Integrity Testing OSCReadiness Abt Assoc 2000

Inspection and Integrity Inspection and Integrity Testing of Tanks and Testing of Tanks and

PipingPiping

OSC Readiness Training February 5, 2008

&

Gary Boley

Mark W. Howard

22OSC Readiness Training February 5, 2008

IntroductionIntroductionThis Module will Discuss:This Module will Discuss:1.1. Overview of Relevant SPCC Requirements Overview of Relevant SPCC Requirements 2.2. Types of Tanks and Piping (construction)Types of Tanks and Piping (construction)3.3. Why Inspect?Why Inspect?4.4. Basic Tank VocabularyBasic Tank Vocabulary5.5. Overview of Inspection ProcessOverview of Inspection Process6.6. Industry Inspection StandardsIndustry Inspection Standards

•• API 653 API 653 •• STI SPSTI SP--001001•• APR 12 R1APR 12 R1•• API RP 1110API RP 1110•• API 570API 570


6.6. Inspection of Other Tank TypesInspection of Other Tank Types7.7. ““HybridHybrid”” InspectionsInspections8.8. BaseliningBaselining9.9. ReRe--rating Tank Capacityrating Tank Capacity10.10. Piping and Piping StandardsPiping and Piping Standards11.11. Items to Look for During an SPCC Items to Look for During an SPCC

InspectionInspection

IntroductionIntroduction (continued)(continued)


Inspections and Testing under the Inspections and Testing under the SPCC Rule SPCC Rule (40 CFR part 112)(40 CFR part 112)

Inspections are required for containers, Inspections are required for containers, associated piping, valves and appurtenances, associated piping, valves and appurtenances, and on other equipment and components that and on other equipment and components that could be a source or cause of an oil releasecould be a source or cause of an oil release

Intended to prevent, predict, and detect Intended to prevent, predict, and detect discharges discharges

Type and scope of the inspection will depend on Type and scope of the inspection will depend on the type of container, secondary containment the type of container, secondary containment configuration, and reference standard selectedconfiguration, and reference standard selected


SPCC Inspection RequirementsSPCC Inspection RequirementsThe rule does not prescribe a specific The rule does not prescribe a specific frequency or methodology to perform the frequency or methodology to perform the required inspections, evaluations, and required inspections, evaluations, and tests tests

Instead, the rule relies on the Instead, the rule relies on the owner/operator to apply good engineering owner/operator to apply good engineering practice as certified by the professional practice as certified by the professional judgment of the PE.judgment of the PE.


Some Requirements Not Yet in Effect Some Requirements Not Yet in Effect -- Compliance Date ExtensionsCompliance Date Extensions

Compliance dates for 2002 SPCC rule extended Compliance dates for 2002 SPCC rule extended in 2003, 2004, 2006, and 2007in 2003, 2004, 2006, and 2007Plan amendment and implementation date is Plan amendment and implementation date is July 1, 2009 for all regulated facilities, except July 1, 2009 for all regulated facilities, except farmsfarms““NewNew”” 2002 requirements are not yet in effect!2002 requirements are not yet in effect!2007 proposal may result in additional 2007 proposal may result in additional amendments to integrity testing requirementsamendments to integrity testing requirements


When there is an Impracticability When there is an Impracticability DeterminationDetermination

If a facility owner/operator finds that If a facility owner/operator finds that containment methods are containment methods are ““impracticable,impracticable,”” facility must:facility must:

Conduct periodic integrity testing of Conduct periodic integrity testing of bulk storage containers and periodic bulk storage containers and periodic integrity testing and leak testing of integrity testing and leak testing of the valves and piping associated with the valves and piping associated with the containers.the containers.

§112.7(d)

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BBrittle Fracture Evaluationrittle Fracture Evaluation

§112.7(i)

Owner/operator is required to evaluate fieldOwner/operator is required to evaluate field--constructed aboveground containers:constructed aboveground containers:−− Undergoing repair, alteration, reconstruction, or Undergoing repair, alteration, reconstruction, or

change in service, particularly colder servicechange in service, particularly colder service−−When there has been a discharge or failure due to When there has been a discharge or failure due to

brittle fracture or other catastrophebrittle fracture or other catastrophe

Owner/operator must take appropriate action, if Owner/operator must take appropriate action, if necessary, to address findingsnecessary, to address findings

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Regularly Scheduled Integrity Regularly Scheduled Integrity TestingTesting

At onshore facilities (excluding production) At onshore facilities (excluding production)

§ 112.8(c)(6) or §112.12(c)(6)

Applies to:Applies to:−− Large (fieldLarge (field--constructed or fieldconstructed or field--erected) and small erected) and small

(shop(shop--built) aboveground containersbuilt) aboveground containers−− Aboveground containers on, partially in (partially Aboveground containers on, partially in (partially

buried, bunkered, or vaulted tanks) and off the buried, bunkered, or vaulted tanks) and off the ground wherever located; ground wherever located;

−− Aboveground containers storing any type of oil. Aboveground containers storing any type of oil.


Regularly Scheduled Integrity Regularly Scheduled Integrity TestingTesting

Performed on a regular schedule, as well as when Performed on a regular schedule, as well as when material repairs are madematerial repairs are made

Performed by properly trained personnel (as defined Performed by properly trained personnel (as defined in the standard referenced in the plan unless hybrid in the standard referenced in the plan unless hybrid used; usually certified inspectors)used; usually certified inspectors)

§ 112.8(c)(6) or §112.12(c)(6)

Example testing techniques identified in the rule:Example testing techniques identified in the rule:−− Hydrostatic testing Hydrostatic testing −− Radiographic testingRadiographic testing−− Ultrasonic testing ( Ultrasonic testing ( ““UTUT””))

−− Acoustic emissions testingAcoustic emissions testing


Buried Piping InstallationsBuried Piping InstallationsConduct regular inspections of all aboveground Conduct regular inspections of all aboveground valves, piping, and appurtenancesvalves, piping, and appurtenances

Assess general condition of items such as flange Assess general condition of items such as flange joints, expansion joints, valve glands and bodies, joints, expansion joints, valve glands and bodies, catch pans, pipeline supports, locking of valves, catch pans, pipeline supports, locking of valves, and metal surfacesand metal surfaces

Conduct integrity and leak testing of buried Conduct integrity and leak testing of buried piping at time of installation, modification, piping at time of installation, modification, construction, relocation, or replacementconstruction, relocation, or replacement

§ 112.8(d)(4)or §112.12(d)(4)

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PProduction Facility Aboveground roduction Facility Aboveground ContainersContainers

Periodically and upon a regular schedule Periodically and upon a regular schedule visually inspect each container for visually inspect each container for deterioration and maintenance needsdeterioration and maintenance needs

Include the foundation and support of Include the foundation and support of each container that is on or above the each container that is on or above the surface of the ground.surface of the ground.

§ 112.9(c)(3)


Tanks DefinedTanks Defined for SPCCfor SPCC……

Completely buried tank means any Completely buried tank means any container completely below grade and container completely below grade and covered with earth, sand, gravel, asphalt, covered with earth, sand, gravel, asphalt, or other material. or other material. Containers in vaults, bunkered tanks, or Containers in vaults, bunkered tanks, or partially buried tanks are considered partially buried tanks are considered aboveground storage containers for the aboveground storage containers for the purposes of the SPCC rule.purposes of the SPCC rule.

§112.2


…… Different than how Tanks are Different than how Tanks are Defined for UST RegulationDefined for UST Regulation

40 CFR part 280 defines a UST as 40 CFR part 280 defines a UST as ““any any one or combination of tanks (including one or combination of tanks (including underground pipes connected thereto) underground pipes connected thereto) that is used to contain an accumulation of that is used to contain an accumulation of regulated substances, and the volume of regulated substances, and the volume of which (including the volume of which (including the volume of underground pipes connected thereto) is underground pipes connected thereto) is 10 percent or more beneath the surface 10 percent or more beneath the surface of the groundof the ground..”” § 280.12

Inspection and Inspection and Integrity TestingIntegrity Testing

Tanks and Tanks and PipingPiping


Types of TanksTypes of TanksASTs/NonASTs/Non--buried tanksburied tanks−− 40 CFR 112: Covered, vaulted, partially buried, true 40 CFR 112: Covered, vaulted, partially buried, true

ASTsASTs

USTs/Buried tanksUSTs/Buried tanks−− 40 CFR 112: Buried storage40 CFR 112: Buried storage−− 40 CFR 280: UST (40 CFR 280: UST (>>10% underground)10% underground)

Operating pressuresOperating pressures−− Atmospheric (Atmospheric to 1/2 psig)Atmospheric (Atmospheric to 1/2 psig)−− LowLow--pressure (1/2 psig to 15 psig)pressure (1/2 psig to 15 psig)−− HighHigh--pressure (>15 psigpressure (>15 psig----pressure vessels )pressure vessels )

