CITY OF TONKA BAY

December, 2017

ELEVATED TANK

INSPECTION REPORT

PAGE 1

250,000 Gallon Spheroid

BSI PROJECT NO. WI 1367

City of Eden Prairie 14100 Technology Drive

Eden Prairie, Minnesota 55344 Phone: (952) 294-5908

Inspected By:

Badger State Inspection, LLC P.O. box 157

Osseo, WI 54758

PAGE 2

1.0 PROJECT INFORMATION ...................................................................... 3

2.0 EXECUTIVE SUMMARIES ...................................................................... 4

2.1 Structural Examination Summary ............................................ 4

2.2 Coating Evaluation Summary .................................................. 4

2.3 Repair and Reconditioning Cost Estimate ............................... 5

2.4 Remaining Tank Life ............................................................... 5

3.0 RECOMMENDATIONS ............................................................................ 6

3.1 Interior Wet Structural ............................................................. 6

3.2 Interior Wet Coating ................................................................ 6

3.3 Cathodic Protection (C.P.) System .......................................... 7

3.4 Water Stagnation and De-icing System (SolarBee GS-12) ..... 7

3.5 Interior Dry Structural .............................................................. 7

3.6 Interior Dry Coating ................................................................. 7

3.7 Exterior Structural ................................................................... 8

3.8 Exterior Coating ...................................................................... 8

3.9 Site and Environmental Considerations .................................. 9

3.10 Antenna Considerations ........................................................ 9

4.0 INSPECTION AND EVALUATION METHODS ...................................... 10

4.1 Methods ................................................................................ 10

4.2 Examination and Evaluation Techniques .............................. 10

5.0 Engineer’s Cost Estimates ..................................................................... 12

T A B L E O F C O N T E N T S

PAGE 3

Section

1.0 1 . 0 P R O J E C T I N F O R M A T I O N

BSI Project No.: WI 1367 Customer P. O. Number:

Customer: City of Tonka Bay Phone: (952) 474-7994

Street/City/State/Zip: 4901 Manitou Road, Tonka Bay, MN 55331

Customer Contact: Robin Bowman

Tank Owner: City of Tonka Bay Phone: (952) 266-9833

Tank Owner Contact: Robin Bowman (952) 266-9833

Client: WSB & Associates Client Contact: Greg Johnson, PE Phone: (651) 286-8466

Owner's Tank Designation: Water Tower #1

Tank Description: 250,000 Gallon Spheroid

Tank Location (Street/City/State/Zip):

Purpose of Inspection: Tank examination and interior and exterior coating evaluation

Date of Inspection: 12-18-2017

Inspected By: Brian Kollmer & Brian McCarthy

Type of Inspection: Dry Tank and Clean-Out

Manufacturer: CBI Construction Date: 1989

Serial No.: 080632 Design Code: AWWA D-100-84

Capacity: 250,000 Gallons

Type of Construction: Welded

Number and Size of Pilasters/Support Columns: One 10 ft Diameter Steel Column

Tank Diameter: 44 feet +/-

Height: Overall 121’-8”____ Shell/Balcony N/A

Height to: HWL 116 ‘_____ LWL 84’-9”

Type of Access to Tank Interior: Roof Manway

Tank Construction Drawings: Yes

Previous Inspection Records: 2014 Badger State Inspection Report

EXISTING COATING INFORMATION

INTERIOR WET INTERIOR DRY EXTERIOR

Date Last Coated 1989 1989 1989

Full or Spot Repair Full ?? Seam Seam

Coating Contractor Unknown Unknown Unknown

Surface Preparation SSPC-SP-10 Unknown SSPC-SP-6

Paint System Epoxy Epoxy Epoxy/Urethane

Paint Manufacturer Tnemec Tnemec Tnemec

Lab Lead Test Paint Chips Yes Yes Yes

4

2.1.1 Based on the inspection data, it appears that there are some miscellaneous structural modifications and repairs that are required. These modifications and repairs serve to bring the tank into compliance with OSHA regulations, AWWA standards, as well as allow for better coating bonding, allow for safer access in and on the tank and, in some cases, removing unnecessary items. 2.2.1 Lead and Chromium Content Analysis The total lead content of the interior and exterior coatings was analyzed. The results in Appendix D indicate a Below Detectable Level for lead content for the interior wet coating and the exterior dry coating. Reconditioning specifications must include provisions for provisions to prevent hazardous waste generation.

.. 2.2.2 Interior Wet Coating The tank requires a complete new interior coating within the next 1 to 2 years. It appears that the tank was last coated in 1989 when the tower was erected, it is 29 years old and is considered non-repairable. A properly applied and maintained immersion service epoxy coating should provide twenty (20) to twenty-three (23) years of service. See photos Appendix A.

2.2.3 Interior Dry Coating Overall the interior dry coating is in fair condition. There are random coating failures throughout the interior. dry surfaces.

The complete interior dry surfaces should be reconditioned at the same time the tower is next scheduled for reconditioning. See photos in Appendix A.

2.2.3 Exterior Coating It appears that the tank was last coated in 1989. The exterior coating is not classified as a lead or chromium based paint. It is in fair condition.

Due to age, chalking, and deterioration, the entire exterior coating is not repairable and should be removed and replaced within the next 1 to 2 years with a zinc/epoxy/urethane coating system. See photos in Appendix A.

Section

2.0 2 . 0 E X E C U T I V E S U M M A R I E S

2.1 Structural Examination Summary

2.2 Coating Evaluation Summary

5

2.3.1 The costs for structural repairs, full reconditioning of the interior wet, full reconditioning of the interior dry, and a full replacement of the exterior coatings with containment are estimated at $476,800. This estimate is based on current pricing. For up-to-date competitive bids, the project should be bid 9 to 12 months before the scheduled starting date. An experienced tank coating contractor with the proper crew and equipment should be able to complete the project in 8 weeks. At the time of reconditioning, the tower will need to be drained and remain off-line during surface preparation and painting. 2.4.1 Based on the inspection data, it appears that, if the recommended structural repairs and coating replacement are completed within the next one (1) to two (2) years, and inspected regularly, the tank is satisfactory for continued service.

The tank and the coating should be first inspected within the warranty period and every five to seven years thereafter. The new interior and exterior coating, if applied and maintained properly, should last to twenty (20) to twenty-five (25) years with only minor repairs.

2.3 Repair and Reconditioning Cost Estimate

2.4 Remaining Tank Life

6

The photographs referred to in this section are in Appendix A. All drawings are found in Appendix B. The surface preparation requirements for all repairs as well as the requirements for welding are described in Appendix C. The exterior and interior paint chip test results are in Appendix D.

Based on an evaluation of the inspection data, the recommendations are:

3.1.1 Seal weld the inside of the joint between the roof plate and the roof manways. See photos 2 and 3. Seal weld the overlapping plate joint seam on the roof dollar plates. See photos 4, 5 and 6. Reweld the seams around the overflow vortex breaker. Grind and radius edges of the weir box. See photos 7 and 8.

