According to the results of phonon diagnostics there have been detected 11 defects: 4.2.1.1. 8 defects of corrosive origin. Defects were formed in the process of tank operation. Corrosive defects were classified according to FFS part 5 as local metal loss. 4.2.1.2. 3 defects of welds. Defects were formed before operation. Welding defects were classified according to FFS part 9 as crack-like defects. 5. EVALUATION OF DEFECTS IN ACCORDANCE WITH FFS REQUIREMENTS Table 5.17 620 1450 1400 609 539 436 436 436 0.20 0.20 0.30 0.40 0.30 0.40 0.50 0.40 tmin, tc, mm mm LTA tmm, mm Rt s LOSS, mm Lmsd, mm 189 189 189 189 189 189 189 189 2.50 2.50 2.50 2.50 2.50 2.50 2.50 2.50 6.40 6.40 6.30 6.20 5.30 7.60 7.50 7.60 0.96 0.96 0.94 0.92 0.93 0.94 0.92 0.94 3.19 3.14 3.34 3.13 3.08 1.97 1.97 1.97 0.10 0.10 0.10 0.10 0.10 0.00 0.00 0.00 463.00 553.00 588.00 722.00 10.00 457.00 293.00 365.00 5.01 5.01 5.01 5.01 4.01 6.41 6.41 6.41 Lmsd1.8 (Dt c 495 487 518 485 428 345 345 345 S, MPa tmm-FCA2 Limiting crteria Rt0. 2 depth, d D4s D5s D6s D7s D8s D9d D10d D11d width, c 1 2 3 4 5 6 7 8 Dimensional characteristics, mm length, s No. Defect number EVALUATION OF LOCAL METAL LOSS LEVEL 1 TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE TRUE FALSE TRUE FALSE FALSE RSF MFH MFHr c TSF 0.98 0.98 0.97 0.96 0.96 0.98 0.97 0.98 13.42 13.42 13.33 13.24 12.87 12.87 12.87 12.87 4.00 9.35 9.02 3.93 3.88 2.48 2.48 2.48 1.02 1.02 1.04 1.05 1.04 1.03 1.03 1.03 12.87 12.87 12.87 12.87 12.87 12.87 12.87 12.87 Evaluation result by level 1 meets meets meets meets meets meets meets meets Table 5.18 EVALUATION OF CRACK-LIKE DEFECTS LEVEL 1 № Defect number 2c a t T,°C Material 1 2 3 D1s D2s D3s 0,5 0,4 0,5 0,8 0,7 0,7 7,8 7,8 7,8 35 35 35 SS400 SS400 SS400 Yield point MYS 245,00 245,00 245,00 Tref T-Tref+56 2csc 2c2csc Evaluation result by level 1 31,00 31,00 31,00 60,00 60,00 60,00 10,52 6,48 10,52 TRUE TRUE TRUE meets meets meets 5.1. Defects Evaluation Results 5.1. According to the results of defects evaluation using Fitness-For-Service method: 5.1.1. 8 defects, classified as local metal loss, meet the criteria of FFS part 5 Level 1. 5.1.2. 3 defects, classified as crack-like defects, meet the criteria of FFS part 9 Level 1. 5.2. All 11 defects of the tank are admissible for further operation. 29 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 6. EVALUATION OF TANK REMAINING LIFE Evaluation of remaining life for tank components with the defects of the type “total metal loss” has been performed on the basis of FFS, Part 4, p. 4.5. Table 6.19 EVALUATION OF REMAINING LIFE WITH DEFECTS OF TYPE GENERAL METALL LOSS No. Tank component tam, mm K tmin, mm 1 2 3 4 5 6 7 8 9 10 11 Bottom Shell course 1 Shell course 2 Shell course 3 Shell course 4 Shell course 5 Shell course 6 Shell course 7 Shell course 8 Shell course 9 Roof 7.95 7.85 7.85 6.65 6.65 6.65 6.65 6.65 6.65 6.65 5.65 1 1 1 1 1 1 1 1 1 1 2.84 2.84 2.50 2.50 2.50 2.50 2.50 2.50 2.50 2.50 2.50 Crate, mm/yrs 0.06 0.03 0.01 0.01 0.01 0.06 0.01 0.01 0.01 0.01 0.04 Rlife, yrs 92.0 150.4 481.9 373.8 373.8 74.7 373.8 373.8 373.8 373.8 70.9 Remaining life, years over 20 over 20 over 20 over 20 over 20 over 20 over 20 over 20 over 20 over 20 over 20 Evaluation of remaining life for tank components