Construction TypesConstruction Types−− Shop built vs. field constructed Shop built vs. field constructed


Tank VocabularyTank VocabularyMinimum Thickness (Piping)

Modification

Reconstruction

Remaining Life (Piping)

Repair *

Shell; Wall

Shop-built

Ultrasonic test

* Also has an SPCC regulatory definition

Alteration *

Brittle Fracture Evaluation

Capacity

Change in Service

Field-erected

Hydrotest

Integrity Test

Leak Test

Maximum Allowable Working Pressures (Piping)

Steel Aboveground Steel Aboveground TanksTanks(AST)(AST)


Shop Built ASTsShop Built ASTs

Steel Steel -- Welded, riveted, and boltedWelded, riveted, and boltedConstruction standards Construction standards −− API 12F, API 650API 12F, API 650−− STI F911, F921STI F911, F921−− UL 80, 142, 2085UL 80, 142, 2085

Methods of fabricationMethods of fabricationParts of shopParts of shop--built ASTsbuilt ASTsFoundationsFoundations


Shop Built ASTs TypesShop Built ASTs Types

Single wallSingle wallDouble wallDouble wallDiked or secondary containment tanksDiked or secondary containment tanksConcrete encased tanksConcrete encased tanksVaulted tanksVaulted tanks


RoofRoof

BottomBottom

ShellShell

Vertical ConstructionVertical Construction


LOW

RO

OF

SH

ELL

BO

TTO

M

MEDIUM

HIGH

Vertical Construction/ Vertical Construction/ probability of tank failureprobability of tank failure


Vertical Tank StandardsVertical Tank Standards

UL 142: Standard for safety UL 142: Standard for safety for steel aboveground tanks for steel aboveground tanks for flammable and for flammable and combustible liquidscombustible liquidsAPI API –– 650 Appendix 650 Appendix ““JJ””: : Standard for the design of Standard for the design of tanks built to APItanks built to API--650 with 650 with diameters not exceeding diameters not exceeding 2020’’


Horizontal ConstructionHorizontal Construction

ShellShell

HeadHead

SupportsSupports


LOW

SH

ELL

HE

AD

SU

PP

OR

T

LOW

HIGH

Horizontal Construction/ Horizontal Construction/ probability of tank failureprobability of tank failure


Horizontal Tank StandardsHorizontal Tank Standards• UL 142: Standard for safety for steel

aboveground tanks for flammable and combustible liquids


UL 80UL 80

The Good

The Bad

& The Ugly

• Standard for Safety for steel tanks for oil-burner fuel


STI F911STI F911

- Can be modified with rain shields

• Dike Around Storage Tank (D.A.S.T.)


STI F921STI F921

- Often used in aviation facilities.- May or may not have pumping systems.

• Double-Walled Horizontal Tanks


UL 2085UL 2085

• Standard for Safety of Protected Tanks for Flammable Liquids


STI F941: Fireguard ASTsSTI F941: Fireguard ASTsFireguardFireguard®® are fireare fire--rated ASTs, UL 2085 Listed using 3" of rated ASTs, UL 2085 Listed using 3" of lightweight insulation between 2 walls of steel.lightweight insulation between 2 walls of steel.Fireguard's secondary containment can be tightnessFireguard's secondary containment can be tightness--tested tested onon--site, using standard testing procedures.site, using standard testing procedures.

Source Steel Tank InstituteSource Steel Tank Institute

Note: can also be UL 58


Field Constructed ASTsField Constructed ASTsSteel Steel -- Welded, riveted, or boltedWelded, riveted, or boltedConstruction standardsConstruction standards−−API 650, 620, 12B, 12C, 12DAPI 650, 620, 12B, 12C, 12D

Method of constructionMethod of constructionParts of field constructed ASTsParts of field constructed ASTs−−Roof (external floating, internal floating, lifter, Roof (external floating, internal floating, lifter,

cone, dome, umbrella)cone, dome, umbrella)−−Bottom (cone up, flat, cone down, double Bottom (cone up, flat, cone down, double

bottom)bottom)−−Shell (welded, riveted)Shell (welded, riveted)−−Foundation & AppurtenancesFoundation & Appurtenances


Field Constructed ASTsField Constructed ASTs

Internal Floating RoofInternal Floating Roof

ventvent



Lifter RoofLifter Roof

innerinner

outerouter



Cone RoofCone Roof



External Floating RoofExternal Floating Roof


Vaulted & Cut and Cover TanksVaulted & Cut and Cover Tanks

AA BB

CC DD


Riveted ASTRiveted AST

Underground Storage Underground Storage Tanks (UST)Tanks (UST)


USTs Materials/ConstructionUSTs Materials/ConstructionShop built standardsShop built standards (see 40 CFR 280.20)(see 40 CFR 280.20)−−SteelSteel

UL Standard 58 & NACE RPUL Standard 58 & NACE RP--0202--8585-- UL 1746UL 1746-- STI STISTI STI--P3P3

−−FiberglassFiberglassUL Standard 1316UL Standard 1316ASTM D4021ASTM D4021--8686

Field constructedField constructed−− Large concrete (Military specification)Large concrete (Military specification)

Parts of an UST SystemParts of an UST System


Piping Piping ConstructionConstruction


Piping Construction StandardsPiping Construction StandardsASTM B31.3 ASTM B31.3 -- Process PipingProcess Piping−−This Code contains rules for piping typically This Code contains rules for piping typically

found in petroleum refineries, terminals and found in petroleum refineries, terminals and related industries.related industries.

ASTM B31.4 ASTM B31.4 -- 2002 2002 -- Pipeline Pipeline Transportation SystemsTransportation Systems−−This Code prescribes requirements for the This Code prescribes requirements for the

design, materials, construction, assembly, design, materials, construction, assembly, inspection, and testing of piping transporting inspection, and testing of piping transporting liquids.liquids.



Why Inspect Tanks and Why Inspect Tanks and Piping?Piping?

Steel corrodes over time and Steel corrodes over time and tanks/piping can lose their integrity.tanks/piping can lose their integrity.Accessories break or stick and may not Accessories break or stick and may not function as they should.function as they should.Unfortunately, the tanks, piping, and Unfortunately, the tanks, piping, and accessories are sometimes not installed accessories are sometimes not installed correctly.correctly.Required by EPA, DOT, OSHA, etc.Required by EPA, DOT, OSHA, etc.


Inspect !! Prevent ThisInspect !! Prevent This……Expect what you inspect Expect what you inspect …………………………


Delivery32%

Other16%

Tank5%

Dispenser12%

Piping35%

Sources of ReleaseSources of Release

“other” includes: fuelfilters, outlet valvesand human spilling.

Source: Florida Cause of Leak Study, Marshall Mott-Smith, Florida DEP

• Data shows that tanks account for about 5% of petrochemical releases, while piping accounts for another 35%.

Corrosion Corrosion


Basic Corrosion ReactionBasic Corrosion Reaction

In soils, the naturally occurring acids, In soils, the naturally occurring acids, bases, and salts dissolved in ground bases, and salts dissolved in ground moisture serve as the electrolyte, while moisture serve as the electrolyte, while the tank bottom itself may serve as the the tank bottom itself may serve as the return circuit.return circuit.


Evaluating Cathodic ProtectionEvaluating Cathodic Protection



NACE and API Corrosion NACE and API Corrosion StandardsStandards

NACE NACE –– RP0193RP0193--2001 2001 –– External cathodic External cathodic protection of onprotection of on--grade carbon steel tank grade carbon steel tank bottomsbottomsAPIAPI--651 651 –– Cathodic protection of ASTsCathodic protection of ASTsNACE NACE –– RP0285RP0285--95 95 –– Corrosion control of Corrosion control of UST systemsUST systemsAPIAPI--1632 1632 –– Cathodic protection of USTs Cathodic protection of USTs and UG piping systemsand UG piping systems

Inspection of Inspection of Aboveground Bulk Aboveground Bulk Storage ContainersStorage Containers

Overview of the Inspection ProcessOverview of the Inspection Process


The inspector needs to understand the potential for a The inspector needs to understand the potential for a given tank to harm the environment.given tank to harm the environment.This knowledge will lead them to focus their energy This knowledge will lead them to focus their energy and resources on the tanks and piping systems that and resources on the tanks and piping systems that are most significant.are most significant.Inspections should begin at the ground and work Inspections should begin at the ground and work upwards on the tank.upwards on the tank.Focus on the tank configuration. Each type of tank is Focus on the tank configuration. Each type of tank is likely to have particular leak potential areas. Focusing likely to have particular leak potential areas. Focusing primarily on these areas will increase the likelihood primarily on these areas will increase the likelihood that the inspector will find a problem and will allow that the inspector will find a problem and will allow time to review more facilities.time to review more facilities.

Overview of Integrity Testing Overview of Integrity Testing Inspection ProcessInspection Process


WhyWhy−− Tanks and piping systems leak.Tanks and piping systems leak.