Seal weld the bottom side of the drywell tube stiffener rings. See photos 9 and 10. Remove the excessive safety climb cable on the interior ladder. See photo 11. Remove the exist drain plug and replace with a stainless-steel frost-free drain valve and a connection to the overflow pipe. See BSI drawing 19 and photos 12 and 13.

3.2.1

The coating Dry Film Thickness (DFT) on the interior wet surfaces is from 14.6 to 32 mils with average of 17.0 mils DFT.

The interior coating is in fair to good condition. The coating is now 29 years old and because of age is not considered repairable. The interior wet coating should be replaced within the next 1 to 2 years. See photos 14 through 20.

After structural repairs are completed, the entire reservoir surfaces should be abrasive blasted and the coating replaced with a zinc primer and a 2-coat epoxy coating system.

Section

3.0 3 . 0 R E C O M M E N D A T I O N S

3.1 Interior Wet Structural

3.2 Interior Wet Coating

7

3.3.1 Currently the tower does not have a cathodic protection (C.P.) system inside this tower. It is always an option to install a new system but BSI believes that with proper inspection during the preparation and coating application, a warranty inspection along with periodic tower inspections every four to five years, that it is unnecessary for the to install a C.P. system inside the tower.

3.4.1 Currently the tower does not have a water stagnation system. BSI is suggesting installing a SolarBee GS-9 unit, located on the bottom of the floor between the drywell tube and the cone plates. The SolarBee unit will also aid in minimizing the formation of ice inside the tower which can damage the coating system. See Solar-Bee GS-9 Brochure. 3.5.1 Remove the existing 12” x 18” oval manway in the drywell tube. Install one new 24-inch diameter, pressure style manway in the same location. The new manway shall be installed approximately 30-inches from the bottom of the bowl. The manway will improve ventilation during reconditioning and bring the tower in compliance with OSHA Confined Space Entry requirements. See BSI Drawing No. 10 and photos 21 and 22. Replace the existing safety climb cables on all the interior of ladders with a new DBI safety cable System and include two (2) new full body harnesses. See DBI Boucher’s in Appendix B. Remove the drain valve piping that connects to the overflow pipe. See photo 23. Install a connection in the overflow pipe for the new Frost-Free Drain Valve. Install a new 24-inch diameter, pressure style manway in the cone plates and a ladder from the upper platform to the cone plates for access to this manway. See BSI Drawing No. 10. Replace all damaged insulation on the inlet pipe and install an aluminum jacket covering. See photo 24. Seal weld a circular angel around the outer edge of the upper platform. Install a 2-inch drain coupling in the platform at the lowest point of the platform where water congregates and a connection to the overflow pipe. See BSI Drawings 18 and 16. Install a 4-inch high collar around the inlet/out and the overflow pipes on the upper platform. Plug weld all drain holes in the upper platform. See photo 25. 3.6.1 The coating on the interior dry is the original coating when the tower was erected in 1989 and is now 29 years old and it is considered non-repairable based upon its age.

3.3 Cathodic Protection (C.P.) System

3.4 Water Stagnation and De-Icing System (SolarBee GS-12)

3.5 Interior Dry Structural

3.6 Interior Dry Coating

8

The complete interior dry surfaces and the piping in the Valve pit should be reconditioned at the same time the tower is next scheduled for reconditioning in the next 1 to 2 years. See photos 26 thru 34.

The coating Dry Film Thickness (DFT) on the interior dry surfaces is from 7.7 to 22.9 mils with an a high of 16 plus mils DFT.

3.7.1 Install a new 24-inch diameter frost-free aluminum mushroom vents with removable covers. The existing vent around the drywell tube does not meet AWWA D100 and local health department regulations. The removable vent will improve ventilation and aid in compliance with OSHA confined space regulations during reconditioning. See Photo 35 and BSI Drawing No. 6. Remove the 4-inch high collar around the drywell tube and 6-inches of the dollar plate. Install a ¼-inch thick plate over the opening and seal weld both interior and exterior to the drywell tube and roof plates. See photos 35 and 36. Remove and relocate the hinges on the roof access manway so when the manway cover is opened it does not hit the dry well tube lid. See Photo 37. Remove the existing 11’ diameter roof hand rail and install a 14’ diameter hand railing. See BSI Drawing # 14 and photos 38 and 39. Remove the existing steel pedestrian door and door frame. Furnish and install a new heavy-duty fiberglass door with pebble grain finish and aluminum door frame. Cut out the welded plate on the interior of the overflow pipe and replace the screen. See photo 40. After reconditioning, replace all damaged, lose or missing concrete grout under the base plate with non-shrink 3000 PSI grout. After recondition epoxy chalk the openings around the anchor bolts. See photo 49.

3.8.1

It appears that the tank was last coated in 1989. The exterior coating is not classified as a lead base paint. It is in fair condition.

The coating Dry Film Thickness (DFT) on the exterior roof plates is from 6.1 to 19.8 mils with an average of 10.5 mils DFT.

The coating Dry Film Thickness (DFT) on the exterior cone plates is from 7.4 to 16.9 mils with an average of 12 mils DFT.

3.7 Exterior Structural

3.8 Exterior Coating

9

Due to age, chalking, and deterioration, the entire exterior coating is not repairable and should be removed and replaced within the next 1 to 2 years with a zinc/epoxy/urethane coating system. See photos 41 thru 49.

The exterior coating is not classified as lead or chromium-based paint. However, due to general location, removing it using conventional open air-dry abrasive blasting methods will cause environmental problems with visible air emissions and fugitive particulate matter. Reconditioning specifications must be designed to be in compliance with local, state and Federal regulations and will require full exterior containment.

3.9.1

No recommendations are made. In conformance with Minnesota State Rules Chapter 7025 and Federal USEPA Rules for air quality and control of dust and fugitive emissions, a risk factor analysis has been performed to determine the class of pollution control required for the tower during reconditioning. The risk factor is a calculation of potential risk for the structure and the values in the table of Subpart 3 (of the standard) are the standards of the risk factor for the surrounding properties. The class of pollution control required for compliance with the rules is Class H, which requires full containment.

3.10.1

There is only one City owned antenna located on the tower, located above the tower access man door. See photo 50. The Owner should consider removing the coaxial cable entrances from the bottom bell plates and welding a plate inside the openings. See photo 47.

3.9 Site and Environmental Considerations

3.10 Antenna Considerations

10

4.1.1

The tank was evaluated on the interior and exterior in conformance with the following:

a) General guidelines of AWWA Manual M42 Appendix C “Inspecting and Repairing Steel Water Tanks, and Elevated Tanks for Water Storage”.

b) BSI “Procedures and Guidelines for Inspecting Existing Steel and Concrete Water Storage Tanks”.

