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SCOPE OF WORK FOR ABOVEGROUND

STORAGE TANKS AS PER API 653


Company Logo Storage Tank Inspection Project

TABLE OF CONTENTS

1. BACKGROUND.............................................................................................................................3

2. STANDARDS................................................................................................................................3

3. TANK DETAILS...........................................................................................................................3

4. PROJECT PLANNING..................................................................................................................5

5. SCOPE OF WORK.........................................................................................................................5

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1. BACKGROUND

Company intends to execute maintenance and inspection project of six (6) aboveground
storage tanks (AST). Storage tanks 3012 & 3015 have nominal storage capacity of 5,000m3,
3010 & 3011 have 10,000m3, while 3013 & 3014 have 20,000m3 each.

The storage tanks have been in service since 2012 (remember to add tank details in a table
or Appendix) and owner seeks the services of a qualified NDT contractor to conduct
comprehensive inspections according to the requirements of Annex C- Checklists for Tank
Inspection in API 653 standard.

2. STANDARDS

All cleaning, inspection and repair activities shall be conducted according the requirements
of the latest editions of standards specified below.

API 653: Tank Inspection, Repair, Alteration and Reconstruction,


API 650: Welded Tanks for Oil Storage,
EEMUA 159: Above ground flat bottomed storage tanks, a guide to inspection,
maintenance and repair.
API 652: Linings of Aboveground Petroleum Storage Tanks Bottoms
API 575: Guidelines and Methods for Inspection of Existing Atmospheric and Low-
pressure Storage Tanks
API RP 651: Cathodic Protection of Aboveground Petroleum Storage Tanks

3. TANK DETAILS

Details of the storage tanks such as diameter, numbers of courses, storage capacity, liquid
content, shell plate thicknesses, shell materials etc. are given below in table 1.

Table 1: Storage tanks details

STORAGE TANK No. 3010 (10,000m³) STORAGE TANK No. 3013 (20,000m³)

Height : 21.6m Height : 21.6m


Diameter: 26m Diameter: 38m
Storage content: Gasoline Storage content: Gasoil
Shell plate materials Shell plate materials
From 1st -6th S 355 J2 EN 10025 From 1st -8th S 355 J2 EN 10025
From 7 -10
th th
S 275 J2 EN 10025 9 shell course
th
S 275 J2 EN 10025
Shell Plate Details Shell Plate Details
10 course
th
6mm 9 course
th
8mm

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9th course 6mm 8th course 8mm


8th course 8mm 7th course 10mm
7th course 9mm 6th course 12.5mm
6th course 10mm 5th course 15mm
5th course 11.5mm 4th course 17mm
4th course 13mm 3rd course 19.5mm
3rd course 14.5mm 2nd course 22mm
2nd course 16mm 1st course 24.5mm
1st course 18mm

STORAGE TANK No. 3011 (10,000m³) STORAGE TANK No. 3014 (20,000m³)
Height : 21.6m Height : 21.6m
Diameter: 26m Diameter: 38m
Storage content: Gasoline Storage content: Gasoil
Shell plate materials Shell plate materials
From 1 -6th
st
S 355 J2 EN 10025 From 1 -8
st th
S 355 J2 EN 10025
From 7th -10th S 275 J2 EN 10025 9 shell course
th
S 275 J2 EN 10025
Shell Plate Details Shell Plate Details
10 course
th
6mm 9 course
th
8mm
9 course
th
6mm 8th course 8mm
8th course 8mm 7th course 10mm
7 course
th
9mm 6th course 12.5mm
6 course
th
10mm 5th course 15mm
5 course
th
11.5mm 4th course 17mm
4th course 13mm 3rd course 19.5mm
3 course
rd
14.5mm 2nd course 22mm
2 course
nd
16mm 1st course 24.5mm
1 course
st
18mm

STORAGE TANK No. 3012 (5,000m³) STORAGE TANK No. 3015 (5,000m³)
Height : 19.2m Height : 19.2m
Diameter: 20m Diameter: 20m
Storage content: Gasoline Storage content: Gasoil
Shell Plate Materials Shell Plate Materials
From 1 -6
st th
S 355 J2 EN 10025 From 1 -6
st th
S 355 J2 EN 10025
From 7th -8th S 275 J2 EN 10025 From 7th -8th S 275 J2 EN 10025
Shell Plate Details Shell Plate Details
8th course 6mm 8th course 6mm
7th course 7mm 7th course 7mm
6th course 8mm 6th course 8mm
5th course 8mm 5th course 8mm
4th course 9.5mm 4th course 9.5mm
3rd course 10.5mm 3rd course 10.5mm
2nd course 12mm 2nd course 12mm
1st course 15mm 1st course 15mm

