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Report Horz PV-510
Report Horz PV-510
Orlando, FL
Report No.: 11033.033.1
Inspector: Jeff Walling
Employer: Eagle Inspection
Inspection Date: 5/26/2011
OUT-OF-SERVICE
Inspection Report For
Propane Tank
0480
Tank Farm
Inspector Signature
API Certification No. 2782
Page 1
INDEX
1.0 EXECUTIVE SUMMARY
4.0 RECOMMENDATIONS
4.1 Foundation
4.2 Vessel Shell
4.3 Vessel Heads
4.4 Appurtenances
4.5 Next Inspection
Page 2
1.0 EXECUTIVE SUMMARY
No major problems were noted during this inspection. Minor discrepancies are
listed in Section 3.0 Inspection Results and 4.0 Recommendations.
TABLE A
Nominal Actual Minimum Design Calculated Remaining
Design Measured Required MAWP MAWP Life
Thickness Thickness Thickness (psi) (psi) (years)
Component (in.) (in.) (in.) Internal Internal
Page 3
2.0 VESSEL DATA
Main Vessel Data General Data:
MAWP (psi): 250 Product: Propane
Design Temp.°F: 125 Build Date: 1966
MDMT °F: -20 NB No.: None
Oper. Press.(psi): 180 Const Code: ASME S8 D1
Page 4
3.0 INSPECTION RESULTS, IN-SERVICE
The following results are the summarization of a field checklist
that was utilized during the inspection of vessel 0480
3.1 Foundation:
3.1.1 The vessel rests in two concrete foundation support saddles with
rubber liners in between the tank and saddles.
3.2 Shell:
3.2.1 The shell is carbon steel with 8 to 15 mil epoxy external coating and is
un-insulated.
3.2.2 The external surface profiles of the shell appear to be smooth and
clean and in satisfactory mechanical condition. The shell coating is in
satisfactory condition.
3.3 Head(s):
3.3.1 The West and East heads are carbon steel with 8 to 15 mil epoxy
external coating and are un-insulated. The West and East heads have a
hemispherical design.
3.3.2 The external surface profiles of the West and East heads appear to be
smooth and clean and in satisfactory mechanical condition. The coating on
both heads is in satisfactory condition.
3.3.3 The nozzle penetration welds through the both heads appeared to be in
satisfactory condition.
3.4 Appurtenances:
3.4.1 The shell and head nozzles appear to be clean and in satisfactory
mechanical condition. There are areas scattered throughout the relief valve
vent piping with coating failure and surface oxidation.
3.4.2 The four (4) pressure relief valves do not have data tags attached
specifying certification date or set pressure.
3.4.3 The flange on shell nozzle K (24" Manway) has visible corrosion in the
flange gap.
3.4.5 The pressure and temperature gauges do not have calibration tags.
Page 5
4.0 RECOMMENDATIONS
4.1 Foundation:
4.1.1 None
4.2 Shell:
4.2.1 None
4.3 Heads:
4.3.1 None
4.4 Appurtenances:
4.4.1 Remove manway, clean flanges of corrosion and coat.
4.4.2 Certify or replace the four (4) existing pressure relief valves.
Page 6
5.0 ULTRASONIC THICKNESS (UT) MEASUREMENTS
5.2 Recommendations:
5.2.1 Next UT inspection of the vessel may be scheduled in 10 years in
accordance with maximum allowable intervals recommended by API-510.
Page 7
APPENDIX A
Engineering Calculations
Page 8
API-510 PRESSURE VESSEL SHELL EVALUATION
MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS
MAWP Calculations
Page 9
API-510 PRESSURE VESSEL SHELL EVALUATION
MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS
Cr = corrosion rate of the vessel part under consideration, in inches per year.
E = (E Internal) lowest efficiency of any joint in the shell course under consideration. For welded
vessels, use the efficiency specified in UW-12.
MAWP = the design maximum allowable internal working pressure of component of interest at the
upper most section of the vessel, (P - static head pressure), in psi.
