D J A INSPECTION SERVICES, INC. Storage Tank Management & Inspection

Transcription

1 D J A INSPECTION SERVICES, INC. Storage Tank Management & Inspection P. O. Box 384 Reno, PA P. O. Box 544 Edison, CA PORT OIL PORTLAND, CT Tank #5 Date of Out - of - Service Inspection: September 3, 2010 Inspector: COLLIN GORDON API Certificate #34922 STI Certificate #AC Copies: Port Oil 3 File - 1 Dependable Judicious Affordable

2 DJA Inspection Service, Inc. Purpose This report is given to enable one to assess the serviceability of this tank. The report is of an API-653 inspection made by DJA Inspection Services, Inc. It is the mission of DJA Inspection Services to provide full service tank inspections to the storage tank industry, to be known for quality and detailed inspections through the dedication and experience of our team and to provide the service worldwide as well as to the individual tank owner. DJA obtains this through the use of proper instrumentation, equipment, and trained inspectors. DJA also insists on its minimum inspection requirements being fulfilled even if they exceed the customer s request. With DJA, the report content and context is weighted heavily in all inspections. DJA intends to provide this service at a reasonable rate and provide reports in a timely manner.

3 SUMMARY/RECOMMENDATIONS Recommendations found in this report made by DJA Inspection Services, Inc. are for report purposes only. Actual repair needs are to be determined and designed by the tank owner after review of the entire report. MISSION STATEMENT It is the mission of DJA Inspection Services, Inc. to provide full service tank inspections to the storage tank industry, to be known for quality and detailed inspections through the dedication and experience of our team and to provide the service worldwide as well as to the individual tank owner.

4 PORT OIL PORTLAND, CT TANK #5 Out-of-Service Inspection of 09/03/2010 Summary: CONTAINMENT AREA - The visual inspection of the concrete walls found minor cracks. The cracks need to be sealed to stop product in the event of a tank failure. The base is mostly soil with stone and asphalt covering the soil. The containment area has poor drainage away from the tank. The containment base should be lowered to improved the drainage. FOUNDATION - The tank is on a soil foundation. The foundation has no berm. The foundation material has allowed the tank to have significant settlement. LEAK DETECTION - None. SECONDARY CONTAINMENT - None. SETTLEMENT SURVEY - An out-of-plane settlement survey was performed on the tank. The out-of-plane settlement is not acceptable per API-653, but the tolerance of the equipment used to perform the elevation survey may exceed the allowable variances in the settlement calculations. FIXED ROOF - The steel dome roof was visually inspected. The visual inspection found no serious conditions. Ultrasound thickness readings could not be safely taken due to the roof configuration. SHELL - The reconstructed riveted and welded shell was visually inspected and thickness readings were taken. No serious conditions were found. NOZZLES - The nozzles were visually inspected and thickness readings were taken. No serious conditions were found. CHIME - NA; riveted bottom. BOTTOM - The riveted 1/4" bottom is coated with an epoxy liner. The epoxy coating should be replaced. The MFE bottom scan found 11 soilside pits and 1 topside pit. The soilside pits ranged from.161" to.211" remaining wall thickness. The visual inspection found no drain hole in the center column pipe. One should be installed. MFE SCANNER - Magnetic Flux Leakage Examination Scanner is set up using MFE

5 Enterprises function test plate. The test plate is 0.25" thickness with two simulated flaws. Flaw #1 is a 3/16" diameter hole and Flaw #2 is a ½" diameter simulated soilside pit stairstepped to 40% wall loss. The unit is then adjusted to bottom actual thickness with coating, if present. EXTERNAL DETERIORATION PROTECTION - The paint is in good condition. BRITTLE FRACTURE - A hydrostatic test should be performed if the tank is going to change service. CATHODIC PROTECTION - Not installed. OVERFILL PREVENTION - Installed; an auto gauge. The visual inspection found no serious conditions. PIPING - Not inspected.

6 PORT OIL PORTLAND, CT TANK #5 Out-of-Service Inspection of 09/03/2010 Recommendations: 1. Seal the large containment wall cracks. 2. Repair all 11 soilside pits found. 3. Install a drain hole in the center column. 4. Install a reinforcement pad under the center column. 5. Install a screen in the roof vent. 6. Replace the epoxy coating on the bottom.

