Assessment and Repair

Recommendations for
Tank No. 5111 FA Shell and Roof
Project: Rehabilitation of 83 storage tanks in QP refinery at Mesaieed.

Report Revision Date Remarks

Tank No. 5111FA Shell and Roof 0 Jan 14, 2014 Issued for Comments
Tank No. 5111FA Shell and Roof 1 Jan 19, 2014 Issued for Approval
 Contents
# Item Page
1 Tank data 3

2 References of Inspection, NDT, and Assessment 3

3 Scope of inspection – Roof Plate 3

Inspection Findings: - Roof Plate 4

4.1 Visual Inspection. 4

4 4.2 Ultrasonic thickness gauging (UTTG). 7
4.3 Wet Visible Magnetic Particle Testing (WVMT). 7
4.4 Vacuum Box Test (VBT). 7
5 Repair Methodology – Roof Plate 7

6 Scope of inspection – Shell Plate 8

Inspection Findings: - Shell Plate
7.1 Visual Inspection. 8
7 7.2 Ultrasonic thickness gauging (UTTG). 12
7.3 Wet Visible Magnetic Particle Testing (WVMT). 12

8 Repair Methodology – Shell Plate 13

Attachments
- Shell plates Visual Inspection Detail Drawing.
- Shell plates Plumbness drawing.
9
- Shell plates Peaking and banding drawing.
 1. Tank Data

Tank Name : 5111FA

Tank Type : Cone roof tank
Service Fluid : Purified water
Specific Gravity : 1.0
Design Temperature : 73°C
Year of Built : 2000
Last Internal Inspection Date : 2005
Tank inner Diameter : 19.500 meter
Tank height : 10.050 meter
Plate Details:-

Description Material Grade Thickness Corrosion Allowance

Roof plate ASTM A 283 Gr C 5.8 mm 1.0 mm
Shell Course -1 ASTM A 283 Gr C 7.3 mm 1.0 mm
Shell Course -2,3,4 & 5 ASTM A 283 Gr C 6.4 mm 1.0 mm

2. References of Inspection, NDT, and Assessment

2.1 QP contract no. GC-11101800

2.2 API 653 Tank Inspections, Repair, Alteration, and Reconstruction, 4th Edition, Addendum 3– Nov. 2013
2.3 API 650 Welded Tanks for Oil Storage, 12th Edition, March 2013 – Errata , July 2013
2.4 Ultrasonic Thickness Gauging (UTTG) Procedure No. SIIC-TECH-SOP-UTT-013 Rev.2
2.5 Wet Visible Magnetic Particle Testing (WVMT) Procedure No. SIIC-TECH-SOP-MPT-014 Rev.2
2.6 Vacuum Box (VB) test procedure no. SIIC-TECH-SOP-VAC Rev.2.

3. Scope of inspection – Roof Plate

3.1 Extensive visual inspection for all roof plates, roof nozzles and fillet welds of lap joints.
3.2 UT thickness gauging (UTTG) for all roof plates (12 points per plate).
3.3 Four quadrants UTTG for all shell nozzles
3.4 VBT for all fillet welds of roof plates lap joints.
3.5 Wet Visible Magnetic Particle Testing (WVMT) for roof to curb angle circumferential fillet
welds and roof nozzles welds
4. Inspection Findings – Roof plate
4.1 Visual Inspection shows the following:
4.1.1 All roof plates don’t show any massive damage or mechanical degradations from external side.
4.1.2 All roof internal surface and roof structures were sweep blasted and inspected and found no
massive damage or mechanical degradation except some mechanical damages and burn through
of plate metals.
4.1.3 Open to surface shallow pores and cluster pores were found since construction stage, observed on
roof structure fillet weld.
4.1.4 Burrs were observed internally around the roof manholes (2 Nos.) (See below photo).
4.1.5 Burn through (since construction stage) was observed on roof internal at 4 locations (See below
photo).
4.1.6 Missing weld found on tertiary rafter gusset plate fillet weld with shell plates. (See below
photo).
4.1.7 General corrosion was observed on internal surface of gauge hatch nozzle (Nozzle M). (See
below photo).
4.1.8 Mechanical damages (since construction stage) were observed on roof internal surfaces. (See
below photo).
4.1.9 M20 nut missing at primary rafter bolt connection with shell gusset plate (1 locations) (See below
photo).
4.1.10 Incomplete welding, open to surface pores, Mechanical damages and arc strikes were found on
roof hand rail fillet welds. (See below photo).
4.1.11 Tack weld (since construction stage) was observed on roof external surface. (1 location)
4.1.12 All support and structural attachments are welded on directly to the roof plates without RF
pad.
 Cluster pore on Roof Truss (Primary rafter)