By WhomBy Whom−− Certified Tank Inspectors will use various nonCertified Tank Inspectors will use various non--destructive destructive

testing techniques to determine the current condition of testing techniques to determine the current condition of tanks and piping.tanks and piping.

To What ExtentTo What Extent−− Industry inspection standards offer assistance to the Industry inspection standards offer assistance to the

owners of tanks to determine the inspection frequency for owners of tanks to determine the inspection frequency for various parts of a tanks such to the bottom, shell and various parts of a tanks such to the bottom, shell and roof. The owner is responsible for contracting with a roof. The owner is responsible for contracting with a certified inspector. The owner is also responsible to direct certified inspector. The owner is also responsible to direct the inspector as to the type of inspection to be performed. the inspector as to the type of inspection to be performed.

Overview of Integrity Testing Overview of Integrity Testing Inspection ProcessInspection Process


Inspection ProcessInspection ProcessOwner becomes aware of the need for an AST and/or Owner becomes aware of the need for an AST and/or piping inspectionpiping inspectionOwner consults with an inspector or engineer to determine Owner consults with an inspector or engineer to determine his inspection needshis inspection needsInspector provides the owner with the appropriate Inspector provides the owner with the appropriate inspection proceduresinspection proceduresInspector conducts the inspectionInspector conducts the inspectionThe inspector analyses the data and develops a reportThe inspector analyses the data and develops a reportThe inspector discusses all maintenance & repair issues The inspector discusses all maintenance & repair issues with the ownerwith the ownerThe inspector addresses any compliance issues that The inspector addresses any compliance issues that requires correction prior to placing the tank back in service requires correction prior to placing the tank back in service or if the tank can continue in serviceor if the tank can continue in serviceThe inspector will include the time schedule for future The inspector will include the time schedule for future inspection requirementsinspection requirements


Integrity Testing and the EPA Integrity Testing and the EPA InspectorInspector

At SPCCAt SPCC--regulated facilities, tanks must be inspected regulated facilities, tanks must be inspected according to requirements of SPCC rule.according to requirements of SPCC rule.EPA inspector can review inspection results / reports.EPA inspector can review inspection results / reports.EPA inspector can review documentation to see EPA inspector can review documentation to see whether recommended repairs were completed in whether recommended repairs were completed in accordance with repairs standards.accordance with repairs standards.EPA inspector should determine inspection frequency, EPA inspector should determine inspection frequency, method and personnel qualifications for each tank.method and personnel qualifications for each tank.EPA inspector should assist (and ensure) that the EPA inspector should assist (and ensure) that the regulated community develops baseline and routine regulated community develops baseline and routine integrity testing schedule.integrity testing schedule.


The following sections will familiarize The following sections will familiarize EPA inspectors withEPA inspectors with

* * inspection standardsinspection standards andand reports reports **

so you know what youso you know what you’’re looking for!re looking for!

API Standard 653API Standard 653

Tank Inspection, Repair, Alteration, Tank Inspection, Repair, Alteration, and Reconstructionand Reconstruction


API 653 Inspectors QualificationsAPI 653 Inspectors Qualifications

Education and experience, when combined, Education and experience, when combined, shall be a minimum of:shall be a minimum of:−−A bachelor of science degree in engineering or A bachelor of science degree in engineering or

technology plus 1 year of experience.technology plus 1 year of experience.−−A 2A 2--year degree or certificate in engineering or year degree or certificate in engineering or

technology, plus 2 years of experience.technology, plus 2 years of experience.−−A high school diploma or equivalent, plus 3 A high school diploma or equivalent, plus 3

years of experience.years of experience.−−A minimum of 5 years of experience.A minimum of 5 years of experience.

Source: API Standards


Using a checklist during the inspection Using a checklist during the inspection process is suggestedprocess is suggestedA sample checklist is provided in Appendix A sample checklist is provided in Appendix C of APIC of API--653653Many Inspectors have their own checklist Many Inspectors have their own checklist for several reasons:for several reasons:−− Difference in API & STIDifference in API & STI®® tankstanks−− Customer requirements (such as product)Customer requirements (such as product)

ChecklistChecklist

Source: API Standards

API 653: External Inspection


API 653 ChecklistAPI 653 ChecklistAPI 653: External Inspection


All Rights Reserved

Types of ASTs CoveredTypes of ASTs Covered

Aboveground tanksAboveground tanksAPI 12 C API 12 C API 650API 650APIAPI--650 App. 650 App. ““JJ””Any metal AST built to a StandardAny metal AST built to a Standard(ie.. API, UL, ASME, ASTM, Mil Standard)(ie.. API, UL, ASME, ASTM, Mil Standard)

API 653


Types of AST InspectionsTypes of AST Inspections

Routine InRoutine In--Service / Monthly InspectionService / Monthly InspectionFormal InFormal In--Service / External Visual Service / External Visual InspectionInspectionFormal InFormal In--Service / External UT InspectionService / External UT InspectionOut of Service / Internal InspectionOut of Service / Internal Inspection

API 653


Routine InRoutine In--Service/Monthly Service/Monthly InspectionInspection

1) Evidence of leaks1) Evidence of leaks2) Shell distortions2) Shell distortions3) Signs of settlement3) Signs of settlement4) Corrosion4) Corrosion5) Paint failure5) Paint failure6) Insulation systems, etc.6) Insulation systems, etc.

• Visual inspection of the tank’s exterior surfaces for issues such as, but not limited to:

•• The interval must be consistent with conditions at The interval must be consistent with conditions at the particular the particular site; but must not exceed one month.

API 653


Periodic inPeriodic in--service inspection of tanksservice inspection of tanksPerformed by Certified Inspector Performed by Certified Inspector Purpose is to assure continued tank integrity Purpose is to assure continued tank integrity Inspection methods required:Inspection methods required:−−Visual InspectionsVisual Inspections

Tanks may be in operation during this Tanks may be in operation during this inspectioninspection

Formal InFormal In--Service / External Visual Service / External Visual InspectionInspection

API 653


FrequencyFrequencyPerformed on a basis not to exceed the Performed on a basis not to exceed the minimum of:minimum of:•• at least every 5 years at least every 5 years

OROR……•• RCARCA / 4N years / 4N years

[where [where RCA RCA (Remaining Corrosion Allowance) is the (Remaining Corrosion Allowance) is the difference between the measured shell thickness and difference between the measured shell thickness and the minimum required thickness in mils, and the minimum required thickness in mils, and N N is the is the shell corrosion rate in mils per year]shell corrosion rate in mils per year]

whichever is less

API 653: Formal External Visual Inspection


Areas of InspectionAreas of Inspection

• Fixed Roof

• Floating Roof

• Fire Protection System

• Tank Mixer

• Compliance with Fire Code (NFPA 30)

• Dike Area

• Foundation

• Shell

• Shell & Roof Appurtenances

• Access Structure

• Windgirder

API 653: Formal External Visual Inspection


Performed on a basis not to exceed the Performed on a basis not to exceed the minimum of:minimum of:•• at least every 15 years at least every 15 years

OROR……•• RCARCA / 2/ 2N N years years

[where [where RCA RCA (Remaining Corrosion Allowance) is the (Remaining Corrosion Allowance) is the difference between the measured shell thickness and difference between the measured shell thickness and the minimum required thickness in mils, and the minimum required thickness in mils, and N N is the is the shell corrosion rate in mils per year]shell corrosion rate in mils per year]

whichever is less

FrequencyFrequencyAPI 653: Formal External In-Service UT Inspection


Ultrasonic Testing (UT) Under Ultrasonic Testing (UT) Under API 653API 653• U.T. the shell plates at least every fifteen years or RCA/2N

API 653: Formal External In-Service UT Inspection


Ultrasonic TestingUltrasonic Testing

Inspection Inspection PortPort

Inspection Inspection PortPort

• Inspection of the shell under insulation

API 653: Formal External In-Service UT Inspection


The bottom plate must extend beyond the outside toe of the shell-to-bottom weld. (2” – annular ring or 1” – sketch plates) picture on left shows under bottom leak and the picture on the right shows the shell to bottom weld area heavily corroded.

ShellShell--toto--Bottom Welds Bottom Welds ((““corner weldcorner weld””) Inspection) Inspection

API 653: Formal External In-Service Inspection


Consider corrosion rateConsider corrosion rate−−Changes inspection intervalChanges inspection interval

−−May need to alter operations of the tankMay need to alter operations of the tank

For example, if only the bottom portion of a For example, if only the bottom portion of a tanktank’’s shell is thinning, that portion can be s shell is thinning, that portion can be repaired or replaced and then the tank can repaired or replaced and then the tank can resume regular usage.resume regular usage.

−−May need to consider mitigative measuresMay need to consider mitigative measures

Shell EvaluationShell EvaluationAPI 653: Formal External In-Service Inspection


VisualVisualLevel SurveyLevel Survey−−Evaluation and acceptance per Appendix BEvaluation and acceptance per Appendix B−−Repair or replacement?Repair or replacement?