7 PORT OIL PORTLAND, CT TANK #5 Out-of-Service Inspection of 09/03/2010 Suggestions: 1. Lower the containment base and improve drainage away from the tank. 2. Install a ground. 3. Install a high level alarm.

8 Procedures THICKNESS TESTING - Thickness readings were obtained by the use of an ultrasonic thickness tester. The calibration was checked before starting each day of inspection. LEVEL AND SETTLEMENT SURVEY - The settlement and / or levelness of the tank foundation was determined with the use of transit level and measuring rod. ROOF LAYOUT - Roof plates were measured with a measuring wheel and reports are to scale. The roof was visually inspected. BOTTOM LAYOUT - Bottom plates were measured with a measuring wheel and reports are to scale. The bottom was visually inspected and thickness readings were taken. NOZZLE LAYOUT - Nozzles were measured as to an X,Y, coordinate in relationship to the shell plate in which they are located. The nozzles size is listed as well as identified by a letter. The nozzles were inspected visually from the internal side of the tank and thickness measurements were obtained by the use of an ultrasonic thickness tester. PIT MEASUREMENT - Pit depth was measured with the use of a pit gauge. VISUAL - A visual inspection was made of the tank and its components. Internal inspection was aided by the use of a flashlight being held parallel to the tank s surface. MAGNETIC FLUX LEAKAGE - The floor was scanned for topside and soilside pitting using a magnetic flux leakage tester.

9 SPREADSHEETS MISSION STATEMENT It is the mission of DJA Inspection Services, Inc. to provide full service tank inspections to the storage tank industry, to be known for quality and detailed inspections through the dedication and experience of our team and to provide the service worldwide as well as to the individual tank owner.

10 Tank Data Summary Customer : PORT OIL Location : PORTLAND, CT Tank # : 5 Serial # : UNAVAILABLE Manufacturer : CBI Year Built : 1934 Tank Description : Lap Riveted / Butt Welded Diameter : feet Product : DIESEL Height : feet Code : UNKNOWN Design Capacity : 81,900 gal Product Specific Grav. : bbl Maximum Filling Height Used by Facility : Calculated Filling Height Using S.G.: feet feet Is vessel on original location? : Y Vessel drawings? : N Normal Venting Evaluation: Is vessel modified? : N Any previous inspection records? : N Venting, Sq in : Any maintenance records? : N Fill openings, Sq in : Any weld examination records? : N Outlets, Sq in : Any leak test records? : N Any mill test records? : N Pressure, operating/design (psig) : Temperature, operating/design ( F) : ATMOS./UNKNOWN AMBIENT/UNKNOWN Shell Material Spec : UNKNOWN Roof type : DOME Floating roof? : N If so, description : NONE Type of seals : Primary : NONE Secondary : NONE Floating Roof access? : If so, description : NONE Bottom construction : CONE UP Second bottom? : Y Flow Rates : If so, year installed : 1990 Max Flow Rate: UNKNOWN External finish : BLUE PAINT Current Flow Rate: UNKNOWN Internal lining : Y Insulation type : NA

11 Date of Inspection Date Taken: 9/3/2010 Tank #: 5 Client: PORT OIL Location: PORTLAND, CT Original thicknesses of Shell and Nozzles are assumed for calculations. In-Service Out-of-Service In-Service Out-of-Service Remaining Remaining Inspection Inspection Inspection Inspection Minimum Inspection Corrosion Corrosion Corrosion Date Based Date Based Date Based Date Based Item Thickness Date Thickness Date Rate Allowance Life in Days on ¼ Life on ½ Life on 5 Years on 20 Years Shell Course /1/ /3/ E Apr Nov Sep Sep-2030 Shell Course /1/ /3/ E Mar Sep Sep Sep-2030 Shell Course /1/ /3/ E Oct Dec Sep Sep-2030 Shell Course /1/ /3/ E May Feb Sep Sep-2030 Shell Course /1/ /3/ E Feb Aug Sep Sep-2030 Shell Course /1/ /3/ E Jul May Sep Sep-2030 Bottom 9/3/ Sep-2030 Nozzle A - 4 " /1/ /3/2010 1E E+104 ############### ############### 3-Sep Sep-2030 Nozzle B - 20 " /1/ /3/2010 1E E+104 ############### ############### 3-Sep Sep-2030 Nozzle C - 1 " /1/ /3/ E Mar Sep Sep Sep-2030 Nozzle D - 4 " /1/ /3/ E Jan May Sep Sep-2030 Nozzle E - 4 " /1/ /3/2010 1E E+104 ############### ############### 3-Sep Sep-2030 Nozzle F - 20 " /1/ /3/2010 1E E+104 ############### ############### 3-Sep Sep-2030 Nozzle G - 2 " /1/ /3/ E Dec Apr Sep Sep-2030 Nozzle H - 6 " /1/ /3/ E May Dec Sep Sep-2030

