SABIC CRYOGENIC STORAGE TANKS

INSPECTION PROCEDURE

JUNE 2001

NAME COMPANY SIGNITURE

PREPARED
ABDALLAH BIN MABROUK AL-KURBI SADAF
BY

SAFCO IBN
MAJED BIN SULIMAN AL-RASSI
AL-BAYTAR

ASHIQ FAZAL HUSSAIN PETROKEMYA

REVEIWED ALI BIN ABDULLAH AL-BEED SADAF

BY

NABEEL BIN JASSEM AL-DOSSARI SADAF

ABDALLAH BIN MABROUK AL-KURBI SADAF

NAME JOB TITLE SIGNITURE

PETROKEMYA GM.
OSAMA S. MIRDAD
TECHNICAL SUPPORT
SAFCO IBN AL-BAYTAR
APPROVED ALI J. AL-MAJED ENGINEERING &
BY INSPECTION MANAGER

SADAF EQUIPMENT
SAUD A. AL-SANEA
ENGINEERING MANAGER

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ACKNOWLEDGMENT

SADAF STATIONARY EQUIPMENT ENGINEERING SECTION

WOULD LIKE TO TAKE THIS OPPORTUNITY TO THANK THE
MANAGEMENT AND INSPECTION DEPARTMENTS IN
PETROKEMYA AND SAFCO IBN AL-BAYTAR FOR THEIR
EXCELLENT AND EFFECTIVE SUPPORT, COOPERATION
AND PARTICIPATION IN DEVELOPING THIS PROCEDURE.
THANKS ARE EXTENDED TO SADAF MANAGEMENT FOR
THEIR SUPPORT.

CRYOGENIC STORAGE TANK INSPECTION PROCEDURE

TABLE OF CONTENTS

Part# Description Page#

I. PURPOSE 04

II. SCOPE 04

III. INTRODUCTION 04

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 REFERENCED REGULATIONS / PROCEDURES /
IV. 04
STANDARDS / CODES / PRACTICE

V. CRITERIA FOR INSPECTION 05

VI. EXTERNAL INSPECTION ACTIVITIES 06

VII. INTERNAL INSPECTION ACTIVITIES 07

VIII. INSPECTION TECHNIQUES AND TESTING 10

IX. REPORT & RECORD KEEPING 11

X. SAFETY 12

I. PURPOSE

The purpose of this procedure is to establish minimum requirements and guidelines

for the inspection of double wall cryogenic (Ammonia / Ethylene) storage tanks to
ensure mechanical and environmental integrity. Relevant codes, Sabic & Sabic
Affiliates Policies, Inspection Procedures, and Specifications are the foundation for
this procedure.

II. SCOPE

This procedure covers only the refrigerated Ammonia / Ethylene storage tanks
(double wall construction) used to store the Liquid Ammonia / Ethylene.

III. INTRODUCTION

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 With this procedure as a guide, the Stationary Equipment Inspector shall focus on
the requirements for run-and-maintain type of inspection. The codes and standards,
under which tanks are constructed and maintained, are referenced within.
Inspections and recommendations for repairs are made, using these codes and
standards as guidelines. Discussions include the types of inspections, inspection
methods and testing. Tank components of particular concern are featured.

The Inspector shall have a working knowledge of this procedure, should review the
equipment files for material specifications, construction drawings, permanent records,
field inspection reports, and inspection history, and shall carry the required inspection
tools before making tank inspections. The inspector shall be qualified as specified in
API 653, Section 4.

Inspector should discuss with operation any abnormal conditions or operational

upsets such as incident of excessive pressures or temperatures during operation.
This data may help to determine the cause, types and location of deterioration.

IV. REFERENCED REGULATIONS /PROCEDURES /STANDARDS

/CODES / PRACTICES

1. SADAF STORAGE TANK INSPECTION PROCEDURE SEI-4.1

2. SAFCO & IBN AL-BAYTAR AMMONIA STORAGE TANK INSPECTION

PROCEDURE

3. PETROKEMYA TANK INSPECTION PROCEDURE

4. REFERENCED STANDARDS/CODES/PRACTICES API Chapter
XIII, GFIORE (Atmospheric and Low Pressure Storage Tanks)

API 510 Pressure Vessel Inspection Code

API-575 Inspection of atmospheric and low pressure storage tanks
API 620 Welded Low Pressure Storage Tanks
API 650 Welded Steel Tanks for Oil Storage
API 652 Lining of Aboveground Petroleum Storage Tanks
API 653 Tank Inspection, Repair, Alteration and Reconstruction
API 2000 Venting Atmospheric and Low Pressure Storage Tanks
API 2201 Welding or Hot Tapping on Equipment Containing
Flammables
API 2207 Preparing Tank Bottoms for Hot Work
API 2217 Guidelines for Confined Space Work in the Petroleum
Industry

ASME Sect. IX Welding Qualifications

ASTM A6 General Requirements for Rolled Steel Plates, Shapes,
Steel Piping, and Bars for Structural Use

5. OSHA Part 1910 Occupational Safety and Health Standards

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V. CRITERIA FOR INSPECTION

1.External inspection

External inspection shall be carried out once every year (min) but not exceeding
two years on routine basis. However, incase abnormality arises during
surveillance, the external inspection shall be done regardless of its frequency.

