CURI Tank 3901-A - Clemson Universitymedia.clemson.edu/facilities/pdf/es/Integrity_Testing_Reports_2012... · Inspection: 26 September 2012 Prepared by: George E. Matthews, E.I.T

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

Page 1 of 10 ATS450, 4/18/12 Proprietary Document

Mechanical Integrity Report for the

CURI Tank 3901-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




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




General Information, Background, Equipment Orientation and Access


Design Pressure Unknown Design Temperature Unknown Operating Pressure Atmospheric Operating Temperature Ambient

Contents None (out of service)

Specific Gravity 1.0 (used for calculations)

Shell Height / Length 11 feet Diameter 40 feet Manufacturer Unknown Year Constructed Unknown Serial Number Unknown National Board Number Not applicable

Material Unknown Carbon Steel Previous Inspection None Drawing(s) None

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 Tank 3901-A. The inspection included an external and internal visual inspection and applicable NDE to the accessible portions of the tank. 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 a ladder.

Overall View




Present Condition and Analysis


External Present Condition Access was limited due to height and vegetative growth. Coating failure was observed throughout. Minor general surface corrosion was observed throughout in areas of coating failure. A 2”x4” vent was located on the roof. Minor general surface corrosion was observed. A grounding cable was not located. Internal Present Condition The roof and shell were coated. Minor general surface corrosion was observed in areas of coating failure. Access to the floor was completely restricted due to a fiber-reinforced plastic (FRP) liner. Cracking, chipping and delamination of the FRP liner were observed. 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

0.222 0.207 0.0900.217 0.191 0.1000.210 0.172 0.100

Minimum Measured Thickness (inches)

ComponentPrevious

Thickness (inches)

Average Measured Thickness (inches)

Roof

Legend> 10% Above Minimum Required

Corrosion rates and remaining life calculations cannot be performed until a second set of UT measurements is Nominal thickness could not be determined. No previous inspection data was available.

Shell 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 carbon steel components should be cleaned and coated to prevent further deterioration. 3

2 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

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: Overall view of the tank.

Photo 2: View of vegetative grown limiting access to tank.




Photographs


Photo 3: Internal view of coated roof.

Photo 4: Internal view of coating failure on manway.




Photographs


Photo 5: View of chipping of FRP liner

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

Access was limited due to vegetative growth. Where accessible, minor general surface corrosion was observed at areas of coating failure.

Coating failure was observed throughout.

No access.

Roof

Floor

Shell

Insulation / Coating


Condition / Comments

Minor general surface corrosion was observed at areas of coating failure.

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:

ATS460, 4/18/12 3901-A Tank Calculations.xls

Minor general surface corrosion was observed at areas of coating failure.

Not applicable.

Grounding Cable

Weld Seam

Jacket / Coils

Support System

Floor Plate Extension

Notes:

Limited access due to vegetative growth. None located as accessible.

Anchor Bolt / Saddle / Lug

Nozzle / Manway / Repad

Relief / Vent

Limited access. Minor to moderate general surface corrosion was observed on accessible nozzles.

2 NPS 4 vents were located on the roof. Minor general surface corrosion was observed.

Minor general surface corrosion was observed.

Minor general surface corrosion was observed.

None located.



Shell Minor general surface corrosion was observed in areas of coating failure.

Component Condition / Comments

Nozzle / Manway Minor general surface corrosion was observed in areas of coating failure

Floor Cracking, chipping and delamination was observed to the FRP liner in isolated areas.

Roof Minor general surface corrosion was observed in areas of coating failure.

Internal Visual Inspection:





Notes:

Baffle / Wear Plate None located.

Agitator / Sparger None located.

Internal Coil Not applicable.

Weld Seam No visible deterioration or damage was observed.

Lining / Coating The roof and shell was coated. The floor had a FRP liner.

Nozzle / Manway Minor general surface corrosion was observed in areas of coating failure.






Roof:

Plan View: (AS SEEN FROM ABOVE)

Floor:

Rollout / Nozzle Locations (NOT TO SCALE):


Shell:Elevation View:


Roof:

14.4 0.090

0.090

0.090

0.090

0.249

19.2 0.090 0.209

0.218

0.215

0.211

0.230

0.228

0.090

0.090 0.209

0.090

0.228

0.214


Distance Across (feet)


0.219 0.215

0.232

0.233

0.217

9.7

19.2

9.7

4.9

0.232

14.4

0.2

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 to 180° Minimum Measured Thickness (inches)

0.217

0.2 0.090 0.241

90 to 270° Minimum Measured Thickness (inches)

