The Implementation of a Storage Facility Inspection Program. Presented By: John R. Rueckel PCA Engineering, Inc.

Transcription

1 The Implementation of a Storage Facility Inspection Program Presented By: John R. Rueckel PCA Engineering, Inc.

2 Storage Facility Inspection Why implement an inspection program? Regulatory Requirements Minimize environmental risk Safety / Insurance Obligations Internal Safety committee & audits May be required by the underwriters Preventative maintenance issues Extend the life of assets Minimize down-time Improve productivity

3 Storage Facility Inspection How does this apply to your facility? PBS: heating fuels, vehicle fuels, generator fuel, lubricating oil. CBS: tanks containing caustic, acid, ammonia, chlorine and other treatment chemicals. Safety (OSHA): all of the above plus pressure vessels, steam vessels, air vessels, process tanks, etc.

4 Storage Facility Inspection Regulatory Requirements NY State 6 NYCRR 613 The Handling and Storage of Petroleum Monthly inspection, typically by qualified facility personnel Calls for a full out-of-service inspection on a 10- year basis

5 Storage Facility Inspection Regulatory Requirements Suffolk County Suffolk County Sanitary Code Article 12 Requires internal inspections on a 7-year cycle Above ground tanks to be internally coated Cathodic protection required for soil-contacted surfaces, and inspected annually Link: s/article12.pdf

6 Storage Facility Inspection Regulatory Requirements Nassau County Article XI Nassau County Public Health Ordinance Requires internal inspections on a 5-year cycle Above ground tanks to be internally coated Cathodic protection required for soil-contacted surfaces, to be inspected annually Link: PDF/Regulations.pdf

7 Storage Facility Inspection 6 NYCRR 598 Chemical Bulk Storage Daily and Monthly inspection, typically by qualified terminal personnel Annual survey of any Cathodic Protection corrosion control 5-year inspection <10,000 gallon: in-service acceptable >=10,000 gallon: Out-of-service and PE review

8 Storage Facility Inspection 6 NYCRR Hazardous Waste Regular inspection by facility personnel 5-year inspection interval as under the CBS regulations Additional containment requirements

9 A Storage Tank: A large container for liquids or gases The American Heritage Dictionary

10 Storage Tank Inspection This might include: Field erected tanks typically as vertical cylinders Shop-fabricated tanks, <50,000 gallons Can be horizontal or vertical

11 Storage Tank Inspection It can also include: Pressure Vessels Process Tanks and Vessels Separators / Clarifiers Typically does not include: DOT vessels Transportable tanks ( Lube Cubes )

12 Storage Tank Inspection

13 Storage Tank Inspection Categories of inspection: In-Service/Exterior The product typically remains in the storage tank The tank can be active or unavailable for only a short term period An inspection is typically required on more frequent intervals Technical standards prescribe a ¼ corrosion life interval

14 Storage Tank Inspection Categories of inspection: Out-of-Service/Internal All product removed and the tank interior is cleaned Tank ventilated and made safe for entry Owner should have a confined space program Surface preparation You can t inspect what you can t see Water blasting or sand blasting

15 Storage Tank Inspection Applicable standards and associated procedures STI001-05: Steel Tank Institute Applies to shop fabricated tanks (UL 142) with a capacity of less than 50,000 gallons The standard references and defers to the API 653 Standard Requires a qualified inspector, either API 653 Certification or STI Tank Inspector

16 Storage Tank Inspection API 653: Tank Inspection, Repair, Alteration, and Reconstruction This applies primarily to field erected carbon steel storage tanks, operating at or near atmospheric pressure Frequently applied to other tanks, non-standard vessels and shop fabricated tanks

17 Storage Tank Inspection API 653: The standard provides inspection guidance across industry and regulatory boundaries The American Petroleum Institute 653 standard is the dominant tank evaluation and repair document

18 Storage Tank Inspection Inspector Qualification The charge inspector should hold certification from an independent entity to determine and identify qualifications Examples: API 653, API 570, API 510, STI 001 STI accepts API 653 in lieu of their certification ASNT Certification covers individual methodologies of non-destructive testing

19 Storage Tank Inspection Inspection: Testing and Procedures Visual Evaluation Ultrasonic Testing Magnetic Flux Leakage Scanning Weld Inspection/Vacuum Box Testing Tank Shell Settlement Coating evaluation Acoustic Emissions