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4. PROJECT PLANNING

This scope of work shall cover all NDT inspection and repair activities to be performed after
the cleaning of six tanks 3010, 3011, 3012, 3013, 3014 & 3015. As per company requirement
the planning will be as bellow:

 TK1002 and TK1003 shall be completed before end of 2018,

 TK1001 and TK1005 shall be completed before end of 2019

The contractor shall submit for approval a detailed inspection and repair plan for each tank
which not exceed 6 working days per tank starting from the day of commencement. After
issuance of commence letter and project kick-off meeting, contractor shall start project not
more than 5 working days.

Contractor shall mobilize to site all NDT equipment and repair tools 5 days working days prior
to kick-off date and 10 work days before commencement of inspection activities. It is the
responsibility of NDT contractor to engage a qualified repair organization where the
contractor lacks capabilities and all anticipated repair planning shall be adequately done
prior to start of project. Company shall not entertain any explanation for delay due to
improper preparation and planning.

In order to utilize the time and minimize delay, some repair activities may be carried out
simultaneously with other inspections after the defects have detected and recorded by the
examiners.

5. SCOPE OF WORK

1.1 Cleaning of Tanks

Before cleaning, contractor should submit tank cleaning procedure for approval. All cleaning
activities of the tank interior shall be carried out with special equipment. These include but
not limited to:

circulating pump equipment package,

heating equipment where necessary package

jetting system and affiliated equipment

chemical cleaning when needed.

contractor shall provide vacuum truck for cleaning and sludge disposal if needed

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Contractor will be responsible for sludge disposal and transfer and all wastes produced during
cleaning process. The treatment for sludge and disposal shall meet the requirements of all
local environmental laws of the Republic of Ghana and according to Company HSE
procedures. Company shall not be responsible for the payment of government fines for
contractors who violate government environmental laws.

After the cleaning, the internal space of tank shall meet the criteria for personnel entry to
carry out inspection and maintenance. Contractor shall provide all equipment, tools,
manpower and consumables required in cleaning work and shall comply with HSE
requirements for confined space entry. The cleaning result shall meet the safety
requirements for next step of the inspection, maintenance and repair activities.

1.2 Inspection Activities of Tanks

All inspections shall be done according to the requirements of Annex C- Checklists for Tank
Inspection in API 653 standard. All NDT inspections shall be conducted by qualified ASNT
Level II or III examiners who are certified according to ASNT SNT-TC-1A while the API
Inspector shall be certified according to API 653. All examiners and inspectors shall hold valid
ASNT Level II or III and API 653 certificates. Inspector CV including a copy of the API 653
certificate shall be listed in the technical bidding documents if needed.

Storage tank inspections shall be conducted as per inspection and test plan (ITP) in table 2
below. The extent of inspection shall be as per the requirements API 653 or as per attached
owner inspection and test plan (ITP) whichever is more stringent.

All completed inspection results shall be recorded on appropriate report sheet, submitted to
company or Contractor API Inspector within 24 hours after completion of inspection for
approval. For the purpose quality control / quality assurance, all site inspection checklists in
which inspection findings are recorded shall be signed by the NDT inspector and filed for
audit.

API 653 Inspector shall perform the assessment of thickness measurement results according
to API 653 and other applicable standards.

Table 2: Inspection and Test Plan for Storage Tanks

REQUIRED PROCEDURES AND SPECIFICATIONS


1.0
Description of Activity Standard Extent Documentation
1.1 UT Thickness Measurement Procedure ASME Sec. V
BS 3900 &
1.2 Surface Preparation & Painting Procedure
BS7079

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1.3 Vacuum Box Test Procedure API 653 TTF Approval