The inspection of the base metal and coatings on interior and exterior surfaces included only areas accessible without scaffolding or special rigging. Where possible, the base metal and coating on the interior wet surfaces were examined from a rubber raft while the tank was being drained. The overall structural condition of the tank was visually examined. No structural analysis was done to determine if the tank design complies with the AWWA D100-96 Standard for “Welded Steel Tanks for Water Storage”. However, any observed non-conformance to the AWWA D100 standard is noted in this report. Although compliance with OSHA regulations was not a part of this inspection, any unsafe conditions or violations of current OSHA regulations that were observed are noted in this report.

Some or all of the following procedures were performed as applicable:

4.2.1 Site Survey

The tank site was evaluated for proper drainage and conditions affecting access. Also, the following site dimensions were obtained; distance to fence(s), power lines, owner buildings, public property, private property/buildings, school/playgrounds, public parks, and other property.

4.2.2 Foundations

The tank concrete foundation was visually examined for cracks, spalling condition of grout, indications of distress or settlement, and elevation above grade.

Section

4.0 4 . 0 I N S P E C T I O N A N D

E V A L U A T I O N M E T H O D S

4.1 Methods

4.2 Examination and Evaluation Techniques

11

4.2.3 Tank Plate Thickness

Plate thickness measurements were taken using ultrasonic methods (UTM). The readings were taken using a digital readout Nova D-100 Ultrasonic Thickness Gage that has a dual element probe (transducer). The probe's transmitter element sends a short ultrasonic pulse to the material. The pulse, reflected as an echo from the opposite side of the plate, returns to the probe's receiver element. The round trip time is directly related to the material's thickness.

4.2.4 Coating Thickness

Interior and exterior coatings, where accessible, were tested in accordance with Steel Structures Painting Council SSPC-PA2 “Measurement of Dry Film Thickness with Magnetic Gages”, using Type 2 Magnet Flux Gages with a fixed probe.

4.2.5 Coating Adhesion

Adhesion testing of the coating to the steel was performed by ASTM D3359 Shear Adhesion Test, Measuring Adhesion by Tape Test. In addition, a subjective coating adhesion evaluation was performed using a penknife.

4.2.6 Coating Serviceability

The estimated remaining coating life, or serviceability, evaluation was performed using a wide variety of inspection instruments such as dry film thickness gauge, penknife, 30x microscope, and serviceability evaluation experience (minimum experience 20 years). The instrument inspection was combined with a close visual inspection of all the interior coating's accessible areas. This was done to detect any holidays (misses), skips, runs, sags, surface contaminants, overspray, dry spray, poor coating cohesion, inter-coat delamination, loss of adhesion to the substrate, adverse conditions of the steel underneath the coating, or any other defects affecting the intended service.

4.2.8 Coating Lead and Chromium Content Analysis

Lead test results indicated that the show that the percent of lead in the coating was below the recoding limit set by the EPA 6010C (ICP AES Method for Determination of Metals). See test results for all eight heavy metals in Appendix E.

12

BSI has prepared a cost estimate for the City to use for budgeting purposes. Due to the age of the coating and the percentage of coating failure, the tower should be fully reconditioned in the next 1 to 2 years.

The following cost estimate is based on a construction schedule of 8 weeks. An updated Engineer’s Cost Estimate should be obtained within 12 months prior to bidding the project. 5.1 Interior Wet Structural Repairs $ 7,000 5.2 Interior Wet Coating - Complete $ 86,400

Type of Coating – Zinc/Epoxy/Epoxy System 5.3 Interior Dry Structural Repairs `$34,000 5.3 Interior Dry - Complete $ 54,000

Type of Coating – Zinc/Epoxy/Epoxy System 5.4 Grid bee GS-9 Mixer $15,000 5.4 Exterior Structural Repairs $ 20,000 5.5* Exterior Coating - Full Replacement $ 156,600

Type of Coating – Zinc/Epoxy/Urethane/Fluoropolymer System 5.6 Exterior Logo $ 20,000 5.9 Mobilization $ 20,000 6.0 Engineering Specifications and Inspection Fee $ 59,800 6.1 2-Year Warranty $4,000 6.1 Estimated Total Cost $ 476,800 * Includes cost for containment. Badger State Inspection, Inc.

Report prepared and certified by: Kelly C. Mulhern, Owner

NACE Certified Coatings Inspector No. 1692

Section

5.0 5 . 0 E N G I N E E R ’ S C O S T E S T I M A T E S

APPENDIX A

PHOTOGRAPHS

Photo No. 1

Overall view of tank

Photo No. 2

Un-welded seam around roof manway

Photo No. 3

Un-welded seam around roof manway.

Photo No. 4

Interior roof over lapped plate seam.

Photo No. 5

Interior roof over lapped plate seam.

Photo No. 6

Interior roof over lapped plate seam.

Photo No. 7

Overflow vortex breaker.

Photo No. 8

Overflow vortex breaker.

Photo No. 9

Un-welded seam on the bottom side of the drywell tube stiffener ring.

Photo No. 10

Un-welded seam on the bottom side of the drywell tube stiffener ring.

Photo No. 11

Excessive length of the safety climb cable.

Photo No. 12

Existing tower drain plug.

Photo No. 13

Existing tower drain plug.

Photo No. 14

Interior coating failure along roof plate over lapped plate seams.

Photo No. 15

Interior coating failure along roof plate plate seams.

Photo No. 16

Coating failure on the drywell tube.

Photo No. 17

Overall roof conditions

Photo No. 18

Pin hole rust along side weld seam on the bowl plate.

Photo No. 19

Coating failures along a bowl plate weld seam.

Photo No. 20

Good condition of the coatings on the bowl plates.

Photo No. 21

Oval manway located in the bottom section of the drywell tube.

Photo No. 22

Interior wet access oval manway in the drywell tube.

Photo No. 23

Existing drain piping that connection to the overflow pipe

Photo No. 24

Insulation on the inlet/outlet pipe

Photo No. 25

Upper platform opening around overflow pipe.

Photo No. 26

Coating failures on the interior of the drywell tube.

Photo No. 27

Condition of the coatings on the interior of the drywell tube and bowl plates.

Photo No. 28

Condition of the coatings on the upper platform.

Photo No. 29

Bowl coating conditions and 8-inch diameter antenna mounts

Photo No. 30

Overall condition of the interior dry coatings from ground level looking upwards.

Photo No. 31

Overall condition of the interior dry coatings from ground level looking upwards.

Photo No. 32

Piping in the Valve pit.

Photo No. 33

Piping in the valve pit.

Photo No. 34

Corrosion around tower entrance door.

Photo No. 35

Tower is venting around the drywell tube. Not AWWA Compliant.

Photo No. 36

4-inch collar around drywell tube.

Photo. No. 37

Roof access manways hitting each other.

Photo No. 38

Roof hand railing.