Inspection of the FoundationInspection of the FoundationAPI 653: Formal External In-Service and UT Inspection


Rigid body tilting of a tank (planar tilt)Rigid body tilting of a tank (planar tilt)

Inspection of the FoundationInspection of the FoundationAPI 653: Formal External In-Service Inspection


OutOut--ofof--plane settlement (differential settlement)plane settlement (differential settlement)





Roof InspectionRoof InspectionExternal Floating External Floating Internal FloatingInternal FloatingConeConeUmbrellaUmbrellaLifterLifterVapor Dome Vapor Dome Geodesic Dome coversGeodesic Dome covers

API 653: External Inspection


Visual inspection of plates and Visual inspection of plates and accessoriesaccessoriesU.T. measurements or Hammer test as U.T. measurements or Hammer test as requiredrequiredPit Gauge areas of interestPit Gauge areas of interestMay use Magnetic Flux Leakage (MFL) May use Magnetic Flux Leakage (MFL) as done on topside of bottom platesas done on topside of bottom plates

Cone Roof InspectionCone Roof InspectionAPI 653: Formal External In-Service Inspection


Vapor Space CorrosionVapor Space Corrosion


Handrails, Access Structure, etc.Handrails, Access Structure, etc.API 653: Formal External Inspection


OutOut--OfOf--Service InspectionService Inspectionaka aka ““Internal InspectionInternal Inspection””

Internal inspection is primarily required Internal inspection is primarily required to:to:−− Ensure that the bottom is not severely corroded and Ensure that the bottom is not severely corroded and

leaking.leaking.−− Gather the data necessary for the minimum bottom Gather the data necessary for the minimum bottom

and shell thickness assessments. As applicable, these and shell thickness assessments. As applicable, these data also take into account external ultrasonic data also take into account external ultrasonic thickness measurements made during inthickness measurements made during in--service service (external) inspections.(external) inspections.

−− Identify and evaluate any tank bottom settlement.Identify and evaluate any tank bottom settlement.

API 653


Inspection MethodsInspection MethodsCombination of methods required:Combination of methods required:−− Leak TestingLeak Testing

Vacuum BoxVacuum BoxPressure TestPressure Test

−− Magnetic Flux Leakage (MFL)Magnetic Flux Leakage (MFL)−− Ultrasonic Thickness ReadingsUltrasonic Thickness Readings−− Hammer TestingHammer Testing−− Magnetic Particle TestingMagnetic Particle Testing−− Parallel Flashlight TestParallel Flashlight Test

API 653: Internal Inspection


FrequencyFrequency

Based on shell or bottom plate thicknessBased on shell or bottom plate thicknessThickness of any component must be Thickness of any component must be suitable for continued service at the time of suitable for continued service at the time of the next inspectionthe next inspectionTanks that do not have an established Tanks that do not have an established corrosion rate must be inspected within 10 corrosion rate must be inspected within 10 yearsyearsTank intervals cannot extend past 20 years Tank intervals cannot extend past 20 years unless a RBI procedure is in placeunless a RBI procedure is in place



Areas of InspectionAreas of InspectionSame areas as the Formal InSame areas as the Formal In--Service Service (External) Inspection(External) InspectionIn addition, the following areas are In addition, the following areas are inspected:inspected:−− Floor plateFloor plate−−Weld seamsWeld seams−− Roof RaftersRoof Rafters−− Underside of fixed roofUnderside of fixed roof−− Primary & secondary sealsPrimary & secondary seals−− Shell plates (interior)Shell plates (interior)



Floor Plate Inspection, OverallFloor Plate Inspection, Overall

• Magnetic Flux Leakage



Floor Plate Inspection, SpecificFloor Plate Inspection, Specific• U.T. Prove-Up of Tank Bottom



Bacterial CorrosionBacterial Corrosion


Cone Roof InspectionCone Roof InspectionAPI 653: Internal Inspection


Cone Roof InspectionCone Roof Inspection (Continued)(Continued)


Floor Plate Inspection, Weld SeamsFloor Plate Inspection, Weld Seams

Leak TestingLeak Testing−−Vacuum Box TestVacuum Box Test

Bottom Lap WeldsBottom Lap WeldsBottom RepairsBottom RepairsCorner WeldsCorner Welds



API Standard 653 allows Risk Based API Standard 653 allows Risk Based Inspection (RBI) proceduresInspection (RBI) proceduresThe RBI assessment may increase or The RBI assessment may increase or decrease the 20decrease the 20--year inspection interval year inspection interval described in API 653.described in API 653.RBI intervalsRBI intervals−− Must be reviewed and approved byMust be reviewed and approved by

Authorized InspectorAuthorized InspectorEngineer knowledgeable in tank design and corrosionEngineer knowledgeable in tank design and corrosion

−− Must be reviewed at intervals not exceeding 10 yearsMust be reviewed at intervals not exceeding 10 years

Alternative Internal InspectionsAlternative Internal InspectionsAPI 653: Internal Inspection


Summary Summary –– What to look forWhat to look forRoutine InRoutine In--Service / Monthly InspectionService / Monthly Inspection−− Report could be single sheet of paper.Report could be single sheet of paper.−− General condition of tank noted. General condition of tank noted. −− This routine inThis routine in--service inspection only includes a visual service inspection only includes a visual

inspection of the tankinspection of the tank’’s exterior. s exterior. −− Evidence of leaks, shell distortions, signs of Evidence of leaks, shell distortions, signs of

settlement, corrosion, and condition of the foundation, settlement, corrosion, and condition of the foundation, paint coatings, insulation systems, and appurtenances paint coatings, insulation systems, and appurtenances should be documented for followshould be documented for follow--up action by an up action by an authorized inspector.authorized inspector.

API 653


External InExternal In--Service InspectionService Inspection−− Extensive paperwork and photos to document a tankExtensive paperwork and photos to document a tank’’s s

condition at a given moment in time.condition at a given moment in time.−− Should include calculations predicting future date of Should include calculations predicting future date of

nonnon--compliance.compliance.−− Must include Ultrasonic Thickness measurements of Must include Ultrasonic Thickness measurements of

tank shell and roof. No specified number of readings are tank shell and roof. No specified number of readings are required and the inspectorrequired and the inspector’’s experience and/or s experience and/or professional judgment must be used. professional judgment must be used.

−− Must include settlement survey.Must include settlement survey.−− Not valid if performed by other than a certified Not valid if performed by other than a certified

inspector.inspector.

Summary Summary –– What to look forWhat to look forAPI 653


Internal InspectionInternal Inspection−− Main focus is on the tankMain focus is on the tank’’s bottom s bottom ““floor platesfloor plates””−− May be performed in conjunction with an May be performed in conjunction with an ““External External

InspectionInspection””..−− May be performed by robots or other such devices if May be performed by robots or other such devices if

the sole purpose is to determine remaining bottom the sole purpose is to determine remaining bottom plate thickness.plate thickness.

Summary Summary –– What to look forWhat to look forAPI 653


Common Pitfalls and ProblemsCommon Pitfalls and ProblemsCheck to see if the inputs have been used Check to see if the inputs have been used correctly throughout the report for items such as correctly throughout the report for items such as the tank height and diameter.the tank height and diameter.−− If the tank was inspected along with several other tanks, the daIf the tank was inspected along with several other tanks, the data ta

can be mistakenly inserted into the wrong tank report.can be mistakenly inserted into the wrong tank report.

Make sure the tank inspection standard is the Make sure the tank inspection standard is the most applicable for the tank type or configuration most applicable for the tank type or configuration that is being inspected.that is being inspected.Unclear statements are used to give the Unclear statements are used to give the appearance of a complete report. Feel free to ask appearance of a complete report. Feel free to ask the owner if they understand the inspection the owner if they understand the inspection report.report.

API 653


Triggers to ask more questionsTriggers to ask more questions•• Many owners simply accept the report and file it away. Many owners simply accept the report and file it away.

Ask for documentation to assure compliance with any Ask for documentation to assure compliance with any recommendations that may be found in the inspection recommendations that may be found in the inspection report.report.

•• Look for a tank settlement chart or graph. This should be Look for a tank settlement chart or graph. This should be present but is often not provided.present but is often not provided.

•• The report should include the Certified InspectorThe report should include the Certified Inspector’’s name s name and I.D. number. Without this the inspection may be and I.D. number. Without this the inspection may be invalid.invalid.

•• If the inspector is only using the standard API If the inspector is only using the standard API --653 653 Appendix Appendix ““CC”” checklist, it may be an indication that they checklist, it may be an indication that they have not performed a large amount of tank inspections. have not performed a large amount of tank inspections. Ask more questions.Ask more questions.

API 653

Brittle FractureBrittle Fracture

API 653API 653


Ashland Tank Failure 1988Ashland Tank Failure 1988


Brittle FractureBrittle Fracture

What is brittle fracture?What is brittle fracture?−− Carbon steel becomes brittle as its temperature gets lower. Carbon steel becomes brittle as its temperature gets lower.

