A Case Study on an Unusual Site with Shop-Fabricated Tanks.

by: John Cornell, Senior Tank Specialist

Mr. John R. Cornell

21 Years Storage Tank Experience Around The Globe
Senior Tank Specialist for H.I.R. Technical Services
API-653 and STI-SP001 Certified Tank Inspector

Current job
Official Contracted Training Provider for API on Both

Introductory and Advanced Level Tank Training Programs.

Exclusive Training Provider for PHSMA, DOT Part

195, Breakout Tanks.

H.I.R. Technical Services
www.storagetanks.info

The Right Approach

Purpose of Presentation
Relate experience to new inspectors . Challenge inspectors to bridge the gap between

standards. Can we only use one inspection standard? Help the tank owner. Sources
API 653. STI SP001. API- 575 and others.

The Inspection Doesnt Start Here

It starts here
How old is the tank?

What has been or is currently being stored in the tank?

What construction code was the tank built to?
Radiation Fire hazards Etc..

Internal or External inspection required?

Other questions
What is the tank configuration?

Horizontal or Vertical axis? What kind of roof?

Cone roof, Formed head, What type of roof access is available?

Vertical ladder, Spiral stairway, none?

Other questions

Is the tank clean?

Choosing the inspection standard

I could keep going & going & going

Choosing the inspection standard

API-653 works for:

Choosing the inspection standard

API-653 and STI-SP001 works for:

Choosing the inspection standard

Dont use API-653 for these, unless you want to.

Case Study: The Ugly Tank

Age: Unknown. Operating Temp: >200 F.

Design Standard: Unknown. Bottom: Cone down.

Bottom: Unsupported.

Should we use API-653

API-653: Temp: Up to 500 F (260C). Bottom must be uniformly supported.

Covers tanks built to API 650 and API 12C.. may apply to any steel tank constructed in accordance with a tank specification.

Can we use API-653

API-620: Does permit bottoms to be sloped. Question: Can API-653 inspector, inspect API-620 tanks. Yes, under limited conditions.
API 653 was intended to inspect tanks constructed in accordance with API 650 or API 620 as well as other large field-erected tanks, while API 12R1 was designed for production tanks. Phil Myers, P.E. The New STI SP001 Tank Inspection Standard and Compliance with The New EPA SPCC Rule for Petroleum Storage Tanks, July 22, 2004

Should we use STI-SP001

STI-SP001: Temp < 200 F (93.3C). Tank may be on legs.

ELEVATED AST an AST which is not in contact with the ground.. Examples of elevated tanks are tanks constructed on grillage or grating, or tanks on supports.

The inspection started at the bottom

API-653 approach

Remember, API 653 minimums are based on a fully supported bottoms.

API-653 approach
Remember, API - 653 minimums are based on a fully supported bottoms. API-653, Table 4.4..050

API-653, 4.3.2.1(old t =/> 60%)

Take-away: The thickness of corroded (Shell / Wall) may be reduced by 40%. .375 x .60% = .225
API-650 calls it a shell, API-620 calls everything a wall..

STI SP001 approach

Category 1 ASTs - The remaining AST shell thickness shall not be less than 25% of the original t. .375 x 25% = .0938

How thick should the cone be?

API-653, Table 4.4..050 653, 4.3.2.1(old t =/> 60%) Plates may be reduced by 40%. .375 x .60% = .225 STI-SP001 - The remaining AST shell t shall not be less than 25% of the original t. .375 x 25% = .0938

Required Floor / Cone Thickness

So for the floor portion of the tank inspection, we instructed the inspector to follow the perceived requirements of API-653.

Floor welds need to be inspected

STI-SP001, 8.3.2 Inspect the welds for cracking by visual inspection or other means.

API-653, 4.3.8 Deterioration of welds must be evaluated

Lessons learned - Coned Tanks

Both API-653 and STI-SP001 have limits.

Use all available standards as tools..

Think about this.. Are you trying to pass the tank or Are you trying to fail the tank

Now onto the shell

Ultrasonic Thickness Readings

API-653:
Insulated tanks need to have insulation removed only to the extent necessary to determine the condition of the exterior wall of the tank or the roof.

No particular guidance was given to our inspector

Ultrasonic Thickness Readings

STI-SP001: Readings must be concentrated in areas where corrosion is likely to occur.

Direct guidance for the inspector to seek out and find the areas at which accelerated corrosion may be located.

Ultrasonic Thickness Readings

API-653 / STI-SP001 Hybrid Combination: Remove the insulation as required to determine the condition of the tanks exterior and take additional readings in areas where internal corrosion is likely to occur.
There was already enough insulation missing on this tank that no addition insulation needed to be removed.

Shell Inspection Results

Shell Inspection Results

14,000 Gallon

Roof Hazards Falling over

Fact: Many tank inspectors do not have training in fall protection.

www.api-u.org/eLearning/FallProtectionIntro.html

Roof Hazards Falling over

A man was killed when he fell from the top of a storage tank.

There were no guardrails or other safety devices on the tops of the tanks, the victim was not using any fall protection equipment.

Roof Hazards Falling over

Employers should follow the OSHA guidelines for personal protective equipment. Owners, consider devices such as nonskid surfaces and railings on top of the tanks, and the surfaces on top should be kept free of oily residue.

Roof Hazards Unsafe Ladders

Check the ladder and stairways for loose treads or missing bolts and etc..

Roof Hazards Unsafe Treads

Check the ladder and stairways for loose treads or missing bolts and etc..

Topside Corrosion

API-575, 7.2.9 Tank Roof Inspection Hammer testing is not a recommended method of establishing roof plate integrity for personnel loading.

Check for corrosion as you go.

API Document 1972, Pre-653 1) All roofs should be hammer tested. 2) Regardless of the external appearance of the roof. 3)The hammer testing should be done with a full swing of the arm.

Underside Roof Corrosion

STI SP001:..It may be necessary to check the plate thickness with a hammer test to verify its adequacy.

Check for corrosion as you go.

API-653 permits any area on a tank roof to corrode to a average thickness of not less than .09 thickness in any 100 square inch area.

Experience shows that there can be isolated thin spots.

Check for corrosion as you go.

Experience shows that there can be isolated thin spots.

Floating Roof Inspection Hazards

This session will discuss approaching the inspection with safety in mind by reviewing:

Both Internal and External floating roofs.

and How various designs will alter the inspections report.

Entry into confined space occurs when the vertical plane of a shell manhole is broken.

Are you trained to be in here?

Shows a floating roof from the top of the cone roof looking in thru the roof hatch.

External Floating Roof Access

Need more tank training?

Go to: www.api-u.org

Inspection of Fiberglass and Plastic Tanks.

Introduction to API 620, 650 and 653.

Advanced Tank Training.

API-12F and 12R1.

Questions???
John R. Cornell H.I.R. Technical Services 701 North Perry Street, Suite 301 Titusville, PA 16354

johncornell@storagetanks.info
www.storagetanks.info

Phone: (814) 436-7453 Cell: (814) 706-7514

H.I.R. Technical Services
www.storagetanks.info