P = MAP = the maximum allowable internal pressure of component of interest, including static head
pressure, in psi.
t = thickness of the vessel part under consideration, variable related to applicable calculation used
therein, in inches.
t act = actual thickness measurement of the vessel part under consideration, as recorded at the
time of inspection, in inches.
t min = nominal thickness minus the design corrosion allowance or the calculated minimum required
thickness of the vessel part under consideration at the design MAWP at the coinciding working
temperature, in inches.
t prev = previous thickness measurement of the vessel part under consideration, as recorded at last
inspection or nominal thickness if no previous thickness measurements, in inches.
Y = time span between thickness readings or age of the vessel if t nom is used for t prev, in years.
Yn = estimated time span to next inspection of the vessel part under consideration, in years.
Page 10
API-510 PRESSURE VESSEL HEAD EVALUATION
MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS
Vessel Head(s)
Head ID Head Type t nom Head ID Head Type t nom Head ID Head Type t nom
West Head Hemispherical 0.525 East Head Hemispherical 0.525
Material S SH P Material S SH P Material S P
CS - A455-B 18300 0.0 250.0 CS - A455-B 18300 0.0 250.0
t min = (in)
Page 11
API-510 PRESSURE VESSEL HEAD EVALUATION
MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS
MAWP Calculations (reference supplemental calcs for other head type formulas)
West Head Hemispherical t = 0.521 (in) P = 292.7 (psi) MAWP = 292.7 (psi)
East Head Hemispherical t = 0.532 (in) P = 299.1 (psi) MAWP = 299.1 (psi)
Page 12
API-510 PRESSURE VESSEL HEAD EVALUATION
MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS
Cr = corrosion rate of the vessel part under consideration, in inches per year.
E = (E Internal Calculations) lowest efficiency of any joint in the vessel part under consideration. For
welded vessels, use the efficiency specified in UW-12.
L = Hemi. Hds - inside spherical or crown radius of the head under consideration, in inches,. Elip. and
Tor. Hds - inside spherical or crown radius, in inches,
MAWP = the design maximum allowable internal working pressure of component of interest at the
upper most section of the vessel, (P - static head pressure), in psi.
P = MAP = the maximum allowable internal pressure of component of interest, including static head
pressure, in psi.
t = thickness of the vessel part under consideration, variable related to applicable calculation used
therein, in inches.
t act = actual thickness measurement of the vessel part under consideration, as recorded at the time
of inspection, in inches.
t min = nominal thickness minus the design corrosion allowance or the calculated minimum required
thickness of the vessel part under consideration at the design MAWP at the coinciding working
temperature, in inches.
Page 13
API-510 PRESSURE VESSEL HEAD EVALUATION
MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS
t prev = previous thickness measurement of the vessel part under consideration, as recorded at last
inspection or nominal thickness if no previous thickness measurements, in inches.
Y = time span between thickness readings or age of the vessel if t nom is used for t prev, in years.
Yn = estimated time span to next inspection of the vessel part under consideration, in years.
Page 14
HORIZONTAL TANK EVALUATION
Date 5/26/2011
(Based on Zick Formula for Two Saddle Tanks)
File No Report No Client Initials Tank No Temp. °F
3 11033.033.1 ACME Energy JLW 0480 125
Service
Propane
SG FH (in.)
0.59 117.00
Material Catagory
CS/Crom. Stl
wt 0.2833 (PCI)
17500 30000 29000000 132
tn Shell Prod # in L limit Mtl # in L limit Head Type tn Head CuFt in Head Mtl # in Head Other Weight, lbs
1.000 243469 110727 Hemispherical 0.525 348.5 5427 1000
ts th D R A H E L P Q a° b
0.937 0.525 130.000 65.000 118 65.252 1.00 957 250 188803 120 18.000
Temp. Total # Material S Y ME K1 K8
125 377607 CS - A212 B 17500
5 30000 29000000 0.335 0.603
Page 15
HORIZONTAL TANK EVALUATION
Date 5/26/2011
(Based on Zick Formula for Two Saddle Tanks)
File No Report No Client Initials Tank No Temp. °F
3 11033.033.1 ACME Energy JLW 0480 125
Service
Propane
SG FH (in.)
