curi tank 39 a - clemson...

APPLIED TECHNICAL SERVICES, INC.

Corporate Office: Marietta, GA • Branch Offices: Birmingham, AL • Mobile, AL • Jacksonville, FL • Augusta, GA • Savannah, GA • Louisville, KY • Baton Rouge, LA Shreveport, LA • Wilson, NC • Charleston, SC • Columbia, SC • Greenville, SC • Chattanooga, TN • Memphis, TN • Arlington, VA • Chesapeake, VA • Rockville, VA

1049 Triad Court, Marietta, Georgia, 30062 • (770) 423-1400 Fax (770) 514-3299 • www.atslab.com

of 13 ATS450, 4/18/12 Proprietary Document

Mechanical Integrity Report for the

CURI Tank 39 A

at

208 North Palmetto Boulevard

Clemson, South Carolina 29631

Inspection: 26 September 2012

Prepared by: George E. Matthews, E.I.T. Senior Consultant

Reviewed by: Jeremy M. Orr, P.E., C.W.I. Principal Engineer - Manager

Purchase Order Number: CU00134445 ATS Job Number: 187436

http://www.atslab.com/




Table of Contents


Table of Contents General Information, Background, Equipment Orientation and Access

Page 3

Present Condition and Analysis Page 4 Action Items Page 6 Future Inspections, Personnel Qualifications and Reference Industry Codes and Standards

Page 7

Photographs Page 8 Appendix A: NDE Report Appendix B: Calculations Appendix C: Raw Crawler Scans





General Information, Background, Equipment Orientation and Access


Design Pressure Unknown Design Temperature Unknown Operating Pressure Atmospheric Operating Temperature Ambient Contents Unknown (out of service) Specific Gravity 1.0 (used for calculations) Shell Height / Length 30 feet Diameter 63 feet Manufacturer Unknown

Year Constructed 1989 (repairs: new roof, concrete slab and metal floor, fiberglass floor liner)

Serial Number Unknown National Board Number Not applicable Material Unknown Carbon Steel Previous Inspection None Drawing(s) 06-89-5656 (repair drawing)

NDE Performed by George Matthews (VT) Peter Dudley, Joey Laprade (UTT)

Background This report contains the results of the inspection, analysis and action items regarding the CURI Tank 39 A. The inspection included an external and internal visual inspection and applicable NDE to the accessible portions of the tank via crawler. Equipment Orientation The zero references as discussed in this report were as follows: • The tank was oriented beginning with 0° at the center of the shell manway MW1 and

progressing to 360° in a counter-clockwise direction (refer to the roll-out in Appendix A). • All nozzles and manways were individually oriented with 0° at the top of the individual

nozzle and manway necks (towards the top of the tank) and progressed to 360° in a counterclockwise direction.

Equipment Access No scaffolding was constructed for the inspection. Access for the inspection was provided by an staircase.

Overall View





Present Condition and Analysis


External Present Condition The externally brick lined tank was out of service at the time of the inspection. The structural shell was inaccessible. The roof was observed with minor to moderate general surface corrosion from the top of the access stairs. The edge of the roof was observed with material loss. Thickness measurements were observed to be below the minimum required thickness for safe access (0.188”), so access was limited to the platform atop the stairs. The tank was contained within an earthen dike. The dike was observed with thick vegetation growth. Internal Present Condition The tank was observed with an internal coating throughout. The roof was supported by 10 columns. Internal access to the roof was not available. Light was observed at the roof to shell interface at roughly 180°. The riveted shell was observed with minor general surface corrosion at locations of coating failure. The floor and approximately 3 feet of the lower shell course were observed with a fiberglass liner. The fiberglass liner was observed with minor cracking and deterioration throughout. The accessible nozzles were observed with minor general surface corrosion. A sump was observed in the floor. At the time of the inspection, the sump was filled with liquid. Analysis The tank was analyzed to API 653 for the operating parameters as provided by the client. A summary of the ultrasonic thickness measurements is located in the Summary of Thickness Measurements table that immediately follows. The completed NDE Report is located in Appendix A. The calculations summary is located in Appendix B. Calculated minimum required thicknesses are exclusive of any corrosion allowance.