Brittle material can fail like shattering glass, instead of the Brittle material can fail like shattering glass, instead of the bending and tearing failure of steel we are used to seeing. bending and tearing failure of steel we are used to seeing.

What is the result?What is the result?−− If a tank fails due to brittle fracture, it is usually a catastrIf a tank fails due to brittle fracture, it is usually a catastrophic ophic

event and can cause massive damage due to the wave of product event and can cause massive damage due to the wave of product leaving the tank all at once.leaving the tank all at once.

How can we test for it?How can we test for it?−− Toughness can be associated with brittle fracture. A common Toughness can be associated with brittle fracture. A common

test to measure for toughness is a Charpy Vtest to measure for toughness is a Charpy V--notch impact test. notch impact test. This test is performed while the metal is at the required DesignThis test is performed while the metal is at the required DesignMetal Temperature (DMT) which is commonly determined by the Metal Temperature (DMT) which is commonly determined by the location where the tank is to be constructed. location where the tank is to be constructed.


Shortly after ConstructionShortly after ConstructionDuring During Hydro testHydro testOn the first filling in cold weather On the first filling in cold weather When a change to a colder service has When a change to a colder service has

occurredoccurredAfter a After a repairrepair or or alterationalteration

Brittle Fracture is Most Likely to Brittle Fracture is Most Likely to Occur:Occur:

API 653


The decision tree, provided in APIThe decision tree, provided in API--653 653 Figure 5Figure 5--1, provides a procedure for the 1, provides a procedure for the assessment of tanks for suitability for assessment of tanks for suitability for continued service or continued service or change of service change of service with with respect to the risk of brittle fracture.respect to the risk of brittle fracture.

Brittle Fracture Considerations: Brittle Fracture Considerations: API Decision TreeAPI Decision Tree

API 653


1) Reaching the maximum liquid fill level, and2) Operating at the lowest operation temperature

to date

without failing due to brittle fracture, future concerns of brittle fracture failure with continued same service is minimal.

Risk of Brittle FractureRisk of Brittle Fracture• History indicates that once a tank has shown

the ability to withstand the combined effects of:


• If the tank shell design thickness is < 0.5”, the risk of brittle fracture failure is minimal, provided that an evaluation for suitability of service has been performed.

• No reported brittle fracture tank failures have occurred at shell metal temperatures > 60°F.

• Heating the contents can add assurance against brittle fracture.

Risk of Brittle FractureRisk of Brittle Fracture (continued)

105105OSC Readiness Training February 5, 2008API 653 Brittle FractureCornell and Associates, Inc. All rights reserved.


Brittle Fracture: Brittle Fracture: Testing to reduce failureTesting to reduce failure• Any change in tank use must be evaluated to

determine if it increases the risk of failure due to brittle fracture. If the change is to a more severe service, consider the need for a hydrostatic test to show fitness for the more severe service.


Brittle Fracture:Brittle Fracture: SummarySummaryAsk if the tank owners knows if the tank Ask if the tank owners knows if the tank has ever been hydrohas ever been hydro--tested. New tested. New construction methods generally require construction methods generally require this to be performed, but not always.this to be performed, but not always.Check inspection reports for Check inspection reports for recommended repairs that were to be recommended repairs that were to be performed after the known hydro date or performed after the known hydro date or original date of construction. These original date of construction. These repairs, alterations and etc. might require repairs, alterations and etc. might require the tank to be retested.the tank to be retested.

STI SPSTI SP--001001

Standard for the Inspection of Standard for the Inspection of Aboveground Storage TanksAboveground Storage Tanks


ScopeScopeAboveground storage tanksAboveground storage tanksStable, flammable, & combustible liquids Stable, flammable, & combustible liquids with specific gravity < 1.0 and operating with specific gravity < 1.0 and operating temp. between ambient and 200temp. between ambient and 200°° FFCovers:Covers:−− ShopShop--fabricated tanksfabricated tanks−− Portable containersPortable containers−− FieldField--erected tanks (up to 30erected tanks (up to 30’’ diameter & 50diameter & 50’’ high high

only, shell thickness less than only, shell thickness less than ½”½”))Covered in Appendix B of the StandardCovered in Appendix B of the Standard

SP-001


Areas of InspectionAreas of InspectionTank shellTank shellSupportsSupportsAnchorsAnchorsFoundationFoundationVentsVentsRelease prevention barriersRelease prevention barriers

• Gauges and alarms• Insulation• Appurtenances• Spill control systems

SP-001


Key ConceptsKey ConceptsSpill ControlSpill Control−− Remote impoundingRemote impounding−− Secondary containment structure (dike/berm)Secondary containment structure (dike/berm)−− DoubleDouble--wall tankwall tank

Continuous Release Detection Method Continuous Release Detection Method (CRDM): (CRDM): −− Release prevention barrier (RPB) of sufficiently Release prevention barrier (RPB) of sufficiently

impervious material (steel, concrete, liner)impervious material (steel, concrete, liner)−− Secondary containment AST (double wall or double Secondary containment AST (double wall or double

bottom)bottom)−− Elevated AST with release prevention barrierElevated AST with release prevention barrier

SP-001


Types of InspectionTypes of InspectionPeriodic AST Inspection (P)Periodic AST Inspection (P)−− Performed by ownerPerformed by owner−− Monthly basisMonthly basis−− Example checklist provided in SPExample checklist provided in SP--001 standard001 standard−− Records maintained for at least 3 yearsRecords maintained for at least 3 years

Formal external inspection (E)Formal external inspection (E)−− Performed by certified inspectorPerformed by certified inspector−− Records retained for life of the tankRecords retained for life of the tank

Formal internal inspection (I)Formal internal inspection (I)−− Performed by certified inspectorPerformed by certified inspector−− Records retained for life of the tankRecords retained for life of the tank

Leak test (L)Leak test (L)−− Performed by owner or his/her designeePerformed by owner or his/her designee

SP-001


Risk Based Inspection ScheduleRisk Based Inspection ScheduleCategoryCategory

P**P**PPPPPortable ContainersPortable Containers

P, E&L(5), I(10)P, E&L(5), I(10)P, E&L(5), I(15)P, E&L(5), I(15)PPE(20)E(20)

ShopShop--Fabricated 30,000Fabricated 30,000--50,00050,000

P, E&L(5), I(10)P, E&L(5), I(10)P, L(2), E(5)P, L(2), E(5)

P, E(10), I(20)P, E(10), I(20)P, E(5), L(10)P, E(5), L(10)

PPE(20)E(20)

ShopShop--Fabricated Fabricated 5,0015,001--30,00030,000

P, E&L(5), I(10)P, E&L(5), I(10)P, L(2), E(5)P, L(2), E(5)

PPE&L(10)E&L(10)

PPShopShop--FabricatedFabricated1,1011,101--5,0005,000

PPE&L(10)E&L(10)

PPPPShopShop--FabricatedFabricated00--1,1001,100

332211Tank Type and Tank Type and Capacity (gallons)Capacity (gallons)

** Discontinue use or have container tested and recertified: Plastic: 7 years – Steel: 12 years – stainless steel: 17 years

SP-001


Risk Based Inspection ScheduleRisk Based Inspection Schedule(continued)(continued)

PPE&L(5)E&L(5)I(10)I(10)

PPE&L(5)E&L(5)I(10)I(10)

PPE(5)E(5)I(10)I(10)

FieldField--Erected ASTErected AST

101020203030**Maximum **Maximum Intervals between Intervals between Formal Internal Formal Internal InspectionsInspections

CategoryCategory332211

** If corrosion rates are established using equations in the standard, inspection interval may be based on corrosion rates, with the intervals between consecutive internal inspections not exceeding the values indicated.

SP-001


ShopShop--Built Tank InspectionBuilt Tank Inspection• This tank meets the definition of a “tank in

contact with the ground” which does not allow for the visual inspection of the exterior of the bottom of the tank.

SP-001


-Test the bottom and the lower 12 inches of the sides of a vertical cylindrical or a rectangular tank.

ShopShop--Built Tank InspectionBuilt Tank Inspection

11’-0”

25

’-0

”1’-0”

• How do we inspect the shell of a vertical, shop-built tank using ultrasonic (UT) in accordance with STI-SP001?

SP-001


SummarySummarySPSP--001 inspection can only be performed 001 inspection can only be performed on tanks less than 30on tanks less than 30’’ diameter & 50diameter & 50’’high.high.Inspection type and schedule is based Inspection type and schedule is based on the categories and inspection on the categories and inspection matrices in the Standard.matrices in the Standard.There must be guidance to the tank There must be guidance to the tank owner explaining the tankowner explaining the tank’’s current s current condition and what should be done to condition and what should be done to maintain integrity.maintain integrity.