1.4 Magnetic Particle Test Procedure ASME Sec V TTF Approval
1.5 Penetrant Test Procedure ASME Sec V TTF Approval
1.6 Welding Procedure Specification ASME Sec IX TTF Approval
1.7 Roundness Inspection Procedure API 653 TTF Approval
1.8 Plumbness Inspection Procedure API 653 TTF Approval
1.9 Visual Inspection Procedure API 653 TTF Approval
1.10 Draining & Disposal of sludge Procedure API 653 TTF Approval
1.11 MFL inspection procedure API 653 TTF Approval
Steam Cleaning & Pressure Washing
1.12 API 653 TTF Approval
Procedure
1.13 Hydrotest / Water Fill-up Test Procedure API 653 TTF Approval
1.14 Detailed planning of the project project SOW TTF Approval
Note: Once all procedures and report templates are approved, kick of meeting will be organized

API 653 INSPECTION OF STORAGE TANK


2.0
Description of Activity Standard Extent Documentation
UT Thickness Measurement (Roof, shell ASME Sec V Minimum 9 points
2.1 Test Report
and bottom) API 653 per plate
Visual Check of Roof ASME Sec V
2.2 All plates Checklist
Primary & Secondary seals API 653
ASME Sec V
2.3 Visual Check of Shell 100% of all plates Checklist
API 653
2.4 Visual Check of Bottom API 653 All plates Checklist
Visual Check of Miscellaneous Tank Parts
2.5 API 653 All tank parts Checklist
(stair, handrail…)
Dike Area and Containment API 653 100% Checklist
Roof Appurtenances API 653 100% Checklist
External Fixed Roof API 653 100% Checklist
Internal Fixed Roof API 653 100% Checklist
External Floating Roof API 653 100% Checklist
Internal Floating Roof API 653 100% Checklist
Shell (Internal) API 653 100% Checklist
Shell (External) API 653 100% Checklist
Tank bottom and internal appurtenances API 653 100% Checklist
Access Structure API 653 100% Checklist
Shell Appurtenances API 653 100% Checklist

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Fixed Roof (Cone/Dome) API 653 100% Checklist


MPI of Bottom to Shell welds (Tank
Internal)
2.6 ASME Sec V 100% Test Report
PT of Bottom to Shell Welds (Tank
External)
PT of Bottom to shell welds (Tank
2.7 ASME Sec V 100% Test Report
External)
2.8 MFL inspection of all bottom plates ASME Sec V 100% bottom plates Test Report
Vacuum Box Test (all bottom weld joints)
2.9 API 653 100% bottom joints Test Report
(For all welds of the bottom plates)
Inspection
2.10 Roundness Check API 653 At each 45 degrees
Report
PT of all welded joints (piping, weld
2.11 ASME Sec V 100% of new welds Test Report
filling and patch repair)

2.12 Inspection of foundation API 653 All foundation Test Report

Minimum of 8
2.13 Plumbness (verticality) Check API 653 Test Report
measurement lines
Check settlement
2.17 Inspection of foundation and settlement API 653 Test Report
after hydrotest
Final Integrity evaluation and assessment Certified API 653
2.18 API 653 Test Report
of storage tank Inspector

1.3 Primary Repair Work of Tanks

All repairs required for tank are the contractor responsibility, this include any partial plate
replacement in roof, shell and bottom plates. The company will be responsible only in case
of replacement of ALL BOTTOM PLATES.

The contractor shall be requested to perform repairs stated below, regardless of the actual
condition:

Provide all equipment/tools, manpower and materials required to carry out repair.
Repair all paint failures and carry out maintenance painting observed during inspection
Proceed to the repair of any detected holes on the roof, shell or bottom plates and any
area showing excessive corrosion and metal loss. The repair methods shall be
according to API 653. Contractor shall provide an individual repair report and a general
map showing all locations that require repairs.
Compile and submit repair procedures based API 653 criteria to company for approval.
Instate the sacrificial anodes as per API 651 if needed. The distribution of anodes shall
be same as original design and shall be approved by company staff, material

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certificate is mandatory for approval. Anode dimensions shall be according design.


Replace any existing foam-type rubber seal that are found ageing and leaking with new
rubber seal. The rubber seal material certificate is mandatory for acceptance.
Reinforce or repair any defect in the foundation around the edge of the tank.
Repair any inacceptable part of the firefighting system of the tank if required.
Replace or install (if not available) 4 new lighting arrestor on the top of tank. Vendor
should submit technical certificate including technical requirement and specifications
of new lighting arrestor to be installed and method of measurement for approval.
Contractor shall be required to install new handrails around the walkway of any tank
without handrails on the top of the roof walkway.
If there are any welding activities, the welding points should be examined by NDT and
shall be accepted by welding engineer.
All electrical installation and cable have to be checked including lighting and earthing
system.
All Instruments shall be checked and replaced if damaged.
Breather valve need to be dismantled cleaned and re-installed.
1.4 Ultrasonic Thickness (UT) Measurement Plan

1.4.1 Bottom / Floor Plates

UT measurement plan of 5 thickness readings minimum per plate shall be conducted on


the bottom / floor plates depending on the geometry. For big plates, the number of
readings shall be between 8 – 9 thickness readings maximum per bottom / floor plate.
See a typical, generic diagram.