with the defects of type local metal loss has been carried out on the basis of FFS, Part 5, p. 5.5. Table 6.20 EVALUATION OF REMAINING LIFE WITH DEFECTS OF TYPE LOCAL METALL LOSS # Tank component Bottom Shell course 5 Shell course 5 Shell course 5 Shell course 5 Roof Defect number Rt RSF D9s D10s D11s D4s D5s D6s D7s D8s 0.76 0.76 0.76 0.83 0.83 0.83 0.81 0.82 0.90 0.89 0.90 0.90 0.90 0.90 0.89 0.90 Rlife, yrs 128.00 101.00 128.00 130.00 130.00 95.00 75.00 73.00 Remaining life, years over 20 over 20 over 20 over 20 over 20 over 20 over 20 over 20 6.1. Remaining Life of Crack-Like Defects In accordance with FSS paragraph 9.4.2 defects No. D1s – D3s do not affect further safe operation of the tank. 6.2. Remaining Life Evaluation Calculation Results 6.2.1. According to the results of remaining life calculation: - in accordance with FSS tank remaining life is 20 years; - according to the results of remaining life calculation with due account of the data of phonon diagnostics - 11 years. 6.2.2. Remaining life of the tank of Butanol plant is 11 years. 30 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 7. CONCLUSION ON TECHNICAL STATE OF THE TANK 7.1. The tank was built as per the standard API 620 9th ED. ADDENDUM 2 in August, 2000 and corresponds to the design documentation. 7.2. The tank is operated in cyclic mode. As for the moment of diagnosis it has run 63 cycles. 7.3. Foundation, drainage and grounding systems are in satisfactory state. Anchors, visible part of the bottom, shell and shell elements, roof and roof elements are in satisfactory state, except for detected damage of protective coating, corrosion in the places of damage. 7.4. Phonon diagnostics determined 11 defects of tank elements: 3 defects of the bottom, 7 defects of the shell, 1 defect of the roof. Out of them 8 defects are of the type of local metal loss, 3 defects of the type of crack- like defects. Evaluation of the defects according to FFS criteria has determined that the defects are not hazardous and do not affect safe operation. 7.5. Corrosion rate of tank components does not exceed 0,06 mm/year. 7.6. Operating temperature of the tank is 30C and does not exceed the design one. 7.7. Unsafe stresses and stress concentrators have not been determined. 7.8. Tank bottom settlement has not been determined. Deviation of tank bottom from horizontal is satisfactory. Deviation of tank shell from vertical is satisfactory. Tank ovality is satisfactory as per FFS criteria. 7.9. Calculated remaining life is 11 years. 7.10. The tank of Butanol plant fits for further service without change of operating modes. 31 SAMPLE REPORT OF TANK MRA INTERNATIONAL SDN BHD (1035028-D) 8. RECOMMENDATIONS ON FURTHER OPERATION AND REPAIR 8.1. Remove corrosion and recover protective coating in the places of damage on tank components in accordance with section 2.3 of the current report. 8.2. Carry out visual inspection and diagnostics of tank geometry in 5 years in April, 2014 in accordance with the procedures of API 653 p. 6.3, Annex B; FFS Part 8, p. 8.4.3.3. 8.2.1. Carry out phonon diagnostics in 10 years in April, 2019 to determine real technical state in accordance with the procedures of API 653 p. 6.4. 32
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