Photo. No. 39 Roof hand railing location to bolted roof manway.

Photo No. 40

Overflow screen retainer and screen.

Photo. No. 41

Condition of the exterior coating inside the roof hand railing.

Photo No. 42

Exterior finish coatings starting to delaminate from epoxy coatings.

Photo. No. 43

Coating failures on the exterior roof plate.

Photo No. 44

Coating failures on the roof hand railing.

Photo. No. 45

Coating failures on the roof plates.

Photo No. 46

View of the exterior coating on the bowl and riser column.

Photo. No. 47

Coating failures around old antenna entrances.

Photo No. 48

Coating failures and severe corrosion on the tower door frame.

Photo. No. 49

Tower access door and anchor bolts.

Photo No. 50

City’s antenna

APPENDIX B

DRAWINGS

Medora Corporation • 3225 Hwy 22 • Dickinson, ND 58601+1 866 437 8076 • Ph +1 701 225 4495 • Fax +1 701 225 0002 • www.medoraco.com

© 2014 Medora Corp.FeatureSpec_GS9_20140520

Technology DescriptionSubmersible, grid powered, circulation equipment for potable water tanks and reservoirs. Designed for continuous operation and can be installed through roof hatch without requiring tank entry.

Minimum Access Opening / Machine Size/Weight

Machine can be installed through 12 inch (30 cm) diameter opening. Assembled machine is 2 feet (0.6 meter) in length X 10 inch (25.4 cm ) in diameter and weighs 65 pounds (34 kg).

Materials of Construction316 stainless steel shell and hardware construction. GS-9 has been constructed using safe materials for contact with potable water. See certifications section below.

Submersible MotorSubmersible motor, designed for continuous operation, low power requirement, direct drive, no gearbox and no lubrication schedule required. See certifications section below.

Power SupplyThe standard 120VAC motor requires 120VAC/1PH power source outlet (20 Amp Service), nominal power consumption is 750 Watts. The GS-9 120v unit draws approximately 11.0 Amps @ 120VAC / 60Hz.

Wiring75 ft (22 m) of submersible power conductor included to terminate within junction box at top of tank. Junction box, also included.

Sealed Tank Fitting316 stainless steel tank fitting and cord grip included for sealed cord entry through tank roof.

Retrieval Chain75 ft (22 m) of 316 stainless steel retrieval chain included for machine installation and retrieval without requiring tank entry.

Chlorine Boost ConnectionChlorine boost connection point, 3/8" NPT Male, on machine for adapting to 1/2" (13mm) hose for fast chlorine dispersion during in-reservoir boosting.

Low Elevation IntakeIntake draws water in a horizontal layer within 8 inches (15 cm) of the tank or reservoir floor. Suspension kit included for suspending the GS-9 if required.

Minimum Water DepthAt depths below 2 feet (0.6 meters), the machine should be shut off to prevent damage.

Accessories Available(1) Portable Chlorine Boost Hose and Boost Pump System, (2) Control and SCADA Panel

Warranty Limited 5-year parts and labor warranty.

CertificationsMedora Corporation's potable water products are certified to ANSI/NSF Standard 61, including Annex G for low-lead content. Learn more at: www.medoraco.com/std61

Subject to change without notice.

GridBee®

GS-9 FEATURES

APPENDIX C

SURFACE PREPARATION REQUIREMENTS

NACE SPO1 78-2007; (formerly RP0178-2003)

Item No.21022

INTERNATIONAL

Standard Practice

Design, Fabrication, and Surface Finish Practices forTanks and Vessels to Be Lined for Immersion Service

This NACE International standard represents a consensus of those individual members who havereviewed this document, its scope, and provisions. Its acceptance does not in any respectpreclude anyone, whether he or she has adopted the standard or not, from manufacturing,marketing, purchasing, or using products, processes, or procedures not in conformance with thisstandard. Nothing contained in this NACE International standard is to be construed as grantingany right, by implication or otherwise, to manufacture, sell, or use in connection with any method,apparatus, or product covered by Letters Patent, or as indemnifying or protecting anyone againstliability for infringement of Letters Patent. This standard represents minimum requirements andshould in no way be interpreted as a restriction on the use of better procedures or materials.Neither is this standard intended to apply in all cases relating to the subject. Unpredictablecircumstances may negate the usefulness of this standard in specific instances. NACEInternational assumes no responsibility for the interpretation or use of this standard by otherparties and accepts responsibility for only those official NACE International interpretations issuedby NACE International in accordance with its governing procedures and policies which precludethe issuance of interpretations by individual volunteers.

Users of this NACE International standard are responsible for reviewing appropriate health, safety,environmental, and regulatory documents and for determining their applicability in relation to thisstandard prior to its use. This NACE International standard may not necessarily address all potentialhealth and safety problems or environmental hazards associated with the use of materials,equipment, and/or operations detailed or referred to within this standard. Users of this NACEInternational standard are also responsible for establishing appropriate health, safety, andenvironmental protection practices, in consultation with appropriate regulatory authorities if necessary,to achieve compliance with any existing applicable regulatory requirements prior to the use of thisstandard.

CAUTIONARY NOTICE: NACE International standards are subject to periodic review, and may berevised or withdrawn at any time in accordance with NACE technical committee procedures. NACEInternational requires that action be taken to reaffirm, revise, or withdraw this standard no later thanfive years from the date of initial publication and subsequently from the date of each reaffirmation orrevision. The user is cautioned to obtain the latest edition. Purchasers of NACE Internationalstandards may receive current information on all standards and other NACE International publicationsby contacting the NACE International FirstService Department, 1440 South Creek Dr., Houston,Texas 77084-4906 (telephone +1 281/228-6200).

Revised 2007-03-10Reaffirmed 2003-03-17

Reaffirmed September 1995Reaffirmed March 1991

Revised 1989Approved 1978

NACE International1440 South Creek Drive

Houston, Texas 77084-4906÷1 281/228-6200

ISBN 1-57590-167-6© 2007, NACE International

Shawn Muihern - Invoice INV-92234-9NXH7T, downloaded on 4/23/2008 11:11:30 AM - Single-user license only, copying and networking prohibited.

SPO1 78-2007

Foreword

When specifying tanks and vessels that are to be internally lined to control corrosion and preventproduct contamination, special design, fabrication, and surface finishing practices must beconsidered to obtain the desired performance of these linings for immersion service. As thecorrosiveness of the product increases, the design and fabrication of the tank or vessel becomesmore critical relative to the performance of the lining.

This standard presents standard practices for the design, fabrication, and surface finish of metaltanks and vessels that are to be lined for corrosion resistance and to prevent productcontamination. The standard explains how the standard practices govern the quality of liningapplications. Appendix A contains illustrations depicting both good and bad practices for tanksand vessels to be lined, and Appendix B contains a list of recommended responsibilities to ensurethat an acceptable lining application is achieved. Appendix C contains written and graphicdescriptions of five degrees of surface preparation of welds in tanks and vessels that may bespecified prior to lining.1

This standard is intended for use or reference by end users, lining specifiers, lining applicators,lining manufacturers, and contracting authorities involved in the surface preparation or lininginstallation in tanks and vessels intended for chemical immersion service.