200mm
TYP

Bottom /Floor Plate UT Inspection Plan 200mm


TYP

1.4.2 Shell Plates

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UT measurement plan of for shall plates shall be 9 thickness readings per plate
minimum and 12 – 15 readings maximum per plate. See a typical, generic diagram.

Shell Plate UT Inspection Plan

1.5 Painting Coating Work for Tanks

Contractor shall compile and submit Sand blasting and painting measure and based NACE and
SSPC criteria to company for approval.

Sand blasting the whole tanks shall include the internal and external surface.
Depending on the wall thickness report, base plate and all accessories of tanks shall be
blast cleaned until smooth and clean surface according to Sa 2½ degree is satisfied.
The tanks dimensions are 47.5 m nominal diameter while nominal height is 18 m.
Coating shall be carried out on the whole tank, including the internal and external
surface, base plate and all accessories of tank. External coating refer to Attached
Spe1, Internal coating refer to Attached Spec 2.
Contractor will submit all the equipment, manpower and consumable materials for the
blasting and painting work.
All paints must from good and acceptable manufactures such as Hempel or Jotun or its
equivalent. Full painting system should be submitted by the contractor including
QA/QC procedure approved by 3rd party.
The paint for the internal shall be resistant oil and anti-static electricity.
After the coating, contractor shall be required to coat the tank mark on the tank shell;
the mark will include the LOGO, CMIT and the tank number. Paint colour shall be
made up of the different colours in the LOGO.
Painting and coating shall be carried out as stated in the sections and tables below.

1.6 Internal Coating of Tanks

The internal surface of the first 2 meters of shell plate (1 course from bottom) and
bottom plates shall be painted with 2 coats of tow component novolac epoxy coating

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Tankguard Storage according to table below. The interior of the remaining 16 meters
of the shell plate above and inside of the roof shall be painted with 2 coats of two
component Tankguard HB Classic polyamine cured epoxy coating.
All welds inside the tank shall be painted with 1 coat by use of brush or roller and
allowed to cure per paint manufacturer recommendation prior to application of paint
on general surface. Internal surfaces inside the pontoons of floating roofs shall be
painted with 2 coats of two component Tankguard HB Classic polyamine cured epoxy
coating.
Contractor shall determine and supply all paints adequate for all painting activities.
Contractor shall determine the total surface areas of the tank for painting.
The dimensions of the storage tank are nominal diameter 47.5m and 18m nominal height.

INTERNAL PAINITNG AND COATING SYSTEM FOR CRUDE OIL STORAGE TANKS

No. DFT
Surface Coating Total DFT
Structure Coating Material of
Preparation Type (m) (m)
Coats

Novolac epoxy
Primer 2 160
Shell plate (Tankguard storage)
(Course 1 Novolac epoxy
Sa 2½ Mid-coat 2 160 480
and bottom
(Tankguard storage)
plates)
Novolac epoxy
Topcoat 2 160
(Tankguard storage)
Polyamine cured epoxy
Primer 2 160
Shell plate (Tankguard HB)
(from Polyamine cured epoxy
Sa 2½ Mid-coat 2 160 480
Course 2 to
(Tankguard HB)
top)
Polyamine cured epoxy
Topcoat 2 160
(Tankguard HB)
Polyamine cured epoxy
Primer 2 160
(Tankguard HB)
Floating
roof Sa 2½ Polyamine cured epoxy 480
Mid-coat 2 160
(interior) (Tankguard HB)
Polyamine cured epoxy
Topcoat 2 160
(Tankguard HB)

Sa 2½ Polyamine cured epoxy 480


Primer 2 160
(Tankguard HB)

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Polyamine cured epoxy


Mid-coat 2 160
Pontoon (Tankguard HB)
(interior)
Polyamine cured epoxy
Topcoat 2 160
(Tankguard HB)

Table 1: Internal painting and coating system


1.7 External Coating of Tanks

Exterior surfaces of all shell plates shall be coated with 2 coats of two component Tankguard
HB Classic polyamine cured epoxy coating as primer and mid-coat while Hardtop Flexi
aliphatic acrylic polyurethane coating shall be used as topcoat.