Present Condition and Analysis


Summary of Thickness Measurements

0.135 0.127 0.094 0.090 0.00035 104.50.250 0.206 0.155 0.100 0.00060 177.80.250 0.233 0.153 0.100 0.00023 583.00.313 0.303 0.254 0.126 0.00013 1417.30.375 0.369 0.288 0.171 0.00008 2451.20.438 0.403 0.305 0.238 0.00047 348.10.500 0.487 0.415 0.288 0.00018 1103.5

Shell Course 4

Minimum Measured Thickness (inches)

ComponentNominal

Thickness (inches)

Average Measured Thickness (inches)

RoofShell Course 6Shell Course 5

Legend> 10% Above Minimum Required

Per repair drawing 06-89-5656.

Shell Course 3Shell Course 2Shell Course 1

Corrosion Rate

(inches/year)

Remaining Life

(years)

Minimum Required Thickness (inches)

At Minimum Required or BelowWithin 10% of Minimum Required





Action Items


Action Items The following are the prioritized action items based on the observations and findings at the time of the inspection: No. Item Priority

1 The roof-to-shell seam should be repaired to prevent moisture ingress into the tank. The seam should be fully inspected to determine the extent of the deterioration.

1

2 The carbon steel components should be cleaned and coated to prevent

further deterioration. 3

3 Proper grounding should be verified or installed. 3

Legend

Priority 1 High likelihood and consequence of failure. Critical Code or Standard deficiency. May not be fit for continued service without repair.

Priority 2 Medium likelihood and consequence of failure.

Priority 3 Low likelihood and consequence of failure. Non-critical Code or Standard deficiency. Industry best practice or preventative maintenance. Housekeeping items.




1049 Triad Court, Marietta, Georgia, 30062 • (770) 423-1400 Fax (770) 514-3299 • www.atslab.com Future Inspections, Personnel Qualifications and Reference Industry Codes

and Standards


Future Inspections The tank should be externally re-inspected in 5 years and internally re-inspected in 10 years, according to API 653. According to the Clemson University Spill Prevention Control and Countermeasure (SPCC) Plan, the tank should be re-inspected within 10 years. Personnel Qualifications Jeremy M. Orr SC PE # 27219 API 653 # 27205

GA, AL, ME, FL, LA, TX, SC, CA registered Professional Engineer; Mechanical Engineer with 13 years experience in inspection, evaluation, repair and design in various industries; AWS CWI, API 653 / 510 / 570 / 580 / 571/ 577 certified; STI certified inspector; NACE coating inspector level I certified; ASNT certified level II VT; SPRAT level I certified rope access technician; ATS certified Level II UTT, MT, PT, VT per SNT-TC-1A; active member of TAPPI, AWS, NACE International, ASME

George E. Matthews GA Registered Engineer-in-Training, Mechanical Engineer with 3 years experience in inspection, evaluation, repair and design in various industries

Jesse B. Showalter GA Registered Engineer-in-Training, Mechanical Engineer with 3 years experience in inspection, evaluation, repair and design in various industries

Peter Dudley ATS certified Level II UTT, MT, PT per SNT-TC-1A Joey Laprade ATS certified Level II UTT, MT, PT per SNT-TC-1A Reference Industry Codes and Standards API 653, Tank Inspection, Repair, Alteration, and Reconstruction Clemson University, Spill Prevention Control and Countermeasure Plan





Photographs


Photo 1: View of the brick-lined shell and the vegetation growth in the containment dike.





Photographs


Photo 2: View of the upper shell.

Photo 3: View of the manway MW1.





Photographs


Photo 4: View of the internally braced roof.

Photo 5: View of the light visible at the roof-to-shell seam.





Photographs


Photo 6: Typical view of the riveted shell.





Photographs


Photo 7: View of the minor general surface corrosion at coating failure.

Photo 8: View of the fiberglass liner on the floor.





Photographs


Photo 9: Detailed view of the cracking and deterioration in the fiberglass liner.

Photo 10: View of the sump in the tank floor.