This standard practice was originally prepared in 1978 by NACE International Task Group (TG) T6A-29, a component of Unit Committee T-6A on Coating and Lining Materials for ImmersionService, in collaboration with Unit Committee T-6H on Application and Use of Coatings forAtmospheric Service. The standard was revised in 1989 by TG T-6G-27, a component of UnitCommittee T-6G on Surface Preparation for Protective Coatings, and was reaffirmed in 1991 and1995. It was reaffirmed in 2003 by Specific Technology Group (STG) 04 on Coatings and Linings,Protective: Surface Preparation. The standard was revised in 2007 by TG 295 on Lining, Tanksand Vessels for Immersion Service: Fabrication Details, Surface Finish Requirements, and ProperDesign Considerations—Review of NACE Standard RPO1 78-2003. This TG is administered bySTG 04. It is also sponsored by STG 02 on Coatings and Linings, Protective: Atmospheric; STG03 on Coatings and Linings, Protective: Immersion and Buried Service; and STG 43 onTransportation, Land. This standard is issued by NACE International under the auspices of STG04.

~> The visual comparator mentioned in Appendix C is a molded plastic replica that illustrates various degrees of surface finishing for weldsprior to coating or lining. Full-seam welds, skip welds, butt welds, lap welds, and others are depicted. For more information contact theNACE FirstService Department, 1440 South Creek Dnve, Houston, TX 77084-4906.

NACE International

Shawn Muihern - InvoIce INV-92234-9NXI-17T, downloaded On 4/23/2008 11:1 1:30 AM - Single-user license only, copying and networking prohibited.

SPO1 78-2007

NACE International gratefully acknowledges the contributions of the following companies in thepreparation of the welding samples and the fabrication of the die from which the plastic replicashave been molded:

Ausimont USA, Inc.,12> Thorofare, NJCenterPoint Energy,~3> Houston; TXS.G. Pinney & Associates, Inc.,L4) Port St. Lucie, FLThe Sherwin-Williams Company,15~ Cleveland, OH

NACE also gratefully acknowledges the assistance of KTA-Tator lnc.,~61 Pittsburgh, PA, indeveloping the weld pattern that was used to mold the plastic replica of weld samples.

In NACE standards, the terms shall, must, should, and may are used in accordance with thedefinitions of these terms in the NACE Pubilcations Style Manual, 4th ed., Paragraph 7.4.1.9. Shalland must are used to state mandatoiy requirements. Should is used to state something consideredgood and is recommended but is not mandatory. May is used to state something consideredoptional.

~21Ausimont USA, Inc., 10 Leonards Lane, Thorofare, NJ 08086.t3tCenterPoint Energy, P.O. Box 1325, Houston, TX 77251-1325.141S.G. Pinney & Associates, Inc., Corporate Office, 1326 S.W. Biltmore St., Port St. Lucie, FL 34983.151 The Sherwin-Williams Company, 101 Prospect Avenue NW., Cleveland, OH 44115.161KTA-Tator, Inc., 115 Technology Drive, Pittsburgh, PA 15275.

NACE International

Shown Muihern - lnvo;ce INV-92234-9NXH7T, downloaded on 4/23/2008 11:1 1:30 AM - Single-user license only, copying and networking prohibited.

SPO1 78-2007

NACE InternationalStandard Practice

Design, Fabrication, and Surface Finish Practices forTanks and Vessels to Be Lined for Immersion Service

Contents

1. General 12. Definitions 13. Design Practices 14. Fabrication Practices 35. Surface Finish Practices 3Bibliography 4Appendix A: Illustrations of Design, Fabrication, and Surface Finish Practices for Metal Tanks

and Vessels to Be Lined for Immersion Service 5Appendix B: Recommended Responsibilities 11Appendix C: Written and Graphic Descriptions of Various Degrees of Surface Finishing

of Welds That May Be Specified in Preparation for Lining of Tanks and Vessels.... 12

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Section 1: General

1.1 This standard presents standard practices for thedesign, fabrication, and surface finish of tanks and vesselsto be lined for immersion service. Tanks and vessels maybe lined for corrosion control or to prevent productcontamination.

1.1.1 Appendix A (mandatory) contains illustrationsdepicting both good and bad practices for tanks andvessels to be lined for immersion service.

1.1.2 Appendix B (nonmandatory) contains a list ofrecommended responsibilities of the purchaser (user),designer, fabricator, lining applicator, and inspector toensure that an acceptable lining application isachieved.

1 .1.3 Appendix C (nonmandatory) contains writtenand graphic descriptions of five degrees of surfacepreparation of welds in tanks and vessels that may bespecified prior to lining. The written descriptions of thefive degrees of surface preparation of welds inAppendix C take precedence over the graphics and thecompanion visual comparator. The graphics are only

pictorial representations of welds and grinding finishesand are not intended to be representative of theintegrity of the welds. The “weld condition prior tofinishing” is not a typical weld; it is only intended toillustrate defects in welds that must be corrected priorto lining.

1.2 Good welding practices and welding codes govern theintegrity of the tank and vessel welds; this standard onlyaddresses surface preparation of the welds for the purposeof lining the tank or vessel for immersion service.

1.3 Other design and construction codes or standards maybe used to complement the details given here. Whenapplicable, the requirements of such other codes orstandards shall be considered. A partial list of such codesand standards can be found in the Bibliography.

1.4 These standard practices may be used in the design,fabrication, and surface finish of tanks and vessels forservices other than immersion, such as dry bulk storage ofsolid materials.

Section 2: Definitions

Lining: A coating or layer of sheet material adhered to or inintimate contact with the interior surface of a container usedto protect the container against corrosion by its contentsand/or to protect the contents of the container fromcontamination by the container material. For the purposesof this standard, lining refers to a surface barrier, usually athin film less than 500 pm (20 mu) thick applied as either alining or a coating. In common usage, the terms coatingand lining are interchangeable, but in this standard, only theterm lining is used. The requirements contained herein mayor may not apply to heavier, thick-film linings, sheet linings,trowel-applied and pumped-into-place finishes, plasma,

flame-sprayed linings, fiber-reinforced plastic linings, orsimilar lining materials.

Surface Finish: The degree of smoothness of a surfaceproduced by the removal of sharp edges and theappropriate surface preparation of welds and other roughareas. The term surface finish is also used to characterizethe degree of smoothness that is necessary to attain asurface to which the lining can be applied satisfactorily inaccordance with the lining specification.

Section 3: Design Practices

3.1 Accessibility

3.1.1 All surfaces of the tank or vessel interior shall bereadily accessible for surface preparation and liningapplication (see Figures Al through Al 0, Appendix A).