4.9 0.090

0.215

0.221


Legend> 10% Above Minimum Required

Within 10% of Minimum Required

At Minimum Required or Below






Shell Ultrasonic Thickness Measurements Graph:

7.0

8.0

9.0

10.0

11.0


0.0

1.0

2.0

3.0

4.0

5.0

6.0

0.000 0.100 0.200 0.300 0.400

Hei

ght (

feet

)

Minimum Measured Thickness (inches)

0 90 180 270 45 135 225 315 Minimum Required Thickness


Notes:A Height restriction


> 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)


Shell Ultrasonic Thickness Measurements:


AA

0.202

0.2370.241

0.241

0.232

0.231

0.2300.218

A

0.191

0.210

0.1980.224

0.209

A0.1920.202

0.2132.9 0.1960.203

0.1921.50.2

0° Minimum Measured Thickness (inches)

0.1000.100

0.1970.100

7.26.0

0.2014.3

0.100

0.1000.100

9.6 0.100

5.7 0.1960.201

A

8.4A

0.207

10.8 A

0.1000.1000.100 0.194

0.201

0.2110.209

0.215

0.197

A

0.2220.199








Notes:A Height restriction


> 10% Above Minimum Required


Shell Ultrasonic Thickness Measurements:

Elevation (inches)

Legend


AA

10.8 0.100 A A A

0.2409.6 0.100 A A A

0.227 0.2388.4 0.100 0.206 0.206

6.0 0.100 0.203 0.1967.2 0.100 0.206 0.238

5.7 0.100 0.204 0.1960.227

2.9 0.100 0.206 0.197 0.222 0.2054.3

0.1721.5 0.100 0.202 0.1990.2 0.100 0.229 0.216 0.218 0.213




0.229 0.244


0.220

315°Minimum Measured Thickness (inches)

0.240 0.239



0.2350.100 0.200 0.195

0.230





Notes:A No safe access

B Obstruction / vegetative growth

C Threaded





Nozzles / Manways / Reinforcement Ultrasonic Thickness Measurements:


Unknown

Unknown

Unknown

UnknownUnknown

UnknownUnknown

Unknown

UnknownUnknownUnknownUnknownN22 0 240 A

A A None N/AA A None N/A

N20 0 240 AN21 0 240 A


N18 4 240 AN19 0 240 A


N16 0 0 BN17 0 240 A

B B None N/AB B None N/A

N14 6 12 BN15 0 0 B

B None N/AB B None N/A

N12 0 0 B BN13 6 12 B B

B B None N/AB None N/A

0 B BNone N/ANone N/A

N11 0 0 B

B BB

BN10 0

N8 0 0 B BN9 0 0

None N/AB None N/A

Unknown

Unknown

UnknownUnknown

UnknownN6 0 0 B B

None N/ANone N/A

N7 0 0 B

B BB

B BUnknown

N4 1 228 CN5 0 0 B

N/A Unknown

N/A UnknownN/A UnknownC C

C NoneNone

CN3 1 228 C

None12 C N/A UnknownN2 2 12 C C C None

C

Nozzle NPS Elevation (inches) Thickness

(inches)

Reinforcement Pad

N1 2

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

(inches)

C


Notes:A No safe access

B Obstruction / vegetative growth

C Threaded




Nozzles / Manways / Reinforcement Ultrasonic Thickness Measurements:



Scan

Nozzle Thickness (inches) Reinforcement Pad Internal Projection (inches)

N23 4

0° 180°

240 A A A None N/A

Width (inches)

Thickness (inches)

None N/A

None N/A

None N/A

Unknown

A A

B B

Nozzle NPS Elevation (inches)

N24 0 0MW1 36 B B B

A A A

36

UnknownNone N/A Unknown

MW2 30 36 B UnknownB

30

UnknownMW4 30 240 A UnknownMW3 30 B None N/AB


Flat Roofs

of the tank. Typical nom2 NPS 4 vents were located on the roof. Minor general surface corrosion was observed. per 100 square inch area is 0.090" without repair.

Where:D = Diameter 40 ftH = Bott. Shell Course to Max. Liquid Level 11 ft (1st course)G = Specific GravityS = Max. Allowable Stress (psi)E = Joint Efficiency

5.06.0


Appendix B: Calculations Summary

0.100

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

Flat roof design thickness depends on the presence of and spacing of rafters and the diameter

Course Height (feet)

0.70

1 0.1002

1.0023595 (remaining courses)23595 (1st & 2nd courses)

SEGHDt )1(6.2

min−

=


Documents

CURI Tank 3901-A - Clemson Universitymedia.clemson.edu/facilities/pdf/es/Integrity_Testing_Reports_2012... · Inspection: 26 September 2012 Prepared by: George E. Matthews, E.I.T