2.Internal inspection (Double wall Construction)

a. Internal inspection should be done within 20 years maximum. However, incase

there are:

1. Externally detectable defects such as leakage of the tank, extreme cold

spots and deformations of the tank wall or bottom plates exceeding the
code limits.

2. Suspicion of internal damages revealed by surveillance results & analysis.

the internal inspection shall be done regardless of its frequency in order to

repair these defects/damages.

b.Incase the scheduled internal inspection is postponed, necessary deferment

approval form shall be issued and kept after approval in the equipment file.

c.The internal inspection interval can be extended more than 20 years if

only justified by the External Inspection Results. In this case, interval analysis
form shall be issued and kept after approval in the tank file. See API-653,
Sec. 4.4.3.

VI. EXTERNAL INSPECTION ACTIVITIES

External inspection shall consist of a complete visual inspection of shell, roof and
appurtenances. The Inspector shall use any inspection technique necessary to obtain
the data needed to verify the equipment is suitable for continued service, i.e., UT,
Radiography, Ultrasonic Flaw Detection, Acoustic Emissions or other effective
techniques.

In certain situations such as a request to defer inspection is submitted, External

inspection may be used in lieu of an internal inspection if justified by
corrosion/maintenance history and approved by the Stationary Equipment Engineer.
The equipment may be in service, on standby or out of service. The requirements of
API 653, Section 4.3.3 shall be met.

External inspection shall include the following: (in addition to the items listed in API
653, Table C-1: Tank In-Service Inspection Check List).

1. Tank leakage - (indicated by wet tank shell, especially at shell/ floor joint and
reinforcement pads, product on the ground, concrete or berm).

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2. Plate buckling.

3. Visual inspection for corrosion.

4. UT survey on accessible shell plates as a minimum.

5. Condition of welds - (cracks, corrosion) especially shell/floor joint.

6. Paint condition – as per the requirements of the applicable Affiliate

Procedure.

7. Insulation:

a. Check condition of insulation, especially around tank appurtenances

(nozzles, bellows, man ways, block valves, ladder clips, thermo wells,
etc.).

b. If a cold spot is observed in the tank shell, consider refilling the

Perlite Insulation because a cold spot may be an indication of
insulation settlement.

c. Corrosion under insulation on tanks, which operate at 150 deg. C or less

by cutting inspection windows in the insulation. (Especially roofs of
insulated tanks or on shell at grade where rainwater may accumulate in
dike areas). See Applicable Affiliates’ Inspection Procedure.

8. External temperature survey by Thermograph. In other words, infra red

examination of the whole tank surface for temperature differences over
the tank wall and possible cold spots.

9. Height measurement of attached pipelines and constructions. Evidence of

uneven tank settlement shall be evaluated according to API 653, Appendix B-
Evaluation of Tank Bottom Settlement.

10. Top roof and vent lines (corrosion & fouling of opening).

11. PSVs

12. Visual inspection for Inlet & outlet lines, bellows and bolting at flanged joints for
external corrosion. Suitable NDT methods to be carried out at locations
suspected of having cracks

13. External budding / pavement

14. Water presence at grade above tank floor.

15. Foundation – sand/asphalt pad, concrete base ring, or concrete pad, shall be
inspected. Check the general condition of concrete for settlement, spalling,
cracks, general deterioration and asphalted joint sealer. Check the condition of
the berm. Check the condition of anchor bolts, when used. Anchor bolts should
be trapped with a hummer to one side of the nut to check for their complete
corrosion. Surface water drainage shall be away from the tank, with no
traps.

16. Ladder, stairway, platform & its supports (defects, corroded or broken

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 parts, stairways tread wear, weld and bolt cracks and corrosion,
looseness or breakage, buckling & other signs of mechanical failure).

17. Condition of all shell/floor appendages such as man ways & nozzles with
Reinforcement Pads - Condition of welds, corrosion, no screwed plug in
vent hole, water sealer in vent hole -, shell/floor stiffeners and shell/floor clips
which support piping, thermo wells, ladders and stairways.