3.1.2 The manway diameter for working entrance andsafety reasons during the lining application shall be aslarge as practical for the tank or vessel being lined.

3.1.2.1 If possible, at least one manway shall belocated near ground (working) level, except in

tanks or vessels designed to be buried belowgrade.

3.1.3 Additional manways and openings should beprovided as needed to facilitate ventilation. Thesemust meet safety requirements.

3.2 Joints

3.2.1 Continuous butt-welded joints shall be usedwhenever possible (see Figure A5, Appendix A).

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3.2.2 Rivets shall not be used.

3.2.3 The use of internal bolted connections shouldbe avoided to the fullest extent possible.

3.2.4 Continuous lap-welded joints may be used butare not preferred. For sheet lining material, this type ofconstruction may not be acceptable.

3.3 Connections

3.3.1 All connections to the tank or vessel shall beflanged.

3.3.2 Threaded connections should not be used intanks and vessels operating in corrosive environments(see Figure A4, Appendix A). However, if threadedconnections cannot be avoided in corrosiveenvironments, these parts shall be fabricated ofcorrosion-resistant materials, or constructed as shownin Figure Al 0, Appendix A.

3.3.2.1 CAUTION: Dissimilar metal (galvanic)corrosion occurs when, for example, an alloy isused to replace the steel bottom of a tank, or in asimilar circumstance when alloy appurtenancesmust be part of the construction of a vessel. If alining is then applied to the steel and part of thealloy (usually 150 to 610 mm [5.9 to 24 in.]), anydiscontinuity in the lining exposes a small anodesurface. Once corrosion starts, it progressesrapidly because of the large exposed alloycathodic area to the much smaller anodic area.Without the lining, galvanic corrosion causes thesteel to corrode at the weld area, but at a muchslower rate. The recommended practice is toapply the lining to all of the alloy as well as thesteel, thereby eliminating the possible occurrenceof a large-cathode-to-small-anode surface.

3.3.3 Nozzle connections to be lined shall be as shortas possible and be a minimum of 50 mm (2 in.) indiameter (see Figure A4, Appendix A). Connectionsless than 50 mm (2 in.) in diameter shall be suitablyattached through a reducing flange (see Figure AlO,Appendix A). When trowel-applied thick-film linings arerequired, additional nozzle inside diameter shall beallowed for lining thickness.

3.4 Appurtenances Inside the Tank or Vessel

3.4.1 The standard practices in Sections 3, 4, and 5shall apply to any item to be installed inside a tank orvessel that is to be lined. Such appurtenances include,but are not limited to, agitators, anti-swirl baffles, outletconnections, gauging devices, vortex breakers, andinternal piping.

3.4.2 If appurtenances inside the tank or vessel,including nuts and bolts, cannot be lined, they shall bemade of corrosion-resistant materials. (CAUTION: SeeParagraph 3.3.2.1.)

3.4.3 If bolted connections are necessary and cannotbe made of corrosion-resistant materials, the matingsurfaces shall be lined before assembly. Gaskets shallbe used on mating surfaces and the sealing surfaces ofnuts and bolts to protect the lining.

3.4.4 Dissimilar metals shall be electrically isolatedfrom the steel tank or vessel surface wheneverpossible. Where dissimilar metals are used, selectionshall be such that the galvanic effect is minimized.Other corrosion mitigation methods may be required(see Figure A8, Appendix A).

3.4.5 Heating elements shall be offset from the tankor vessel surface to provide access for surfacepreparation, application, inspection, and cleaning.Elements shall be positioned so as not to damage thelining system.

3.5 Structural Reinforcement Members

3.5.1 Structural support members should be installedon the exterior of the tank or vessel. However, if suchmembers are installed internally, they shall befabricated of simple shapes such as smooth, roundbars or pipe for ease of applying the lining material.

3.5.2 The use of internal flanged connections,stiffening rings, reinforcement pads, angles, channels,I-beams, and other complex shapes should beavoided, If they must be installed internally, thesemembers shall be fully welded and welds and sharpedges ground to a radius of at least 3.2 mm (0.13 in.)or as agreed between the tank or vessel fabricator,tank or vessel owner, and lining applicator (see FiguresAl and A6, Appendix A).

3.6 Heat Sinks

3.6.1 Heated, forced curing of lining systems is oftenpreferred if not specifically required. During tank orvessel design and fabrication, especially with field-erected units, consideration must be given to avoidingor minimizing heat sink areas. Such areas mightinclude opposite saddles or support lugs, flat bottomson foundations, and stiffening rings.

3.6.2 These situations may be addressed either bytank or vessel design or by construction or insulation ofthe foundation or supports. Another possible solutionis the use of temporary constructions, such as falsefloors or temporary shelters, to achieve uniform heatingand curing.

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Section 4: Fabrication Practices

4.1 All design practices in Section 3 shall apply to allfabrication.

4.2 All welding shall be continuous. Intermittent or spotwelding shall not be allowed.

4.3 Fillets and corners must be accessible for grinding.

4.4 Field tanks fabricated for use with high-heat-curedlinings (e.g., unmodified phenol formaldehyde thermosettinglinings) should have bottoms suitably insulated and installedon properly drained foundations to facilitate proper cure ofthe lining on the floor of the tank. Because the sand-filledearthen foundation, concrete pad, or other similarfoundation is a poor insulator, some means must beconsidered prior to the application of the lining either tooverride the heat sink or to distribute the heat uniformly.This may be accomplished in several ways:

(a) with the use of properly sized heaters;

(b) by placing the tank on a concrete pad topped witha 100-mm (4-in.) layer of vermiculite concrete;

(c) by insulating with a high-compressive-strengthstructural grade insulation between the tank bottomand foundation;

(d) by installing an internal temporary false bottomapproximately 1.5 m (5.0 ft) above the floor of the tankprior to the final high-temperature bake; or

(e) by other suitable means that practically andeffectively ensure a properly cured lining on the tankfloor.

Section 5: Surface Finish Practices

5.1 Sharp edges shall be ground to a smooth radius of atleast 3.2 mm (0.13 in.) or as agreed between the tank orvessel fabricator, tank or vessel owner, and liningapplicator.

5.2 Tank and vessel internal surfaces to be lined shall notbe marred by gouges, handling marks, deep scratches,metal stamp marks, slivered steel, or other surface flaws.Flaws shall be repaired by welding or grinding, asappropriate.

5.2.1 Limits on surface flaw depth and geometry shallbe set by agreement between the tank or vesselfabricator, tank or vessel owner, and lining applicator.

5.2.2 All restorative welding shall be performedaccording to applicable tank or vessel design codes,approved job-specific procedures, or both.