12 Remaining Service Life of Tank Bottom based on API-653 Section and allowable minimum bottom thicknesses. Tank #: 5 Client: PORT OIL Location: PORTLAND, CT Formula: OR1 = RTip - MRT StPr+UPr OR2 = RTbc - MRT StPr+UPr See API-653 Section for definitions. After Repair Bottom lined (Y/N): Y Y Liner > 50 mils thickness(y/n): N N Leak detection (Y/N): N N Secondary containment (Y/N): N N Cathodic protection (Y/N): N N Age of bottom 20.0 years Original thickness inches Measured min avg thickness inches StPm, max internal pit depth inches inches Are these values corrected to original tank bottom (Y/N): Y UPm, max underside pit depth inches 0.10 inches Overall corrosion rate = Calculated remaining service life : After Repair: Or1 : Exceeds 20 year inspection interval requirement. Or2 : Exceeds 20 year inspection interval requirement. StPr = UPr = inches/year inches/year inches/year RTbc = minimum remaining thickness from bottom side corrosion after repairs RTip = minimum remaining thickness from internal corrosion after repairs StPr = maximum rate of corrosion not repaired on the top side. StPr = 0 for coated areas of the bottom. The expected life of the coating must equal or exceed the next inspection interval to use StPr = 0. UPr = maximum rate of corrosion on the bottom side.

13 See API-653 Sections and Data taken: 9/3/2010 Tank No. : 5 Course Ht, FT Client : PORT OIL Location : PORTLAND, CT TANK DIAMETER, D : FT SHELL HEIGHT : FT FACILITY FILL HT : FT G, PRODUCT SP. GRAV.: (water = 1.0) 7 Y, YIELD STRENGTH : 30,000 PSI 8 T, TENSILE STRNGTH: 55,000 PSI 9 JOINT TYPE : RIVETED 10 No. OF RIVET ROWS : 2 E, JOINT EFFICIENCY: PER CODE OR USE DESIGN VALUE 1.0 FOR CORRODED PLATE CALC. t, MINIMUM MEASURED SHELL THICKNESS, INCHES S, MAXIMUM ALLOWABLE STRESS, PSI COURSE 1-2: 21,000 PSI (PER API-653 CODE) COURSE 3-9: 21,000 PSI (PER API-653 CODE) RCA, REMAINING CORROSION ALLOWANCE, INCHES REQUIRED THICKNESS FORMULA FROM API-653 t = {2.6D(H)G}/{SE} OR, REARRANGING TERMS: H = {t(se)/(2.6dg)} SHELL READINGS, CONSTRUCTION, AND RESULTS FILL HEIGHTS, FT SHELL MIN. AVG. RCA, JOINT JOINT (BASED ON S.G. = ) COURSE THK, IN THK, IN in. EFF., E TYPE ALLOW'D CAL'D % RIVETED % RIVETED % RIVETED % RIVETED RCA based on Facility FIll Ht and Product S.G.

14 See API-653 Sections and Data taken: 9/3/2010 Tank No. : 5 Course Ht, FT Client : PORT OIL Location : PORTLAND, CT TANK DIAMETER, D : FT SHELL HEIGHT : FT FACILITY FILL HT : FT G, PRODUCT SP. GRAV.: (water = 1.0) 7 Y, YIELD STRENGTH : 30,000 PSI 8 T, TENSILE STRNGTH: 55,000 PSI 9 JOINT TYPE : BUTT 10 E, JOINT EFFICIENCY: PER CODE OR USE DESIGN VALUE 1.0 FOR CORRODED PLATE CALC. t, MINIMUM MEASURED SHELL THICKNESS, INCHES S, MAXIMUM ALLOWABLE STRESS, PSI COURSE 1-2: 23,595 PSI (SMALLER OF 0.80Y OR 0.429T) COURSE 3-7: 25,960 PSI (SMALLER OF 0.88Y OR 0.472T) RCA, REMAINING CORROSION ALLOWANCE, INCHES REQUIRED THICKNESS FORMULA FROM API-653 t = {2.6D(H)G}/{SE} OR, REARRANGING TERMS: H = {t(se)/(2.6dg)} SHELL READINGS, CONSTRUCTION, AND RESULTS FILL HEIGHTS, FT SHELL MIN. AVG. RCA, JOINT JOINT (BASED ON S.G. = ) COURSE THK, IN THK, IN in. EFF., E TYPE ALLOW'D CAL'D % BUTT % BUTT RCA based on Facility FIll Ht and Product S.G.