0.59 117.00
Material Catagory
CS/Crom. Stl
wt 0.2833 (PCI)
Ratio NA NA
Ratio 1.07 Vessel strength is adequate for stress at the saddle horn (<1.50*S)
Stress at Wear Plt Edge (S4) = -([Q]/(4*[ts]*([b]+1.56*([R]*[ts])^0.5)))-((3*[K6]*[Q])/(2*[ts]^2))
Ratio NA
Stress in Bottom of Shell (S5) -5075 =-([K7]*[Q])/([ts]*([b]+1.56*([R]*[ts])^0.5)) Stiffening Ring(s) No
Ratio 0.17 Vessel strength is adequate for stress in shell bottom (<.50*Y)
NOTES:
Page 16
HORIZONTAL TANK EVALUATION
Date 5/26/2011
(Based on Zick Formula for Two Saddle Tanks)
File No Report No Client Initials Tank No Temp. °F
3 11033.033.1 ACME Energy JLW 0480 125
Service
Propane
SG FH (in.)
0.59 117.00
Material Catagory
CS/Crom. Stl
wt 0.2833 (PCI)
DEFINITIONS,
Calculations based on L.P. Zicks analysis presentation in 1951
Variable = Definition
A = distance from tangent line of the head to center of saddle, in.
a° = horn of saddle contact angle, degrees
b = width of saddle, in.
D = outside diameter of vessel, in.
E = joint efficiency
FH = fill height, in.
H = outside depth of dish of head, in.
K = constant from table
L = length of vessel tan-tan, in.
M = material
ME = modulus if elasticity, psi
P = vessel maximum allowable working pressure, psi
PCI = pounds per cu. in.
PSI = pounds per sq. in.
Q = load on one saddle
R = outside radius of component, in.
S = allowable stress value, psi
SG = specific gravity
th = actual thickness of head, in.
tn = nominal thickness, in.
ts = actual thickness of shell, in.
Wpa° = wear plate contact angle, degrees
WPL = wear plate length beyond horn of saddle, in.
WPt = wear plate thickness, in.
WPw = wear plate width, in.
wt = weight, lbs
Y = yield stress of material, psi.
Page 17
APPENDIX B
Thickness Measurement Records
Page 18
API-510 PRESSURE VESSEL COMPONENT THICKNESS RECORD
Inspection Data
Report No Client Inspector Vessel Date
11033.033.1 ACME Energy Jeff Walling 0480 5/26/2011
Components with Vert. Axis: tml-1 N., tml-2 E., tml-3 S., tml-4 W. (Drawing N.)
Components with Horz. Axis: tml-1 Top, tml-2 Side, tml-3 Bttm., tml-4 Side (Clock Wise)
002 Vessel Shell Course 1 Propane 0.978 0.977 0.977 0.975 0.975
003 Vessel Shell Course 2 Propane 0.974 0.975 0.978 0.968 0.968
004 Vessel Shell Course 3 Propane 0.955 0.958 0.959 0.955 0.955
005 Vessel Shell Course 4 Propane 0.959 0.955 0.969 0.973 0.955
006 Vessel Shell Course 5 Propane 0.933 0.935 0.940 0.933 0.933
007 Vessel Shell Course 6 Propane 0.972 0.970 0.968 0.964 0.964
008 Vessel Shell Course 7 Propane 0.958 0.959 0.966 0.966 0.958
009 Vessel Shell Course 8 Propane 0.962 0.966 0.959 0.955 0.955
010 Vessel Shell Course 9 Propane 0.954 0.955 0.955 0.958 0.954
011 Vessel Shell Course 10 Propane 0.956 0.956 0.957 0.952 0.952
012 Vessel Shell Course 11 Propane 0.951 0.952 0.957 0.952 0.951
013 East Head Crown Radius Propane 0.533 0.532 0.533 0.532 0.532
Page 19
APPENDIX C
Inspection Drawings
Page 20
Page 21
APPENDIX D
Inspection Checklist
Page 22
API-510 PRESSURE VESSEL INSPECTION CHECKLIST Inspector: Jeff Walling
Cert No.: 2782
Company: ACME Energy Vessel: 0480 Report No.: 11033.033.1 Date: 5/26/2011
1 FOUNDATION 1.2 Containment
1.1 Steel Members Inspect the area for buildup of trash, vegetation and obstructions.
a.