SP-001


Common Pitfalls and ProblemsCommon Pitfalls and ProblemsCheck to see if the same input has been used Check to see if the same input has been used throughout the report for items such as, but not limited throughout the report for items such as, but not limited to, the tanksto, the tanks’’ heights and diameter. heights and diameter. Make sure the tank inspection standard is the most Make sure the tank inspection standard is the most applicable for the tank type or configuration that is being applicable for the tank type or configuration that is being inspected. Remember STI SP001 is limited to tanks < inspected. Remember STI SP001 is limited to tanks < 3030’’--0 in diameter. 0 in diameter. STI SP001 requires specific areas of the tanks to be STI SP001 requires specific areas of the tanks to be inspected and the results must fall within specific inspected and the results must fall within specific parameters. There should be clear pass/fail statements parameters. There should be clear pass/fail statements based strictly on the current condition as compared to based strictly on the current condition as compared to the design condition.the design condition.

SP-001


Triggers to ask more questionsTriggers to ask more questionsLook for a settlement chart or graph. This Look for a settlement chart or graph. This should be present but is often not provided.should be present but is often not provided.STI SP001 inspections cannot be performed on STI SP001 inspections cannot be performed on tanks containing a product with specific gravity tanks containing a product with specific gravity > > water.water.STI SPSTI SP--001 inspections cannot be performed on 001 inspections cannot be performed on tanks containing a product that is required to be tanks containing a product that is required to be stored at temperatures of 200stored at temperatures of 200˚̊ or higher. or higher.

SP-001

API 12R1API 12R1

Recommended Practice for Setting, Recommended Practice for Setting, Maintenance, Inspection, Operation, and Maintenance, Inspection, Operation, and

Repair of Repair of Tanks in Production ServiceTanks in Production Service


NoteNote: Many in industry consider API 12R1 to be a standard but it is : Many in industry consider API 12R1 to be a standard but it is only a recommended practice.only a recommended practice.

ScopeScope• This recommended practice should be

considered as a “guide” for production facilities on:-New tank installations-Maintenance of existing tanks-Bolted, welded or fiberglass tanks

API 12 R1


Applicability / UsageApplicability / UsageFor tanks at production facilities onlyFor tanks at production facilities onlyIntended primarily for application to tanks Intended primarily for application to tanks fabricated to API Specifications 12F, B, D, F, and Pfabricated to API Specifications 12F, B, D, F, and PTanks fabricated to API Standard 650 or its Tanks fabricated to API Standard 650 or its predecessor (API Standard 12C) should be predecessor (API Standard 12C) should be maintained in accordance with API Standard 653maintained in accordance with API Standard 653Not applicable to refineries, petrochemical plants, Not applicable to refineries, petrochemical plants, marketing bulk stations, or pipeline storage marketing bulk stations, or pipeline storage facilities operated by carriersfacilities operated by carriers

API 12 R1


Tank ExampleTank ExampleAPI 12 R1


Factors to Consider for Continued Factors to Consider for Continued ServiceService

Internal corrosionInternal corrosionExternal corrosion due to environmental exposureExternal corrosion due to environmental exposureStress levels and allowable stress levelsStress levels and allowable stress levelsProperties of the stored productProperties of the stored productMetal design temperatures at the service locationMetal design temperatures at the service locationExternal roof life, wind, snow, and seismic External roof life, wind, snow, and seismic loadingsloadingsTank foundation, soil, and settlement conditionsTank foundation, soil, and settlement conditionsDistortions of the existing tankDistortions of the existing tank

API 12 R1


Education and ExperienceEducation and ExperienceQualified InspectorsQualified Inspectors−− Degree in engineering + 1 year experienceDegree in engineering + 1 year experience

OROR

−− 22--year certificate in engineering or technology + 2 year certificate in engineering or technology + 2 years tank experience including 1 year of years tank experience including 1 year of inspection experienceinspection experience

OROR

−− High school education + 3 years tank experience High school education + 3 years tank experience including 1 year of inspection experienceincluding 1 year of inspection experience

API 12 R1


Examination, Inspection and Examination, Inspection and Maintenance Topics CoveredMaintenance Topics Covered

GeneralGeneralMaintenanceMaintenanceRoutine Operational ExaminationRoutine Operational ExaminationExternal Condition ExaminationExternal Condition ExaminationInternal Condition ExaminationInternal Condition ExaminationInternal/External InspectionsInternal/External InspectionsInspection TechniquesInspection Techniques

•Shell Welds•Records

API 12 R1


Items Covered During InspectionItems Covered During InspectionAPI 12 R1


RecordsRecordsRecords should be maintained including:Records should be maintained including:−−Pertinent data reportsPertinent data reports−−Tank identificationTank identification−−Relief equipment test informationRelief equipment test information−−Results for inspections and repairsResults for inspections and repairsRecords should demonstrate that repairs are Records should demonstrate that repairs are consistent with the service and appropriate consistent with the service and appropriate codescodesInspection records should be retained with Inspection records should be retained with permanent equipment recordspermanent equipment records

API 12 R1


SummarySummaryFewer inspections required than APIFewer inspections required than API--653.653.Make sure inspections performed to this Make sure inspections performed to this RP are not on APIRP are not on API--650 or STI tanks.650 or STI tanks.Few inspectors can inspect fiberglass Few inspectors can inspect fiberglass reinforced plastic or plastic tanks. We must reinforced plastic or plastic tanks. We must ensure inspectors have a working ensure inspectors have a working knowledge of these types of tanks.knowledge of these types of tanks.Records of inspections and other items of Records of inspections and other items of interest must be kept.interest must be kept.

API 12 R1


Common Pitfalls and ProblemsCommon Pitfalls and Problems

•• Check to see if the same input has been used Check to see if the same input has been used throughout the report for items such as but not throughout the report for items such as but not limited to the tanks heights and diameter.limited to the tanks heights and diameter.

•• Make sure the tank inspection standard is the Make sure the tank inspection standard is the most applicable for the tank type or most applicable for the tank type or configuration that is being inspected. Remember configuration that is being inspected. Remember APIAPI--12 R1 is limited to production tanks.12 R1 is limited to production tanks.

API 12 R1


Triggers to ask more questionsTriggers to ask more questionsThis standard should not be used to This standard should not be used to inspect tanks that are more suited to inspect tanks that are more suited to being inspected using the APIbeing inspected using the API--653 or the 653 or the STI SP001 tank inspection standards. STI SP001 tank inspection standards. This recommended practice provides This recommended practice provides guidelines for: guidelines for:

a)a) setting and connecting of lease tanks at new tank setting and connecting of lease tanks at new tank battery installations and in other production and battery installations and in other production and treating services, treating services,

b)b) maintaining and operating lease tanks, and maintaining and operating lease tanks, and c)c) inspecting and repairing tanks constructed in inspecting and repairing tanks constructed in

accordance with API 12 series (B, D, F and P) accordance with API 12 series (B, D, F and P) standards.standards.

API 12 R1


Inspection of Other Tank TypesInspection of Other Tank Types


Fiberglass Reinforced Plastic Fiberglass Reinforced Plastic Tank InspectionsTank Inspections

Periodic inspection of the inside of the tank Periodic inspection of the inside of the tank is important when assessing performance.is important when assessing performance.−−Once a year is a good frequency for aggressive Once a year is a good frequency for aggressive

service conditions. service conditions. −−Every two years in less aggressive service (such Every two years in less aggressive service (such

as water, etc.). as water, etc.).

* Standard for In* Standard for In--service Inspections of Aboveground Atmospheric Fiberglass service Inspections of Aboveground Atmospheric Fiberglass Reinforced Plastic Tanks and VesselsReinforced Plastic Tanks and Vessels

FTPI-2005-2 *


Visual inspection in accordance with ASTM Visual inspection in accordance with ASTM D 2563 "Standard Test Method for D 2563 "Standard Test Method for Classifying Visual Defects in GlassClassifying Visual Defects in Glass--Reinforced Plastic Laminate Parts.Reinforced Plastic Laminate Parts.““Defects include cracking, crazing, Defects include cracking, crazing, blistering, thermal/chemical degradation, blistering, thermal/chemical degradation, etc.etc.

Fiberglass Reinforced Plastic Fiberglass Reinforced Plastic Tank InspectionsTank Inspections

FTPI-2005-2


Location of Most Defects in Location of Most Defects in Fiberglass TanksFiberglass Tanks

The location of most defects will be The location of most defects will be found in the liquid containing areas of found in the liquid containing areas of the tank or equipment. the tank or equipment. −−A vertical tank is more susceptible to A vertical tank is more susceptible to

defects where the shell meets the floor. defects where the shell meets the floor. −−A horizontal tank is more susceptible to A horizontal tank is more susceptible to

effects in the areas of the saddle supports.effects in the areas of the saddle supports.