5.3 All rough welds shall be ground to remove sharp edgesand other such irregularities (see Figure A2, Appendix A).Chipping may be used to remove sharp edges if followed bygrinding. See Appendix C for written and graphicdescriptions of five degrees of surface finishing of weldsthat may be specified preparatory to the lining of tanks andvessels.

5.3.1 The amount of grinding performed shall bejudicious and performed only to the extent necessary to

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prepare the weld surface and surrounding metalsurfaces in accordance with the specification. Over-grinding, which would result in decreasing the wallthickness or the integrity of the weld beyond thelimitations imposed by good welding practices,applicable welding codes, or tank or vessel ratings,shall be avoided.

5.4 Automatic machine welds may be acceptable asdictated by the specifications for film continuity.

5.5 All weld spatter and arc strikes must be removed.Chipping may be used if followed by grinding or the use ofan abrasive disc.

5.6 If an anti-spatter material is applied adjacent to theweld area prior to welding, the anti-spatter material shall beone that is readily removable. Anti-spatter materials shallbe removed prior to abrasive blasting.

5.7 When checking weld continuity, the tank or vesselfabricator shall avoid the use of oils, lubricants, or otherforeign materials that would leave a contaminating residuenot easily removed by abrasive blasting.

5.8 Surfaces shall be cleaned and decontaminated asrequired by the governing lining application specification(s).

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Bibliography

APl17~ Standard 650 (latest revision). ‘Welded Steel Tanks Directive 97/23/EC (latest revision). “Pressure Equipmentfor Oil Storage.” Washington, D.C.: American Directive (PED).” Brussels, Belgium: EuropeanPetroleum Institute (API). Commission.t9>

API RP 652 (latest revision). “Lining of Aboveground NACE Standard SP0294 (latest revision). “Design,Petroleum Storage Tank Bottoms.” Washington, D.C.: Fabrication, and Inspection of Storage Tank SystemsAPI. for Concentrated Fresh and Process Sulfuric Acid and

Oleum at Ambient Temperatures.” Houston, TX:ASME>8> Boiler and Pressure Vessel Code (latest revision). NACE.

New York, NY: ASME.

>7) American Petroleum Institute (API), 1220 L Street, NW, Washington, D.C. 20005-4070.(8) ASME International (ASME), Three Park Avenue, New York, NY 10016-5990.19) European Commission (EC), Rue de Ia Loi 200, B-i 049 Brussels, Belgium.

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APPENDIX A:Illustrations of Design, Fabrication, and Surface Finish Practices for Metal Tanks and Vessels to Be

Lined for Immersion Service

FIGURE AlAll construction involving pockets or crevices that do not drain or that cannot be properly abrasive blasted and lined shall beavoided.

Full Seam Weld Skip Weld

Round All Sharp Edgesper Paragraph 5.1.

DO

2 Channels 6ack-to-~ack

DON’T DON’T

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Inside of Tank orVessel Grind Smooth

Inside of Tank orVessel

Pinhole

5

DO

FIGURE A2All joints shall be continuous full-penetration porosity-free welds. In tanks and vessels that require a 100% holiday-free lining, allwelds must be smooth with no holes, high spots, lumps, or pockets. Grinding is required to eliminate sharp edges and highspots. Weld metal shall be used to fill in undercut or pits.

Inside of Tank

FIGURE A3All weld spatter shall be removed.

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DON’T

DO DoN’T

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Flanged OutI~

Inside ofTank orVessel

Pad TWe

h

Round TheseCorners

/Inside of Tank orVessel

1/1~~

tE3

DO DON’T

Sharp Corner

FIGURE A4The outlets shall be flanged or pad-type rather than threaded. Within pressure limitations, slip-on flanges are preferred becausethe inside surface of the attaching weld is readily available for rounding edges and grinding. If operating pressure dictates theuse of weld neck flanges, the inside surface of the attaching weld is in the throat of the nozzle, making repair of surfaceirregularities by grinding rather difficult.

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DO CornersDON’T

Sharp

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Inside of Tank orVessel

tDO

Grind Smooth

3

Inside of Tank orVessel

5Gap

DON’T

4

Inside of Tank orVessel

DO

Continuous FilletWeld

1~

Inside of Tank orVessel

LI,

Gap

DON’T

Weld

4

FIGURE A5Buff welding shall be used whenever possible rather than lap welding or riveted construction.

AngleStifferer

DO

Inside of Tank orVessel

DON’T

Inside of Tank orVessel

FIGURE A6Stiffening members should be on the outside of the tank or vessel.

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Roof

Inside Eliminate Crevice

_

Shell

DON’T

FIGURE A7Roof-to-Shell Joint. Eliminate crevice and lap weld at roof-to-shell joint in a tank or nonpressure vessel.

Pit (Anode)

Steel

ProtectiveLining

Alloy (Cathode)

DO

1

Pit (Anode)

Steel

ProtectiveLining

Alloy (Cathode)

V_DONT

FIGURE A8Dissimilar metal (galvanic) corrosion occurs when, for example, an alloy is used to replace the steel bottom of a tank, or, in asimilar circumstance, when alloy appurtenances must be a part of the construction of a vessel. If a lining is then applied to thesteel and part of the alloy (usually 150 to 610 mm [5.9 to 24 in.]), any discontinuity in the lining exposes a small anode surface.Once corrosion starts, it progresses rapidly because of the large exposed alloy cathodic area to the much smaller anodic area.Without the lining, galvanic corrosion causes the steel to corrode at the weld area, but at a much slower rate. The recommendedpractice is to apply lining to all of the alloy as well as the steel, thereby eliminating the possible occurrence of a large-cathode-tosmall-anode surface.

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Inside of Tank orVessel

Proper Lining Application

Inside of Tank orVessel

DO

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Tank Shell

Screwed Nipple for Use DuringFabrication and Heat Curing ofThermosetting Linings - -

It is recommended thatthe plug be left out forventing and the hole pluggedwith grease to preventatmospheric corrosion ofthe threads:

Installation of Curved (Preferred) or FlatPlate, Fully Seal-Welded and Ground, toEliminate Inaccessable Area for ProperSurface Preparation and Lining inMulti-Compartment Tanks Cénstructed withDished Heads Between Compartments

FIGURE A9A technique (detail of fabrication) to allow for good continuity of lining application for inaccessible areas such as those inmulticompartment tanks or vessels.

Slip-on Flange —

circle.

If en alloy flange is required,the designer should considerthe use of insulating sleevesand washers as a protectionagainst galvanic corrosion.

as

FIGURE AlOMinimum 50-mm (2-in.) diameter nozzle required for most thin-film linings. Thicker-film linings may require a larger-diameternozzle. This diagram also illustrates fabrication practice where a threaded connection is required in a tank or vessel that requiresa holiday-free lining.