a. Visually inspect for pitting and corrosion. b. Inspect sump drain operation.
b. Check fnd bolts secure with minimum thrd engagement. c. Check that runoff rainwater drains away from the tank.
c. Check for coating failures d. Describe type of construction - Earthen, Concrete, Asphalt, Grave
d. Check attachment welds for cracking and corrosion. e. Inspect condition of containment.
a. X Inspect for broken concrete, spalling and cracks. a. Check for degradaded members (split, broken, dry rotted et.).
b. X Inspect for erosion under foundation. b. Inspect for errosion and vegetation tank fnd.
c. X Check for settlement around perimeter of tank. c. Check for settlement around perimeter of tank.
2 SHELLS
2.1 External Visual Inspection
a. X Visually inspect shell surface for paint failures, pitting, corrosion, denting, out-of-round and part deformation.
b. Clean angles and other components that form catch basins and check for degradation and corrosion..
c. X Inspect nozzle penetration surfaces and welds for corrosion, cracking and deformation.
d. X Check for broken, unused insulation rod supports causing corrosion nodes.
e. X Visually inspect weld joints for cracking, pitting, corrosion and signs of leaking (product residue).
f. Perform dye penetrant or magnetic particle tests if leaks or cracks are suspected.
g. X Check for proper grounding
3 SHELL APPURTENANCES
3.1 Manways and Nozzles
a. X Inspect for cracks or signs of leakage on weld joints at nozzles, manways, and reinforcing plates.
b. X Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection.
c. X Inspect for flange leaks and leaks around bolting.
d. X Check flange bolts are secure and have minimum thread engagement.
e. Inspect sealing of insulation around manways and nozzles.
f. Check for inadequate manway flange and cover thickness on mixer manways.
g. X Check exposed flange and cover faces.
a. Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line.
b. Check circulation pump for leaks and operating problems.
c. Test bracing and supports of sample system and equipment.
Page 1 of 3
Page 23
API-510 PRESSURE VESSEL INSPECTION CHECKLIST Inspector: Jeff Walling
Cert No.: 2782
Company: ACME Energy Vessel: 0480 Report No.: 11033.033.1 Date: 5/26/2011
3.4 Heater (Steam Coils)
3.5 Mixer/Agitator
a. X Inspect deck plate for corrosion-caused thinning or holes (not drain holes) and paint failure.
b. X Inspect plate-to-frame weld for rust scale buildup.
c. Inspect grating for corrosion-caused thinning of bars and failure of welds.
d. Check grating tie down clips. Where grating has been retrofitted to replace plate, measure the rise of the step below and above the grating
surface and with other risers on the stairway.
a. Inspect stairway stringers, rungs and treads for corrosion, paint failure and weld failure.
b. Inspect stairway supports to shell welds and reinforcing pads.
c. Inspect steel support attachment to concrete base for corrosion.
4 VESSEL JACKET
4.1 Jacket Shell
a. Identify type of jacket (half pipe, cylindrical, dimpled and spot welded, etc.)
b. Measure and record pitch distances.
c. Visually inspect shell surface for paint failures, pitting, corrosion, denting, out-of-round and part deformation.
d. Clean angle support rings and inspect for corrosion and thinning on plate, annular space and welds.
e. Inspect the shell-to-foundation seal or barrier.
f. Check for broken, unused insulation rod supports causing corrosion nodes.
g. Visually inspect for weld joints for cracking, pitting, corrosion and signs of leaking (product residue).
h. Perform dye penetrant or magnetic particle test if leaks or cracks are suspected.