Corporate Office: Marietta, GA • Branch Offices: Birmingham, AL • Mobile, AL • Jacksonville, FL • Augusta, GA • Savannah, GA • Louisville, KY • Baton Rouge, LA

Brick lined. No access to metal shell.

None.

No access.

No access.

Not applicable.

Roof:

Floor

Grounding Cable

Weld Seam

Jacket / Coils

Support System

Shell

Floor Plate Extension

Insulation / Coating

Notes:

None located.


Anchor Bolt / Saddle / Lug

Nozzle / Manway / Repad

Relief / Vent

No access to the nozzle necks due to brick lining. Minor general surface corrosion on manway MW2. The roof nozzles and manway were observed with minor general surface corrosion from the access platform.

Two vents were observed on the roof at nozzles N1 and N3.

Condition / Comments

Minor to moderate general surface corrosion. Material loss at outer edge.

Not applicable.

No access.

APPLIED TECHNICAL SERVICES, INC.Shreveport, LA • Wilson, NC • Charleston, SC • Columbia, SC • Greenville, SC • Chattanooga, TN • Memphis, TN • Arlington, VA • Chesapeake, VA • Rockville, VA

Component

Appendix A: NDE Report

External Visual Inspection:

No access.

ATS460, 4/18/12 Tank 39 A - Calculations form


ShellThe shell was observed with a coating. Minor general surface corrosion was observed at locations of coating failure. The lower ~3' of shell course 1 was observed with a fiberglass liner.

Component Condition / Comments

Notes:

Baffle / Wear Plate Not applicable.

Agitator / Sparger Not applicable.

Internal Coil Not applicable.

Weld Seam Not applicable.

Lining / Coating Minor coating failure throughout the shell/roof. Fiberglass liner cracking along floor.

Nozzle / Manway The nozzles were observed with minor general surface corrosion.

Floor The floor was observed with a fiberglass liner. The liner was observed with cracking in various locations.

Roof Not accessible. Light was visible from the roof-to-shell junction in several locations.

Internal Visual Inspection:









Shell:

Roof:

Elevation View:

Plan View: (AS SEEN FROM ABOVE)

Floor:

Rollout / Nozzle Locations (NOT TO SCALE):


Roof:

SPOT MEASUREMENTS

Legend> 10% Above Minimum Required

Within 10% of Minimum Required

At Minimum Required or Below

0.090

0.090

0.119

0.090 0.142 0.098

0.129

0.142



0.147

0.146

0.153

Shreveport, LA • Wilson, NC • Charleston, SC • Columbia, SC • Greenville, SC • Chattanooga, TN • Memphis, TN • Arlington, VA • Chesapeake, VA • Rockville, VACorporate Office: Marietta, GA • Branch Offices: Birmingham, AL • Mobile, AL • Jacksonville, FL • Augusta, GA • Savannah, GA • Louisville, KY • Baton Rouge, LA



Ultrasonic Thickness Measurements:

0.094

0.090 0.096

0.090






Shell Ultrasonic Thickness Measurements Graph:

0.0

1.0

2.0

3.0

4.0

5.0

6.0

7.0

8.0

9.0

10.0

11.0

12.0

13.0

14.0

15.0

16.0

17.0

18.0

19.0

20.0

21.0

22.0

23.0

24.0

25.0

26.0

27.0

28.0

29.0

30.0

0.000 0.100 0.200 0.300 0.400 0.500 0.600 0.700

Hei

ght (

feet

)

Minimum Measured Thickness (inches)

0 45 90 135 180 225 270 315 Minimum Required Thickness


Notes:A Fiberglass linerB Rough surface


> 10% Above Minimum Required



Legend

Shreveport, LA • Wilson, NC • Charleston, SC • Columbia, SC • Greenville, SC • Chattanooga, TN • Memphis, TN • Arlington, VA • Chesapeake, VA • Rockville, VA


Elevation (feet)

0.2610.261


Shell Ultrasonic Thickness Measurements:


B

0.2920.310

0.3070.3010.2940.294

0.2610.2730.261

B

0.261

0.1970.2040.202

B

B

BB

0.203

0.283

B

BB

BB

BB

0.4120.430

BB

0.3860.412

BB

0.4010.501

A

0.5080.519

0.436

0.559

0.436

0.4170.438

B

0.3560.2880.359

0.3440.375

0.381

A

AA

A

BB

0.384

A3.0 0.455A

A2.01.0

0.364

0.330

0.205

0° Minimum Measured Thickness (inches)