FTPI-2005-2


Delamination & Exposed FibersDelamination & Exposed Fibers


““The intended effects of these actions are to improve the The intended effects of these actions are to improve the crashworthiness of tank carscrashworthiness of tank cars…”…”

RailcarsRailcarsDepartment of Transportation, 49 CFR Part 171Department of Transportation, 49 CFR Part 171

Hybrid Testing Hybrid Testing MethodologiesMethodologies

SiteSite--specific approaches to tank specific approaches to tank inspections and integrity testinginspections and integrity testing


RationaleRationale

The PE can certify a customized inspection The PE can certify a customized inspection and testing program for the facilityand testing program for the facilityFactors such as, but not limited to, tank Factors such as, but not limited to, tank configuration, products stored, and configuration, products stored, and temperature may drive this choice.temperature may drive this choice.Input from the tank owner should have Input from the tank owner should have little to do with this decision.little to do with this decision.Other siteOther site--specific factors should be specific factors should be considered.considered.


Common Pitfalls and ProblemsCommon Pitfalls and ProblemsThe EPA inspector should:The EPA inspector should:−− Ensure against the use of standards such as APIEnsure against the use of standards such as API--12R1 being 12R1 being

used to simply eliminate the need for authorized tank used to simply eliminate the need for authorized tank inspectors.inspectors.

−− Be aware that hybrids may be used as a shortcut to do less Be aware that hybrids may be used as a shortcut to do less intense inspections or to reduce inspection frequency.intense inspections or to reduce inspection frequency.

−− The use of a hybrid does not eliminate the need for The use of a hybrid does not eliminate the need for comprehensive inspection checklists to verify that the comprehensive inspection checklists to verify that the inspection covers at least the minimum elements as inspection covers at least the minimum elements as referenced in national tank inspection standards and are in referenced in national tank inspection standards and are in accordance with the PEaccordance with the PE--certified inspection and testing certified inspection and testing program.program.

−− The facility must maintain records of all visual inspections The facility must maintain records of all visual inspections and integrity testing.and integrity testing.

Hybrid Program

BaseliningBaselining

Initiating a Tank Inspection Initiating a Tank Inspection ProgramProgram


Example Baselining Plan to DetermineExample Baselining Plan to DetermineTesting & Inspection Schedule (STI SPTesting & Inspection Schedule (STI SP--001)001)

Scenario:Tank A is a 20,00020,000 gallon horizontal tank with secondary containment. Tank B is a 10,00010,000 gallon vertical tank without secondary containment.Tank C is a 1,0001,000 gallon vertical tank with secondary containment.

Category 1 (Tank Category 1 (Tank ““CC””))−− AST with spill control, and with CRDMAST with spill control, and with CRDM−− Example: vertical tank with RPB and spill controlExample: vertical tank with RPB and spill control

Category 2 (Tank Category 2 (Tank ““AA””))−− AST with spill control, but without CRDMAST with spill control, but without CRDM−− May include an AST in contact with the ground. May include an AST in contact with the ground.

Category 3 (Tank Category 3 (Tank ““BB””))−− AST without spill control, and without CRDMAST without spill control, and without CRDM−− Example: AST in contact with the groundExample: AST in contact with the ground

CRDM = continuous release detection methodCRDM = continuous release detection method RPB = release prevention barrier RPB = release prevention barrier


CategoryCategory

P**P**PPPPPortable ContainersPortable Containers

P, E&L(5), I(10)P, E&L(5), I(10)P, E&L(5), I(15)P, E&L(5), I(15)P P E(20)E(20)

ShopShop--Fabricated 30,000Fabricated 30,000--50,00050,000

P, E&L(5), I(10)P, E&L(5), I(10)P, L(2), E(5)P, L(2), E(5)

P, E(10), I(20)P, E(10), I(20)P, E(5), L(10)P, E(5), L(10)

P P E(20)E(20)

ShopShop--Fabricated Fabricated 5,0015,001--30,00030,000

P, E&L(5), I(10)P, E&L(5), I(10)P, L(2), E(5)P, L(2), E(5)

PPE&L(10)E&L(10)

PPShopShop--FabricatedFabricated1,1011,101--5,0005,000

PPE&L(10)E&L(10)

PPPPShopShop--FabricatedFabricated00--1,11001,1100

332211Tank Type and Capacity (gallons)Tank Type and Capacity (gallons)

Category 3, Tank

Category 3, Tank ““BB””

Category 2, Tank

Category 2, Tank ““AA””

Category 1, Tank

Category 1, Tank ““CC””

Example Baselining Plan to DetermineExample Baselining Plan to DetermineTesting & Inspection ScheduleTesting & Inspection Schedule(STI SP(STI SP--001)001)


UnknownUnknown19991999Tank Tank ““CC””

2016201620062006UnknownUnknown20022002Tank Tank ““BB””

Past DuePast DuePast DuePast DueUnknownUnknown19811981Tank Tank ““AA””

Next Next Required Required Internal Internal Inspection Inspection Date?Date?

Next Next Required Required External External Inspection Inspection Date?Date?

Last Last Inspection Inspection DateDate

Construction Construction DateDate

EquipmentEquipment

Example Baselining Plan to DetermineExample Baselining Plan to DetermineTesting & Inspection Schedule (STI SPTesting & Inspection Schedule (STI SP--001)001)

Monthly & Yearly Reviews Required


Example: Baselining Plan to Determine Example: Baselining Plan to Determine Testing & Inspection Schedule (APITesting & Inspection Schedule (API--653)653)

2014 or less based on calculated corrosion rates from the 1994 inspection

1999 & 2004 formal visual 2009 non-destructive shell test both intervals may be decreased based on calculated corrosion rates from the 1994 inspection.

19941984Tank 3

2011 (i.e., not to exceed 10 years when corrosion rate of tank bottom is not known)

2006 for both visual inspection and non-destructive shell test

none 2001Tank 2

formal (internal) bottom inspection within first five-year Plan review cycle (Due Now)

formal visual and shell test (external) within first five-year Plan review cycle (Due Now)

none unknown Tank 1

Next Inspection (Internal) Next Inspection (External) Last

Inspection Construction

Date

ReRe--rating of Tank rating of Tank CapacityCapacity

Limiting CapacityLimiting Capacity


Definition of Storage CapacityDefinition of Storage Capacity40 CFR Part 112.240 CFR Part 112.2−−Storage Capacity Storage Capacity of a container means the of a container means the

shell capacity of the container.shell capacity of the container.Under the SPCC rule, a container has a requisite Under the SPCC rule, a container has a requisite capacity, capacity, (Maximum Enforceable Capacity (Maximum Enforceable Capacity ““MECMEC””), w), which is always equal to the tankhich is always equal to the tank’’s shell s shell capacity.capacity.

−−ReRe--RatingRating is the process of limiting the is the process of limiting the amount stored in a tank to less than the shell amount stored in a tank to less than the shell capacity.capacity.

Tank Re-rating


“Requisite capacity”or“Maximum Enforceable Capacity”or“Shell capacity”

But the owner promises to only fill the tank to this “redline” on the tank.

“Redlining a tank was used to prevent filling a tank past its useful rerated capacity.”

Tank RedliningTank RedliningTank Re-rating


Acceptable TechniqueAcceptable Techniqueaccording to the SPCC Ruleaccording to the SPCC Rule

• An owner or operator may only reduce the capacity of a tank by changing the shell dimensions (i.e., by removing shell plate sections). Since SPCC requirements are based on shell capacity, modifying a vent, overflow, or other tank appurtenances that reduce the working fill capacity does not affect SPCC requirements, including facility capacity determination and secondary containment requirements.

Tank Re-rating


Adding new or modifying existing shell Adding new or modifying existing shell penetrations are not considered to be permanent penetrations are not considered to be permanent and therefore making these changes alone may and therefore making these changes alone may not be considered as rerating the tank.not be considered as rerating the tank.

Unacceptable TechniqueUnacceptable Techniqueaccording to the SPCC Ruleaccording to the SPCC Rule

• The overflow could be easily closed off in the future and the tank capacity would then return to the shell capacity.

Tank Re-rating


Unacceptable TechniqueUnacceptable TechniqueThis inspection provided an engineering This inspection provided an engineering evaluation of the tank overflow which was evaluation of the tank overflow which was installed on May 2, 2002 to reduce the installed on May 2, 2002 to reduce the tank capacity. All welding of the pipe to tank capacity. All welding of the pipe to the shell was done in accordance with API the shell was done in accordance with API 650. The welds were inspected by a 650. The welds were inspected by a Certified Weld Inspector. A drawing of Certified Weld Inspector. A drawing of the overflow is attached. (This is a the overflow is attached. (This is a Virginia AST)Virginia AST)


Unacceptable TechniqueUnacceptable Technique

Remarks/Legend:

Drawing Title: Tank Description:

Date: Rev. No.: Scale:

Drawn By:

Company:

5/2/2002 N/AXYZ, Inc.