5 INSULATION
5.1 Visual Inspection
a. Check for holes, missing portions, deterioration due to corrosion or abuse.
b. Check for sufficient sealing, especially around vessel appurtenances.
c. Check for wetness
Page 2 of 3
Page 24
API-510 PRESSURE VESSEL INSPECTION CHECKLIST Inspector: Jeff Walling
Cert No.: 2782
Company: ACME Energy Vessel: 0480 Report No.: 11033.033.1 Date: 5/26/2011
7.2 Record Following ASME Data
a. X Board Number None
b. X Serial Number T-57340
c. X Radiography Examination 250 @ 125F
d. X MAWP
e. X MDMT
f. X Nominal Shell Thickness
g. X Nominal Head Thickness
h. X Nominal Height
i. X Head Material
j. X Shell Material
k. Jacket Material
l. X Manufacturer Trinity Steel Co., Inc
m. X Year Built 1966
8 VESSEL LAYOUT DRAWINGS 9 UT THICKNESS READINGS
8.1 Record Following Data 9.1 Measure and Record Vessel Part Thicknesses
a. X Head and skirt lengths and type. a. X Heads - (4) locations, (1) in each quadrant.
b. X Shell lines of support (Head Tang, Braces, Jckt Closures) b. X Shell - (4) locations, (1) in each quadrant for each course.
c. X Foundation support member dimensions and orientation. c. Jacket - As required (at least (4) locations).
d. X Inside/Outside diameter. d. Nozzles - (4) locations, (1) in each quadrant for 2 inches and
Vessel part nominal thicknesses. greater, (1) for < 2"
e. X
f. X Nozzle layouts, sizes and uses.
Notes:
Page 3 of 3
Page 25
APPENDIX E
Manufacturers Data Sheets
Page 26
Page 27
APPENDIX F
Inspection Photographs
Page 28
ACME ENERGY – TANK 0480
REPORT 11033.033 - INSPECTION PHOTOGRAPHS
Dataplate
Page 29
ACME ENERGY – TANK 0480
REPORT 11033.033 - INSPECTION PHOTOGRAPHS
Page 30
ACME ENERGY – TANK 0480
REPORT 11033.033 - INSPECTION PHOTOGRAPHS
Relief vents
Page 31
ACME ENERGY – TANK 0480
REPORT 11033.033 - INSPECTION PHOTOGRAPHS
Walkway
Page 32
APPENDIX G
NDE Records
1) UT Calibration Record
2) NDE Technician Certification
3) API Inspector Certification
Page 33
ULTRASONIC EXAMINATION REPORT
TEST PARAMETERS
UT UNIT
Unit: Dakota MVX S/N: 77143 Cal Date: 05/26/2011
PROBE SPECIFICATIONS
Long Frq 5 mHZ Size: .5 Type: HD S/N F7
SW Frq: mHZ Size: Type: S/N
SW Frq: mHZ Size: Type: S/N
SW Frq: mHZ Size: Type: S/N
COUPLANT
MFG: Ultra Grade Gel-40 Surface Cond: Coated
CALIBRATION STANDARD
Type: 4 lvl step wedge, 4340 FE CS S/N: 052-5609
Calibration Reference Level (db)
0: 51 45: 60: 70:
Other:
0: 45: 60: 70:
Start Time: 0700 End Time: 10:30 Start Time: 3:30 End Time: 15:00
Page 34
EAGLE I. TECHNOLOGIES NAME: Jeffrey Walling
NDT CERTIFICATION / QUALIFICATION RECORD Employee ID Number: 3965
NDT CERTIFICATIONS EXAM SCORES EXPIRATION
RESTRICTIONS
METHOD LEVEL DATE EXAMINER GENERAL SPECIFIC PRACTICAL COMPOSITE DATE
UTT II 4/9/2010 Joe Monroe 86% 100% 95% 94% 4/9/2015 thickness only
PT II 9/3/2010 Wayne Bailey 93% 95% 91% 93% 9/3/2015 None
MT II 9/3/2010 Wayne Bailey 93% 95% 85% 91% 9/3/2015 None
MFE II 1/21/2011 Brian Rotto 90% 85% 89% 88% 1/21/2016 None
Jeff Walling -
NDE PROGRAM MANAGER ASNT
CERT No.
10/22/2012 This NDT Qualification record is in accordance with EIT-WP-01 and SNT-TC-1A (2006). All historical
SIGNATURE DATE
information supplied for this document is true and accurate to the best of my knowledge.
EIT Certification Record Form: CAPE-FRM-102
Page 35
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