15 Nozzle Reinforcement Calcs See API-653 Section 8.5 Tank #: 5 NOTE: Nozzle Ht. Per API-650 column is for informational purposes only. Client: PORT OIL TThis column indicates whether the height of the nozzle meets the Location: PORTLAND, CT present API-650 normal height requirement, but does not indicate THE REINFORCING CROSS-SECTIONAL AREA ( X x Y) MUST BE LESS THAN THE FOLLOWING: whether it is in violation of API-653. (SEE NEXT PAGE FOR DEFINITIONS) X(Y) < (A)(B-X) + (4)(T)(T)(2) + (2)(T)(Y) Reference Template NR-1 Size Sheet Co-ord., ft Nozzle Thick, inches Re-pad X x Y Reinf Area Approv'd Nozz Ht Tag in. Service ID Tag X-Axis Y-Axis Top Left Btm Right Thk, in B, in X, in Y, in A, in T, in Sq. in. Sq. in. per API-653 per API-650 A 4 PRODUCT SC YES YES B 20 MANWAY SC YES YES C 1 TI SC Not Req'd YES D 4 PRODUCT SC YES YES E 4 BLANK SC YES YES F 20 MANWAY SC YES YES G 2 WATER DRAW SC Not Req'd YES H 6 PRODUCT SC YES YES I J K L M N O P Q R S T U V W X Y Z

16 Nozzle Reinforcement Pad Layout Client: PORT OIL Tank #: 5 Location: PORTLAND, CT Reference Template RPT-1 Nozzle Repad Measurement Location-measurement in feet Letter Type A B C D R A B D E F G 2A H

17 Shell Vertical Thickness Readings Tank #: 5 Reference Template Client: PORT OIL STV-1 or STVR-1 Location: PORTLAND, CT Data taken: Shell Drop Point No. V - ===> Readings in thousandths of an inch Course No SC-1 MAX: 252 MIN: 232 AVG: SC-2 MAX: 251 MIN: 228 AVG: SC-3 MAX: 251 MIN: 231 AVG: SC-4 MAX: 206 MIN: 185 AVG: SC-5 MAX: 191 MIN: 180 AVG: SC-6 MAX: 256 MIN: 225 AVG: /3/2010

18 Shell Horizontal Thickness Readings Reference Template STR-1 or STR-2 Tank #: 5 Client: PORT OIL Location: PORTLAND, CT Data taken: 9/3/2010 Shell Sht Point No.===> Readings in thousandths of an inch Course No SC-1 MAX = 241 MIN = 229 AVG =

19 Bottom Plate Thickness Readings Readings in thousandths of an inch Tank #: 5 Overall Min: 215 Data taken: 9/3/2010 Client: PORT OIL Overall Max: 267 Location: PORTLAND, CT Overall Avg: Reference Template AR-1, AR-2, BP-1, or BP-2 Btm Point===> Plate Btm Point===> Plate Btm Point===> Plate Btm Point===> Plate Plate No Type Plate No Type Plate No Type Plate No Type B C B-31 B-61 B-91 B A B-32 B-62 B-92 B E B-33 B-63 B-93 B E B-34 B-64 B-94 B E B-35 B-65 B-95 B E B-36 B-66 B-96 B E B-37 B-67 B-97 B E B-38 B-68 B-98 B F B-39 B-69 B-99 B D B-40 B-70 B-100 B-11 B-41 B-71 B-101 B-12 B-42 B-72 B-102 B-13 B-43 B-73 B-103 B-14 B-44 B-74 B-104 B-15 B-45 B-75 B-105 B-16 B-46 B-76 B-106 B-17 B-47 B-77 B-107 B-18 B-48 B-78 B-108 B-19 B-49 B-79 B-109 B-20 B-50 B-80 B-110 B-21 B-51 B-81 B-111 B-22 B-52 B-82 B-112 B-23 B-53 B-83 B-113 B-24 B-54 B-84 B-114 B-25 B-55 B-85 B-115 B-26 B-56 B-86 B-116 B-27 B-57 B-87 B-117 B-28 B-58 B-88 B-118 B-29 B-59 B-89 B-119 B-30 B-60 B-90 B-120