N/A

Tank # 1Tank Layout [1 of 1]

XXXXXX; ZZ,VA

NWNO 270

S180

E90 0

40' S

hell

Hei

ght

"A"8" Nozzle 4" Nozzle

"B"4" Nozzle

"C" 4" Nozzle"D"

4" Nozzle"F"

4" Nozzle"G"24" Manhole

"E"

New Overflow

Elev. 0

Piping Piping RequirementsRequirements

Piping Inspection Standards, Piping Inspection Standards, Requirements for Aboveground Requirements for Aboveground

Piping, and Corrosion Protection of Piping, and Corrosion Protection of Buried PipingBuried Piping

Piping Inspection Piping Inspection StandardsStandards

API Std 570, API RP 1110API Std 570, API RP 1110


Reference Standards: Pipe Reference Standards: Pipe System Design StandardsSystem Design Standards

ASTM B31.3 ASTM B31.3 -- Process PipingProcess Piping−− This Code contains rules for piping typically found in This Code contains rules for piping typically found in

petroleum refineries, terminals and related industries.petroleum refineries, terminals and related industries.

ASTM B31.4 ASTM B31.4 -- 2002 2002 ––Pipeline Transportation Pipeline Transportation SystemsSystems−− This Code prescribes requirements This Code prescribes requirements

for the design, materials, for the design, materials, construction, assembly, inspection, construction, assembly, inspection, and testing of piping transporting and testing of piping transporting liquids.liquids.


Reference Standards: Pipe Reference Standards: Pipe System Inspection Standards System Inspection Standards and Recommended Practicesand Recommended Practices

API 570API 570 Piping Inspection Code: Inspection, Repair, Piping Inspection Code: Inspection, Repair, Alteration, and Rerating of InAlteration, and Rerating of In--Service Piping Systems Service Piping Systems −− Covers inspection, repair, alteration, and rerating procedures fCovers inspection, repair, alteration, and rerating procedures for inor in--

service metallic piping systems. Establishes requirements and guservice metallic piping systems. Establishes requirements and guidelines idelines that allow owner/users of piping systems to maintain the safety that allow owner/users of piping systems to maintain the safety and and mechanical integrity of systems after they have been placed intomechanical integrity of systems after they have been placed into service. service.

APIAPI--1110 Pressure Testing of Liquid Petroleum Pipelines 1110 Pressure Testing of Liquid Petroleum Pipelines −− This recommended practice covers the pressure testing of new andThis recommended practice covers the pressure testing of new and

existing liquid petroleum pipelines. It recommends minimum proceexisting liquid petroleum pipelines. It recommends minimum procedures dures to be followed, suggests equipment to be used, and points out fato be followed, suggests equipment to be used, and points out factors to ctors to be considered during the pressure testing of liquid petroleum pibe considered during the pressure testing of liquid petroleum pipelines. pelines. This recommended practice does not address low pressure pneumatiThis recommended practice does not address low pressure pneumatic c testing.testing.


Reference Standards: Pipe Reference Standards: Pipe System Inspection Standards System Inspection Standards and Recommended Practicesand Recommended Practices

API 570API 570 is not a standis not a stand--alone document. alone document. APIAPI--1110 is a Recommended Practice used 1110 is a Recommended Practice used to perform a hydraulic test on buried pipe to perform a hydraulic test on buried pipe if an APIif an API--570 inspection is being 570 inspection is being performed on buried pipe.performed on buried pipe.For example, a facility may have both aboveground and buried For example, a facility may have both aboveground and buried piping. The aboveground piping may only require ultrasonic piping. The aboveground piping may only require ultrasonic thickness testing while the buried piping will be required to bethickness testing while the buried piping will be required to beinspected using APIinspected using API--1110 as a reference document for additional 1110 as a reference document for additional testing needed on buried pipe.testing needed on buried pipe.


Inspection IntervalsInspection IntervalsThe frequency and extent of inspection The frequency and extent of inspection for piping depend on the forms of for piping depend on the forms of degradation that can affect the piping and degradation that can affect the piping and consequence of a piping failure.consequence of a piping failure.After the consequences and risk After the consequences and risk probability have been determined, an probability have been determined, an inspection frequency can be established.inspection frequency can be established.This frequency may be more but never This frequency may be more but never less frequent than those listed in APIless frequent than those listed in API--570 570 Section 6 and as shown in later slides.Section 6 and as shown in later slides.


External InspectionExternal InspectionEach piping system shall be given a visual Each piping system shall be given a visual external inspection, preferably while in external inspection, preferably while in operation, not to exceed the following operation, not to exceed the following class schedules:class schedules:–– Class 1 Class 1 -- 5 years5 years–– Class 2 Class 2 -- 5 years5 years–– Class 3 Class 3 -- 10 years10 years


Thickness Measurement Thickness Measurement InspectionInspection

The period between thickness The period between thickness measurement inspections shall not exceed measurement inspections shall not exceed one half the estimated remaining life of one half the estimated remaining life of the piping based on corrosion rate but not the piping based on corrosion rate but not to exceed the following class schedules:to exceed the following class schedules:–– Class 1 Class 1 -- 5 years5 years–– Class 2 Class 2 -- 10 years10 years–– Class 3 Class 3 -- 10 years10 years


Soil to Air InterfaceSoil to Air Interface

No Corrosion ProtectionModerate Corrosion Present


Piping over WaterwayPiping over Waterway


Leaking UG PipeLeaking UG Pipe(Shown after uncovering)(Shown after uncovering)


Deteriorated WeldDeteriorated Weld(shown after wrap is removed)(shown after wrap is removed)


Leaking UG Piping Leaks Leaking UG Piping Leaks UncoveredUncovered


SummarySummary• The use of API-570 and API-RP-1110 has proven

to be a successful means of finding the current condition of a pipe system as well as establishing its projected useful life.

• Not all pipe systems will require pressure testing.• Look for documentation. API Certified inspectors

have consistently developed and improved their inspection forms and are proud to have them reviewed.


Common Pitfalls and ProblemsCommon Pitfalls and Problems• The piping configuration including the location

of fittings, valves etc. along with photographs should be gathered and reviewed before any testing begins.

• Check for documentation of test pressure calibrations on equipment to be used for pressure test. Forgetting to document these calibrations can void a successful test.

• Ensure that the test pressure and the test time span are recorded. Without this documentation a test can be rejected afterwards

Specific Items to Look Specific Items to Look for During an SPCC for During an SPCC

InspectionInspection


Tank Integrity Assurance through Tank Integrity Assurance through Periodic InspectionPeriodic Inspection

The SPCC rule does not refer The SPCC rule does not refer specifically to or mandate the specifically to or mandate the use of a particular industry use of a particular industry standard for tank inspection.standard for tank inspection.Ask for tank inspection reports with names Ask for tank inspection reports with names & contact info. of the certified inspector. & contact info. of the certified inspector. Remember the tanks have not been Remember the tanks have not been inspected if the inspector is not certified!inspected if the inspector is not certified!Review the recommendations section.Review the recommendations section.


Inspection FollowInspection Follow--upupHas the owner/operator followed or Has the owner/operator followed or complied with the requirements or complied with the requirements or recommendation found within their recommendation found within their inspection reports?inspection reports?−− Often the tanks and piping have been inspected but Often the tanks and piping have been inspected but

the required repairs have not been performed. the required repairs have not been performed. −− Remember, under current tank inspection Remember, under current tank inspection

standards, if the recommendations have not been standards, if the recommendations have not been performed, a certified inspection has not technically performed, a certified inspection has not technically been completed.been completed.

−− Inquire whether there is a schedule to address the Inquire whether there is a schedule to address the recommendations.recommendations.


Secondary ContainmentSecondary ContainmentAsk for containment capacity and how they Ask for containment capacity and how they intend to meet the performance standard under intend to meet the performance standard under §§112.8(b)(2) of 112.8(b)(2) of ““sufficiently impervious to contain sufficiently impervious to contain discharged oil.discharged oil.””−− One way is to perform a permeability test, however One way is to perform a permeability test, however

this testing is not required. this testing is not required.

Tank and piping inspections only provide a Tank and piping inspections only provide a reasonable understanding of the tankreasonable understanding of the tank’’s current s current ability to hold product. A facility must provide ability to hold product. A facility must provide assurance that they have proven ability to assurance that they have proven ability to contain a release.contain a release.


Double Ring Infiltrometer TestDouble Ring Infiltrometer Testfor permeabilityfor permeability


Get the information you need!!!Get the information you need!!!

DonDon’’t hesitate to ask questions.t hesitate to ask questions.Ask for contacts in engineering or Ask for contacts in engineering or ““at the at the home officehome office””. Often the facility personnel . Often the facility personnel do not get involved with inspection do not get involved with inspection projects and may not be able to answer projects and may not be able to answer your questions.your questions.

Integrity Testing OSCReadiness Abt Assoc 2000

Documents

magnetic flux

osc readiness

remaining

liquid petroleum

measured shell

calculated

floor plate

piping transporting