All external structures and superstructures (staircase, ladder & handrails etc.) shall be
painted with 2 coats of 2 components Barrier Smart Pack reinforced polyamide cured zinc
rich epoxy coating as primer. Roof deck exposed to atmosphere shall be coated with one coat
of two components of Jotafloor PU Universal aromatic cured polyurethane coating as a mid-
coat while two coats of two components Hardtop Flexi aliphatic acrylic polyurethane coating
shall be used as topcoat for roof deck exposed to atmosphere.

EXTERNAL PAINITNG AND COATING SYSTEM FOR CRUDE OIL STORAGE TANK

Surface Coating No. of DFT Total DFT


Structure Coating Material
Preparation Type Coats (m) (m)

Tankguard HB classic 1 100


Primer
polyamide epoxy

Shell plate Sa 2½ Tankguard HB classic 1 120 320


Mid-coat
polyamide epoxy
Hardtop flexi aliphatic 1 100
Topcoat
acrylic polyurethane epoxy
Barrier smart pack polyamide 1 100
Primer
staircase, cured zinc rich epoxy
gratings, Tankguard HB classic
Sa 2½ Mid-coat 1 120 320
ladders & polyamide epoxy
handrails etc.
Hardtop Flexi aliphatic 1 100
Topcoat
acrylic polyurethane
Roof deck Sa 2½ Barrier smart pack polyamide 1 100 600
(exposed to Primer
cured zinc rich epoxy
atmosphere)
Mid-coat Jotafloor PU Universal 1 400
aromatic cured polyurethane

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Hardtop flexi aliphatic 1 100


Topcoat
acrylic polyurethane epoxy

Table 2: External painting and coating system


1.7.1 Inspection of Surface Preparation and Coating

Contractor shall be required to conduct inspection activities after surface preparation, prior
to painting, during and after completion of painting and coating activities. These include but
not limited to:

1.7.1.1 Inspection of Surface Preparation

After blast cleaning, contractor shall demonstrate cleanliness and roughness of the metal
surface profile according Sa 2½ with a roughness tester. Surface preparation and profile shall
be approved by FMD integrity representative before painting shall be applied.

1.7.1.2 Inspection of Dry Film Thickness (DFT)

After application of painting and coating, coated surfaces shall be allowed to cure according
to paint manufacturer’s recommendation. The coating dry film thickness (DFT) of all painted
surfaces shall be measured randomly with a DFT tester.

All coated surfaces shall have a dry film thickness according to tables 1 and 2 of this
document. Any painted surface with a dry film thickness less than the specified in this
document shall be re-painted to meet the requirement. Painting shall not be approved until
the required DFT is met.

1.7.1.3 Holiday Inspection

After complete of coating, the whole bottom plates including all welds and the first 2 meters
of the shell plates from the bottom of the tank shall be inspected for holidays. Holiday
detection shall be done with a DC high voltage wire brush according to NACE RP 0188. The
following conditions shall be satisfied.

 Maximum testing voltage shall not be more than 2,000V.


 Maximum rating for the high voltage DC device shall not be more than 3,000V.
 The sponge shall be moved over the coated surface at 0.3m/s with a double pass.
 Portions where holidays are detected (spark or alarm) shall be repainted and retested
after curing.

1.7.1.4 Monitoring of Environmental Factors

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Contractor shall consider the prevailing environmental conditions during painting. All
environmental conditions shall be measured and monitored during painting activities. These
include but not limited to:

Maximum Relative Humidity (RH) shall not be more than 80% and it should be
measured with a sling psychrometer or hygrometer. Painting shall stop at maximum RH
> 80%.
The surface temperature of the metal and atmospheric temperature should be
measured with an infra-red thermometer or any other equivalent dew-point
thermometer probe.
The minimum surface temperature of steel shall be 3 oC (5 oF) higher than the dew-
point temperature during painting.
Painting and coating activities shall not continue under the following conditions;
When minimum air temperature is less than 6 oC and maximum air temperature
is 50 oC and above.
When the minimum steel temperature is less than 3 oC below the dew-point
temperature.
When there is rain and high wind speed. Wind speed may not exceed 15 mph
when painting exterior surfaces of the tanks.

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