20 Bottom Edge Thickness Readings Data Taken: 9/3/2010 Tank #: 5 Client: PORT OIL Location: PORTLAND, CT Reference Template BER-1 Point No. E- Readings in thousandths of an inch Plate No MAX = 262 MIN = 233 AVG = 248 E E E E E-5 E-6 E-7 E-8 E-9 E-10 E-11 E-12 E-13 E-14 E-15 E-16 E-17 E-18 E-19 E-20 E-21 E-22 E-23 E-24 E-25 E-26 E-27 E-28 E-29 E-30 Note: Readings taken approximately 2" from tank edge adjacent to shell sheets. E-1, E-2,... E-max correspond to shell course sheets. Btm Edge Data Pg 1

21 Bottom Pitting Layout If you can not locate the respective pit, can not read a number, or do NOTE:: Remaining Wall Thickness (Soilside Pitting) and Tank #: 5 not understand something on this page, please contact a DJA Pit Depth (Topside Pitting) are in thousandths of Client: PORT OIL representative or an inch. Reference Template BPO-1 Remaining Wall Pit In Critical Remaining Wall Pit In Critical Sheet # Thickness Depth X Y Zone Sheet # Thickness Depth X Y Zone N N N N N N N N N N N N

22 CORRECTED DATA - Readings in feet. NOTE: Elevations are based on lowest station Tank #: 5 point at the shell being 0.00' Tank Dia: 22 ft Max Reading: 6.2 ft at edge, used to correct data Distance across tank from edge ==> seam edge 10 ft center Data taken: 9/3/2010 Description of Benchmark : Elevation on Benchmark :

23 Out-of-Plane Edge Deflection Analysis - API-653 Appendix B Tank No.: 5 Formula for Out-of-Plane Deflection: S < or = (L² x Y x 11) / [2(E x H) ] Where: S = deflection, in feet L = arc length, in feet feet = 1.17 inches Y = yield strength, in psi L: 8.6 feet E = Young's modulus, in psi Y: 30,000 psi H = tank height, in feet E: 29.5 x 10^6 psi H: feet S allow: feet Out-of-Plane edge settlement is NOT acceptable per API-653. Planar Tilt = 0.36' Sequence Equiv. Data Cos Averaged No. Station Angle, deg feet Curve Diff. Diff

24 Out-of-Plane Edge Deflection Distance above low point, ft Measured Data Cosine Curve Station No.

25 TEMPLATES For Templates, Please refer to Templates File MISSION STATEMENT It is the mission of DJA Inspection Services, Inc. to provide full service tank inspections to the storage tank industry, to be known for quality and detailed inspections through the dedication and experience of our team and to provide the service worldwide as well as to the individual tank owner.

26 DRAWINGS MISSION STATEMENT It is the mission of DJA Inspection Services, Inc. to provide full service tank inspections to the storage tank industry, to be known for quality and detailed inspections through the dedication and experience of our team and to provide the service worldwide as well as to the individual tank owner.

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37 PHOTOS MISSION STATEMENT It is the mission of DJA Inspection Services, Inc. to provide full service tank inspections to the storage tank industry, to be known for quality and detailed inspections through the dedication and experience of our team and to provide the service worldwide as well as to the individual tank owner.

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46 CERTIFICATION For Certifications, Please refer to Inspector Certification File MISSION STATEMENT It is the mission of DJA Inspection Services, Inc. to provide full service tank inspections to the storage tank industry, to be known for quality and detailed inspections through the dedication and experience of our team and to provide the service worldwide as well as to the individual tank owner.

47 RAW DATA Hand written field obtain data will be available upon request. MISSION STATEMENT It is the mission of DJA Inspection Services, Inc. to provide full service tank inspections to the storage tank industry, to be known for quality and detailed inspections through the dedication and experience of our team and to provide the service worldwide as well as to the individual tank owner.