18. Bottom of shell/tank floor. Evaluation of External tank bottom plate condition
using a proper test method shall be done.

19. Electrical grounding connections and cathodic protection system.

20. Auxiliary equipment such as gauge connection, pressure vacuum vents

and breather valves, fire-fighting equipment, flame arresters etc. to be
inspected visually for corrosion or signs of mechanical damage. Visual
checking for condition of seal for any breakage, cracks and deformation.

VII. INTERNAL INSPECTION ACTIVITIES

1. General Requirements

a. Be familiar with the requirements of API 653:

1. Section 2.2 - Tank Roof Evaluation
2. Section 2.3.3 - Minimum Thickness Calculation for Welded Tank
Shell.
3. Section 2.4.7 - Minimum Thickness for Tank Bottom Plate.
4. Section 2.4.8 - Minimum Thickness for Annular Plate Ring
5. Section 4.4 - Internal Inspection.

b. Inspect all items listed on the "Tank Out-of-Service Inspection Checklist",

shown in Appendix C, Table C-2 of API 653 in addition to the items listed in
point#02 below.

c. Actual thickness requirements shall be calculated using the formulas

specified in API 653, Section 2–Suitability for Service.

d. Internal coatings/linings:
1) Inspection of the internal coating or liner shall proceed in a manner that
will ensure that all areas have been thoroughly examined and
discontinuities are identified. Paint or liner condition shall be inspected as
required by the applicable Affiliates.
2) Review the guidelines set forth in API RP 652 (Lining of Aboveground
Petroleum Storage Tanks), where applicable

e. Tank repairs and alterations shall be done in accordance with API 653,
Section 7 - Repair and Alteration.

2.Internal inspection shall cover the following items but not limited to:

a.Thickness check of and Weld inspection by proper NDT methods for shell,

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 roof, bottom / annular plates, nozzles, bellows, connecting pipes and
internal hardware such as heating coils and associated piping. Where any
indication of metal cracking is seen, the process of inspection shall be
expanded, using Liquid Penetration Inspection or Magnetic Particle
Inspection to determine the extent of cracking. Cracks shall be removed by
grinding or other acceptable method and repaired as required.

b.Inner sides of both shell plates condition

Visual Inspection for both general and pitting types of corrosion.
The vapor space, liquid/ vapor interface point and the bottom of the shell
(especially Shell to floor welds) are the most likely areas where
corrosion will be found.

c.Visual inspection for Inner & outer shell appendages such as man ways,
nozzles, stiffeners, clips and thermo wells.

d.Insulation levels between both shells

e.Inner bottom plate condition.

 Perform a complete visual inspection
 Measure and record the depth of floor plate pits. Evaluate the extent
of floor plate corrosion and pitting and make recommendations for
repairs as required.
 Review the common bottom failures listed in API 653 - 2.4.2.
 Advanced NDT scanning:
 NDT scanning techniques are required to document corrosion
and/or pitting on the underside of tank bottoms. See the applicable
Affiliate Procedure corresponding to the NDT technique used for
detail requirements.
 The requirements for patching a tank floor when underside pitting is
a factor shall be made on a case-by-case basis with approval of the
Stationary Equipment Engineer.
 The minimum thickness requirement for tank bottom plate shall be:
o 2.5mm for a tank bottom with no means for detection and
containment of a bottom leak and
o 1.3mm for a tank bottom that provides a leak detection system
and containment of a bottom leak OR a tank bottom which has a
reinforcing lining, greater than 1.3mm, in accordance with API
652.
 If NDT scanning inspection is not conclusive, sample coupons may
be removed from the tank floor to determine the condition of the
floor underside to ensure environmental integrity.
 The basis for design of repairs and alterations shall be an API 650/
620 equivalence based on the original design code of the tank.
 Tank floor repairs shall be performed as required by API 653- 7.9,
Repair of Tank Bottoms.

f.Evaluation of External tank bottom plate condition using a proper test

method

g.Dome (roof) plate / support condition:

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 The roof and upper shell shall be visually inspected. Where visual
inspection of the roof and upper shell is not possible, thickness data
shall be obtained externally.
If roof plates are corroded to an average thickness of less than 0.09"
(2.3mm) in any 100 sq. in (2500 sq.mm) area OR if roof plates have any
holes through, the roof plates shall be repaired or replaced.

h.Suspended deck (roof) & its closure plate

 Visual inspection for all welds in the Suspended deck (roof) & its closure
plate for corrosion, pitting and cracking especially at the joint between
the susp. deck and its closure plate and the joint between the closure
plate and the inner shell.

i.Visual inspection for Suspended deck (roof) insulation, ladder, sleeves &
stiffeners.

j.Visual inspection for Roof rafters, girders & hanger’s rods especially at
joints with the dome and suspended deck.

k.Vacuum Leak Test for bottom plate welds, when required.

l.Visual inspection for Internal hardware such as heating coils and associated
Piping.