20 Storage Tank Inspection A basic API 653 inspection may include all of the above, but typically includes: Visual inspection Ultrasonic thickness gauging

21 Visual Evaluation The qualified inspector will base a significant portion of the assessment on the results of a visual inspection The consistency of a visual inspection is enhanced though the use of checklists, such as API 653 appendix C, and documented by digital photography The visual evaluation will be the primary tool for the periodic inspection (by facility personnel)

22 Visual Evaluation Perform a visual assessment of/for structural issues

23 Visual Evaluation Address maintenance issues

24 Ultrasonic Testing Theory (How the heck does this work?) Thickness Gauging Pitch-Catch / Single Echo Multiple Echo Flaw Detection B-Scan, C-Scan Weld Inspection

25 Vacuum Box Testing Evaluation of Welds for through-indications ( Leaks ) Theory Straight Box Lap (fillet) welds Corner Box 90 degree angle

26 Coatings Assessment The evaluation of internal coatings can include: Visual inspection of new and existing coatings Holiday Testing; an electronic test to locate small openings through the coating Dry-film thickness Review of the coating application process, including surface preparation

27 Coating/Lining Assessment

28 Common Methods of AST Floor Evaluation Visual Inspection: Observation of topside conditions Ultrasonic Thickness Gauging: Measuring the thickness using a digital thickness gauge at individual locations Ultrasonic Scanning: Evaluating sections of the tank floor for thickness

29 Limitations of Previous Standard Inspection Methods Visual Inspections: Only evaluates topside corrosion. Access limited by scale or coatings Thickness Gauging: Provides data only at point of measurement Ultrasonic Scanning: Provides back surface profile, but typically of limited area.

30 Improving inspection result by increasing area evaluated The quality of the inspection is raised by increasing the amount of usable data evaluated. Increase the quantity of U/T scans. Time and surface prep are issues.

31 Evaluation Of Above Ground Storage Tank Bottoms Using Magnetic Flux Leakage to provide improved results John R. Rueckel PCA Engineering, Inc. Pompton Lakes, NJ (800)

32 Comparison of Inspected Floor Area Based on 30 ft. diameter U/T Gauging: > 1% U/T Scanning: 7% for 50 1sq.ft. scans MFL Scanning: 80% or greater, typically U /T U /T Sc G an au gi ng M FE Sc an

33 What is Magnetic Flux Leakage Scanning? The scan, variously known as MFE, MFL, or Mag-Flux scanning is a means to evaluate large area of plate producing a qualitative result. This increase in the percentage of floor evaluated increases the reliability of the overall result, and adds to the Sleep - Nights factor.

34 How does Magnetic Flux scanning work? The Mag-Flux scanner operates using a fixed magnet to bring a section of the steel floor plate to magnetic saturation. A defect, located on the front or back surface, causing a scattering of the magnetic lines of force or flux. Sensors located proximal to the magnets display the result on some form of output device, typically as an LED waterfall

35 The Magnetic Flux Scan Graphic is courtesy of MFE Enterprises

36 What data does a MFL scan provide? The MFL result is a Qualitative assessment of the floor plate, that is it serves to identify top and bottom side localized indications. The indications are Quantified through the use of U/T equipment to provide a direct correlation of the indication as a remaining thickness.

37 Inspection Preparation U/T inspections require careful cleaning and surface preparation. This may include sand or high pressure water blasting or local grinding. The typical MFL preparation requires removal of all loose product, liquid and scale. Tight scale is usually acceptable. As usual, cleaner = better inspection

38 MFL/MFE Review MFL scan provides for inspection of the majority of the floor area. This helps to increase your Sleep-Nights Factor. Inspection can be completed through coatings, tight scale, and other adverse conditions. MFL is an important portion of the overall API 653 inspection package.

39 Inspection Result Indications are marked on a floor drawing, and also on a sketch of the floor plates. The drawing is included with other data as part of an API 653 inspection report. The U/T data continues to be part of the overall inspection package to provide the Quantitative aspect as well as the thickness data required to complete calculations.

40 Weld Inspection Vacuum Box Testing Dye Penetrant Magnetic Particle Dry vs. Wet Visible vs. Fluorescent Application Finds surface & near surface discontinuities Inspection of Welds Inspection of Castings or Forgings

41 Settlement Survey The API 653 standard addresses concerns for differential settlement, that is a vertical tank that does not settle in a planar manner. Evaluated for calculated tolerances based on tank diameter, height and construction.