0.1000.1830.265

0.100 0.189

0.1000.126

0.3100.297

0.1000.100

0.1830.243

0.1000.100

0.468

0.1710.171

BB

0.358

0.2380.238

0.388

4.0

0.1710.238

0.2880.288

0.126

9.0 0.2380.238

7.0

5.0

0.3180.314

0.447

0.299

0.391

16.0

0.1260.126

6.0

0.373

20.019.0

28.0

B0.388

0.1000.100

0.2580.261

18.017.0

8.0B

0.371

12.011.010.0 B

15.0

0.126

0.1710.171

27.026.025.024.023.022.021.0

30.029.0 0.100

0.2880.288

14.013.0

0.288 A

0.2650.216

0.321

0.2830.270

0.511

0.308

0.3900.376

0.4640.462

0.439

0.381

0.382

0.443

0.441

0.314

0.1720.261

0.435

0.317

A

0.329

0.379

A






Notes:A Fiberglass linerB Rough surface


> 10% Above Minimum Required


Shell Ultrasonic Thickness Measurements:

Elevation (inches)

Legend


30.0 0.100 0.280 0.20429.0 0.100 0.186 0.217

0.161 0.2100.155 0.1710.173 0.172

28.0 0.100 0.210 0.20427.0 0.100 0.186 0.206 0.175 0.179

0.181 0.22426.0 0.100 0.186 0.196 0.157 0.230

24.0 0.100 0.188 0.19225.0 0.100 0.187 0.190

0.191 0.186 0.203 0.1950.232 0.231

22.0 0.100 0.186 0.18523.0 0.100

21.0 0.100 0.345 0.2260.275 0.256

B 0.2070.214 0.153

20.0 0.126 0.319 0.27919.0 0.126 0.304 0.264 0.330 0.280

0.276B 0.283

18.0 0.126 0.337 0.254 B 0.287

16.0 0.126 0.288 0.33817.0

0.171 0.357 0.342 0.317 0.341

0.126 0.279 0.2540.390

14.0 0.171 0.380 0.407 B 0.34615.0

13.0 0.171 B B B 0.32812.0 0.171 0.381 B 0.327

0.30611.0 0.171 0.428 0.366 0.366 0.365

0.32410.0 0.238 0.381 0.369 0.453

0.3239.0 0.238 0.357 0.366 B

0.430 0.4038.0 0.238 0.392 0.372

6.0 0.238 0.441 0.4347.0 0.238 0.392 B

5.0 0.288 0.654 0.5580.434

3.0 0.288 A A A A4.0

A2.0 0.288 A A1.0 0.288 A A A A




0.444 0.305


A

315°Minimum Measured Thickness (inches)

0.488 0.415



0.4990.288 B B

0.427

0.376



Notes:A No safe access

B Obstruction / lack of clearance


None N/A 0

0MW1 24"x24" 360 A A

None N/ANone N/A

MW2 20 24 B

B BA

B BUnknown

N4 10 12 BN5 6 36 B

N/A >1'

N/A UnknownN/A UnknownA A

B NoneNone

BN3 3 360 A

None360 A N/A UnknownN2 4 360 A A A None

A

Nozzle NPS Elevation (inches)



Thickness (inches)

Reinforcement Pad

N1 4


Nozzles / Manways / Reinforcement Ultrasonic Thickness Measurements:

Nozzle Thickness (inches) Internal Projection (inches)0° Scan 180° Width

(inches)

A


Internally Braced Cone Roofs

Where:D = Diameter 63 ftH = Bott. Shell Course to Max. Liquid Level 30 ft (1st course)G = Specific GravityS = Max. Allowable Stress (psi)E = Joint Efficiency (API 653 Table 4.3)