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Inside of Tank orVessel

This area is inaccessible forlining application

aInternal Dished Head

mm (1 .0 in.) thread nipple

Inside of Tank or VesselGrind and Radius

Line completely to bolt

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APPENDIX B: Recommended Responsibilities

This appendix is a list of recommended responsibilities thatshould be assigned to the purchaser, designer, fabricator,lining applicator, and inspector in order to obtain a properlydesigned and fabricated tank or vessel for interior lining.

Bi .1 Joint Responsibilities

Bi .1.1 The purchaser, designer, fabricator, liningapplicator, and inspector(s) should review and agree tothe requirements involved before contractualagreements are made.

B1 .1.2 The purchaser, in agreement with thefabricator and lining applicator, should assignresponsibility for inspection of fabrication, surfacefinish, and lining application, and such responsibilityshould be defined in all contracts.

Bi .2 Responsibilities of the Purchaser (Owner or User)

B1.2.1 The purchaser should be responsible forspecifying and/or approving the detail requirements fordesign, fabrication, and surface finish to all partiesconcerned.

B1.2.1.1 The detailed requirements should befully described in writing and include drawings ofthe tank or vessel to be fabricated and lined andservice requirements.

B1.2.1.2 The purchaser should advise thedesigner, fabricator, lining applicator, and allinspectors of the detailed requirements,including time schedules, inspection, andacceptable requirements, in writing.

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Bi .3 Responsibilities of the Designer

B1.3.1 The designer should be responsible forincluding the required fabrication and surface details onall sketches and drawings related to the tank or vessel.

Bi .4 Responsibilities of the Fabricator

BI .4.1 The fabricator should be responsible foradhering to the fabrication and surface finish detailsshown on the working drawings and described in thetank or vessel specifications.

31 .4.2 Responsibility for an inspection of the blast orany additional welding, grinding, or surface finishingthat may be revealed by the surface preparation forlining, plus any subsequent reblasting, should bedefined in the lining contract.

31 .4.3 The fabricator, when checking the quality ofthe weld, should use only those materials that can bereadily and thoroughly removed by the fabricator aftercompletion of the inspection procedure.

B1 .5 Responsibilities of the Lining Applicator

Bi .5.1 Responsibility for additional welding, grinding,or surface finishing that may be revealed by the surfacepreparation for lining, plus any subsequent reblasting,should be defined in the lining contract.

Bi .6 Responsibilities of the Inspector(s)

B1 .6.1 A qualified inspector whose qualifications andaffiliation are acceptable to all parties should beresponsible for the verification of fulfillment of design,fabrication, and surface finish requirements.

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Appendix. C—Written and Graphic Descriptions of Various Degrees of Surface Finishing of Welds That May Be Specifiediii Preparation for Lining of Tanks and VesseIs~

I1ACE WeldPrepflion Type of Qinding Butt l*Id Fillet V~k1ed Tee Jolt Lap VtICJDefljnaicn

~eId spatter isremovéd and all sitfai~A ~~ imperfections are repairedasnasessay: Not Applicable Not Applicable

d‘~, The weld is g’àund flush with the plateefasts. surtase.

~Not Applicable Not Applicable

~

0 nd fI hMinor imperfections such as PCYoSdy Not Applicable Not Applicable

~ rou us and undercutting exist. The weld isground flush with tte plate 5thace.

: Not Applicable Not Applicable

Groundsmooth; free Weld spatter is remoyed and al[sthace ~Vpldspatter is removed and all stha~ Filletweld bet~ertthet~ plates. Weldc of all defects.’~ imperfections are repaired as necessay. imperfections arerepaired as

The weld is g’ound smooth and blended: necessay. The weld is ground smooth Th~ weld is cround imooth and blendeJ intointo the platesurfaDes. and blended into theplate surfases. the pléte sullases.

~ A k_inside of Tank or Vessel

“a The written descriptions ot the various degrees of sufaDe prepa’ation of welds in the Oppendicesof th~ stand&d take preca:lence Over the~graphics and the compénion visualcomparator The graphics are only pictorial representations of welds and grinding finishes and are not intended to be representative ot the integrity of the welds The Weld corsirtionprior to finishing is not a typical weld it is only intended to illustrate defects in welds that must be corrected prior to lining Good welding paotces and welding codes gova’n theintegrity ot the tank and vessel welds; this standaiti only ad&esseésurfase pr~arationot the’Aèlds.fcrthepurpse otlining thetank orvessel for immersion sàvice.

The visual comparator mentioned in Appendix C is a molded plastic replica that illustrates various degrees.of surface finishing for welds prior to coating or lining. Full-seam welds,skip welds, butt welds, lap welds, and others are depicted. For more information, contact the NACE International Firstservice Department, 1440 South Creek Dr., Houston, Texas77084-4906 (telephone +1 2811228-6200).

12 NACE International

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Appendix C (Continued)11)

Type of Butt Weld Fillet Welded Tee Joint Lap WeldDesign Grinding

Minor imperfections such as pcrosity and Minor imperfections such as pcrosity and Minor imperfections such as pcrosity andci Ground smooth undercutting exist. Weld spatter is undercutting exist. Weld spatter is undercutting exist. Weld spatter isand blended.Z removed; welds era then g’ound smooth removed; welds ere then ~‘ound smooth removed; welds ere then g’ound smoothand blended into the plate surfases. and blended into the plate surfases. and blended into the plate surfaDes.

aw j~~j~f Tank

E Sharp projections on the Sharp projections on the Sharp projections on theMinimal weld bead, slag, and weld weld bead, slag, and weld weld bead, slag, and weld

spatter ere removed, spatter a’e removed, spatter a’e removed.

SW ~1!eZ.2i~

Weld Condition Prior to FinishingH~.’

Jj~,~l~id~:sfeiank —

t~The written descriptions of the various degrees of surfase p’eparation of welds in the appendb of this standa’d take presederce cwer the g’aphics and the companion visual comparator. Thegraphics are ont~’ pictcrial representations of the welds and grinding finishes and are not intended to be representativa of the integrity of the welds. The “as is” criginal weld is not a t~pical weld;it is only intended to illustrate defaDts in welds that must be cc4’rected prict to coating and lining. Good welding praDtices and welding codes govern the integrity of the weld; this standerd onlyaddresses surfase pre~ration of the welds fci the purpose of coating and lining fci immersion service.~ Abrasive blasting in preperation for coating may reveal additional porosity and undercutting. Some applicators request the fthrication to blast the welds to reveal these imperfestions prior torequesting inspection of the grinding by ti-a lining applicator. Responsibility for repair of imperfections so revealed should be resolved in the pit-job confererce.

The visual comparator mentioned in Appendix C is a molded plastic replica that illustrates various degrees of surface finishing for welds prior to coating or lining. Full-seam welds,skip welds, butt welds, lap welds, and others are depicted. For more information, contact the NACE International FirstService Department, 1440 South Creek Dr., Houston, Texas77084-4906 (telephone +1 2811228-6200).

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ISBN 1-57590-167-6NACE International

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APPENDIX D

PAINT TEST RESULTS