42 Settlement Survey OUT OF PLANE DEFLECTION CURVES E l e v a t i o n Field Data 9.96 Theoretical Station

43 Coating Evaluation Coatings are provided as a means of corrosion control, either atmospheric or product related Exterior coating are typically visually evaluated Interior coatings receive Holiday tests, dry film thickness measurement, and occasionally destructive testing

44 Acoustic Emissions Acoustic emission is a technique to monitor for potential failure. The formation of defects in structural materials used in tanks pressure vessels and piping releases energy, detected by the method Widely used to evaluate composite materials A procedure is available to act as a means of leak detection for the floor of a vertical tank

45 Storage Tank Inspection Reporting typically includes: Data Sketches Photographs Calculations Recommendations Usually citing an applicable repair standard, and separate from a repair plan or specification

46 Piping Inspection API 570 Piping Inspection Code Standard for the inspection and repair of product piping May be implemented for other types of piping at the owners discretion or under regulatory requirements Ex. Fire water, waste or steam piping

47 Piping Inspection Piping is typically evaluated using similar techniques as those discussed for tanks. API 570 identifies areas of concern to allow the inspection to be focused at areas with the highest probability of failure or the greatest risk (RBI: risk-based inspection). Examples: Soil-Air interfaces. Corrosion under insulation (CUI). Underground segments. Segments near or over water, or with the potential to spill into a waterway.

48 Pressure Vessel Inspection API 510 Pressure Vessel Inspection Code: Maintenance Inspection, Rating, Repair, and Alteration The standard covering the inspection of a pressure vessel Due to their properties, some products may be stored in a pressure vessel. Ex. Ammonia

49 Pressure Vessel Inspection Why are we even talking about pressure vessels? Some of the products require storage in a way that requires a tank that is capable of keeping the product under pressure. Most typical petroleum tanks are designed for atmospheric storage. This especially true with the implementation of the chemical bulk storage (CBS) regulations

50 Pressure Vessel Inspection Why?. In addition to the environmental aspects, pressure vessels can pose safety issues. The safety aspect is governed under what is referred to as Process Safety Management or PSM. Typically, materials stored in pressure vessels are potentially more hazardous, either as a result of health or stored energy aspects.

51 Pressure Vessel Inspection How does inspection differ from a regular storage tank? A more extensive evaluation may be required in specific areas such has welds, potential modes of failure, and conditions specific to the product stored. Inspection intervals as governed by industry standards may be different, especially for high pressure, or low/high temperature vessels.

52 Pressure Vessel Inspection An evaluation of the pressure and temperature capabilities of the tank/vessel can be part of the inspection process. The historical and construction design data is important, more so that with a tank or pipeline.

53 Pressure Vessel Inspection Vessels that may be on your sites: Propane and/or butane Fire-fighting materials Ammonia Steam Compressed Air (!) Other chemicals

54 Inspection Results The goal of the inspection is to provide an action plan based on three categories of repair: Required repairs or modifications required to meet applicable codes or regulations Recommended consistent with industry practices or site conditions. Suggested To provide improved service and operability as a goal: minor repairs

55 Repair & Return to Service A storage tank, pipeline, or pressure vessel is a repairable portion of the infrastructure In most cases, repairs can be completed for significantly less then the cost of replacement The repair is a means to extend the service life and inspection interval of the storage tank

56 Repair & Return to Service Inspections Interval. Based on corrosion rate calculations that compare previous thickness data or assumed original thickness with the current thickness information. Used to confirm that the tank is suitable to return to service for a minimum interval. The interval may be specified by a regulation or an industry standard.

57 Repair & Return to Service Return-to-service Is the service life suitable for the required interval? Have repairs been completed in accord with the consensus code and inspected? Is a standing head test required? Are reports in place and required regulatory documentation completed? Has all equipment been reconnected, is the tank interior clean/clear, piping oriented, manways suitably closed, etc.?

58 Storage Facility Inspection The inspection helps meet these goals: Prevent environmental releases or unnecessary down time Extend the operational life of the infrastructure Allow the operator to Sleep at night!

59 Storage Facility Inspection Questions?

60 Thank You for your time! If you have any further questions: John Rueckel - PCA Engineering, Inc. jrueckel@cpbypca.com (800) x12