VIII. INSPECTION TECHNIQUES AND TESTING

Tank repairs must be inspected and tested to ensure the tank is suitable for
continued service. Inspection and testing is done in accordance with API 653,
Affiliate Project Narrative Specifications and the standards under which the tank
was fabricated. More sophisticated tools and techniques are becoming available to
accomplish this objective. Some of these methods are discussed below.

A. Non-Destructive Examination

1. Leak Detection

a. Vacuum Testing:
Vacuum testing is a standard method for testing floors & roofs for
leakage. It can also be used for testing shell leak repairs, especially
small ones. (Hydro-tests are preferred for large repairs.)

b. Penetrating Oil:
Testing for leakage of welds, which can be accessed from both sides,
may be done by brushing or spraying penetrating oil, such as diesel,
on one side of the joint and checking the opposite side of the joint for
leakage. The penetrating oil is sprayed on the face of the weld, and

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 the root side is checked for oil coming through after about a 30-minute
soak period. When testing weld repairs, this method shall be done
prior to painting.

c. Acoustic Emissions Testing (AE):

AE testing can locate floor leaks in tanks, which contain product. The
tank contents must remain stagnant for several hours before and
during the test. Several monitors are placed on the shell around the
tank. Sensitive listening devices are used to monitor activity levels
generated by fluid moving through leaks in the floor. By triangulation,
each leak can be located within few meters. More liquid head is
better, because the higher differential pressure across the holes
generates more activity. Very small holes are difficult or impossible to
detect.

2. Dye Penetrant

Liquid Penetrant Testing is a non-destructive method for detecting surface

discontinuities in relatively nonporous materials. This is a preferred method
of finding surface discontinuities on tank floor repairs. Proper
preconditioning of the surface will permit detection of nearly all extremely
tight or very shallow indications. Liquid penetrant testing can also be used
for leak testing instead of oil.

3. Advanced Ultrasonic Scanning Techniques (B-Scan & others) And

Magnetic Flux Leakage (MFL)

This technique is used to scan the tank floors to determine the extent of
underside corrosion and plate thickness.

4. Radiography

Some degree of radiography is usually appropriate for shell repairs. The

integrity of the lower vertical seams and vertical to horizontal junctions are
especially important. The quantity and location of radiographs shall be in
accordance with API Standard 650 and the requirements set forth in API
Standard 653, Section 10. In certain circumstances radiography may be
used in lieu of hydro testing after a proper evaluation.

B. Hydrostatic Pressure Testing

When testing tanks after repairs, as for new tanks, hydro test is the most positive
method for assuring the integrity of repairs. Hydro test ensures that the tank will
neither leak nor fail catastrophically when filled with product. For example,
radiography shows only that the subject portion of a weld does not have
imperfections greater than permitted by the code. Hydro test essentially proves
that all of the weld joints are adequate for the intended service (i.e., adequate
strength of weld metal and sufficient ductility), and is recommended whenever
practical. Reminder: the "minimum required" thickness is usually based on a

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 specific gravity of less than 1.0 and therefore requires a reduction in the hydro
test fill height.

Metal that is cold from ambient conditions or from cold water; (i.e., when testing in
the winter time) is susceptible to brittle fracture. The test temperature shall
always be considered especially for older steels and thick plate.

For specific requirements, refer to API 653, Section 3 - "Brittle Fracture

Considerations", and API 653, Section 10 - "Examination and Testing (10.3,
Hydrostatic Testing)".

IX. REPORT & RECORD KEEPING

Reporting and record keeping shall be as per the following guidelines:

1.Inspection report shall be issued after each external and/or internal inspection.

2.Inspection reports submitted by an external inspection agency shall be kept in

the equipment file.

3.The requirements established by API- 653 - 4.8 - Records, and 11.2, Record
Keeping shall be met

X. SAFETY

The Inspector shall be familiar with the requirements of:

1. Applicable Plant Safety Procedures.

2. API- 653 - Tank Inspection, Repair, Alteration, and Reconstruction

Section 1, Paragraph 1.4 - Safe Work Practices.

3. Inspector should make sure that a valid safe work permit and entry attendant
are available before performing internal inspection. Before starting the
inspection, the inspector shall ensure that surfaces are clean and suitable for
carrying out the desired inspection

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