5.05.05.0

5.0


Appendix B: Calculations Summary

0.126

0.238

0.100

0.1715.0

Shell Course

APPLIED TECHNICAL SERVICES, INC.Corporate Office: Marietta, GA • Branch Offices: Birmingham, AL • Mobile, AL • Jacksonville, FL • Augusta, GA • Savannah, GA • Louisville, KY • Baton Rouge, LA Shreveport, LA • Wilson, NC • Charleston, SC • Columbia, SC • Greenville, SC • Chattanooga, TN • Memphis, TN • Arlington, VA • Chesapeake, VA • Rockville, VA

API STANDARD 653: Minimum Required Thickness for Welded Roof


API STANDARD 653: Minimum Required Thickness for Welded Shell

Course Height (feet)

Internally braced cone roof design thickness depends on the presence of and spacing of rafters and the diameter of the tank. Typical nominal thickness is 0.135" and the minimum average thickness required per 100 square inch area is 0.090" without repair.

65 0.10043

5.0

0.70

1 0.2882

1.0025960 (remaining courses)23595 (1st & 2nd courses)

SE

GHDt

)1(6.2min





Appendix C: Raw Tank Crawler Scans

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Ap

plied

Tech

nical S

ervices1049 T

riad C

ourt

Marietta, G

A 30062

(770) - 423 - 1400

DescriptionC

ustomer

LocationInspection D

ateInspection M

ethod

Clem

sonC

harlston

SC

T(09/12)

Clem

sonC

harston

, SC

9/25/2012A

utom

ated

Ob

ject Insp

ectedD

escriptionS

torage Tan

k # 39 - A

API 653

Diam

eter756"

[63.0 ft.]Joint Efficiency

Plate Tensile Strength p

siD

esMax. Liquid Level

0.0 ft.C

alc'd Max LL

Actual Tank H

eight32.0 ft.

Max Specific G

ravity0.00

Plate Yield

0.00 psi

Seams

Riveted

If Rivited, Type

Lap

Rivet R

ows

Scan

Plan

Description

PatternLength

Increment

Depth R

angeM

aterialN

umber of M

anways

Num

ber of ScansTechnician

Notes

Sh

ell Scan

Vertical C

ylind

er32' - 0.000"

{384.00"}

0.250"1.000"C

arbon

Steel

18P.D

ud

ley J.Lap

rade

Man

way =

0 Degrees

Weld

s were p

ut in

to sh

ow th

e Rivits an

d

chan

ge betw

een sh

ell corses. ScanTech Instrum

ents

Cod

e Legen

d

Manw

ay

Nozzle

Paint

Poor Surface Condition

Fiber Glass C

oating

Rivit

BS

can L

egend

Black Line = D

ataN

avy Line = TMin

Red Line = D

ata below TM

inPurple V

ertical Line = Weld Line / Joint

Sky Blue V

ertical Line = Entered Liquid LevelR

ed Circle = C

ritical Point used for calc. MLL (t2)

ScanTech Instrum

ents, Inc. assumes no responsibility for the accuracy, use, or interpretation of the data presented in this report. A

nalysis functions are available in the Analyst™

software to aid in the tim

ely and efficient presentation of the data by the inspector. A

ll analysis functions and instrument settings are subject to proper application by the inspector, w

ho is assumed to be properly qualified by the proper authority, and w

ho is responsible for data accuracy and interpretation. A

PI 653 analysis functions, w

hen applied here are the result of an effort to utilize the guidelines within the environm

ent of a high sample count, autom

ated data acquisition process that may offer a m

ore consistent and objective analysis in a real-w

orld ultrasonic corrosion inspection, where reasonable lim

itations are still incurred. Results are subject to proper data screening and input variables w

here applicable. ScanTech Instrum

ents, Inc. does not guarantee compliance or

interpretation of the AP

I 653 standard. The variable design point method for storage tanks greater than 200 ft diam

eter is not implem

ented in this release. The terms listed in "S

pecial Notes" of the A

PI S

tandard 653, Third Edition, D

ec. 2001, A

ddendum 1, S

ept 2003 apply. For details on algorithms utilized by the softw

are, contact ScanTech Instrum

ents. Inc.

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Clipping and C

oating Offset Functions have been applied to this scan.

ScanTech Instruments

0.000" S

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135.000" S

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curi tank 39 a - clemson...

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