Burrs around roof manhole internal

Burn through on roof internal surface

Weld missing at the bottom side of gusset plate of roof tertiary rafter
 General corrosion on internal surface of gauge hatch nozzle

Mechanical damage on roof internal surface Missing Nut at the Roof Primary Rafter

Incomplete welding, Mechanical damages on Roof hand rail fillet weld

 Tack welds on roof external surface

4.2 Ultrasonic Thickness Gauging (UTTG).

4.2.1 UTTG reports for roof plates don’t show any mechanical degradation or severe thinning of cone
roof plates. (Report no.: 5111FA-FTNDT-UTG-ROOF-01).
4.2.2 UTTG reports for roof structures doesn’t show any mechanical degradation of structure members.
(Report no.: 5111FA-FTNDT-UTG-03A).
4.2.3 UTTG report for roof nozzles don’t show any mechanical degradation (Report no.:5111FA-
FTNDT-UTG-ROOF-02).

4.3 Visible wet Magnetic particle testing.

4.3.1 WVMPT for fillet welds curb angle to roof plate circumferential fillet weld joint, roof plate
fillet weld inaccessible for Vacuum box test, roof attachments (structure welding with roof
plate) and roof nozzles fillet weld joints doesn’t show any rejectable flaws. (Report
no.:5111FA-FTNDT-VMPT-04).
4.4 Vacuum Box (VB) testing.
4.4.1 All roof plates fillet welds of lap joints were found accepted. (Report no.:5111FA-FTNDT-
VBT-04).

5. Repair Methodology – Roof Plate

The purpose of any repair or replacement of roof component is to maintain the tank roof integrity and
their fitness for continuous service up to next shutdown (internal inspection) after10years, without any
perceived potential risk to the assets or operators.
 The repair of Roof plates will be as follow:
5.1 Mechanical damages, tack welds, burn through and arc strikes on roof plate will be flushed by
grinding to have the same original plate surface / contour, and any surface flaw has a depth of 1.0
mm or more could be repaired by buildup welding using the approved WPS#08 and examined by
WVMT/PT.
5.2 Open to the surface pores and cluster pore existing in fillet welds will be ground up to the sound
weld metal then re-weld using WPS No. 8, and the final weld will be examined by WVMT/PT.
5.3 Burrs observed on roof manhole internal shall be flushed by grinding to have the same original
plate surface / contour, then any surface flaw has a depth of 1.0 mm or more could be repaired by
buildup welding using the approved WPS#08 and examined by WVMT/PT.
5.4 Missing Bolts/Nuts shall be provided as per the original construction drawing VP-5111FA-010 to
016.
5.5 Missing weld found on tertiary rafter gusset plate shall be repaired by welding using the approved
WPS#08 and examined by WVMT/PT.
5.6 Incomplete welding, open to surface pores, Mechanical damages and arc strikes found shall be
ground up to the sound weld metal then re-weld using WPS No. 8, and the final weld will be
examined by WVMT/PT

Shell plates Inspection

6. Scope of inspection – Shell Plate
6.1 External and internal visual inspection for all shell course plates and shell nozzles.
6.2 12 points UTTG for all shell course plates (6 plates) at different shell courses (1 to 4)
6.3 Four quadrants UTTG for all shell nozzles.

7. Inspection Findings
7.1 Visual Inspection shows the following:
7.1.1 All shell plates don’t show any mechanical degradation from both external and internal except
pitting corrosion observed on shell internal plate & shell internal horizontal and vertical butt
weld joints (Depth up to 2.5 mm). See below photos and visual inspection drawing # J198-
5111FA-016 Rev-0.
7.1.2 Open to surface pore was observed on shell horizontal and vertical butt weld joints (See below
photos).
7.1.3 Lack of side wall fusion and continuous under cut was observed on shell horizontal butt weld
joint from tank inside. See below photos and visual inspection drawing # J198-5111FA-016
Rev-0.
7.1.3.1 Localized corrosion was observed on over flow nozzle TP and around the vent hole of inlet
piping (Depth of corrosion up to 1.0 mm) (See below photos)
7.1.3.2 Mechanical damages, spatters and arc strikes were observed on shell plate internal. (See below
photos).
7.1.3.3 Localized corrosion was observed on Shell manhole (H3 & H4) cover plate.
7.1.3.4 Shell distortion was observed on shell plates at inlet nozzle pipe support and over flow pipe
support location. See attached plumbness and peaking & banding drawings. (See below
photos).
7.1.3.5 All supports and structural attachments were welded on directly to the Shell plates without RF
pad.

Pitting corrosion on shell plate & Pore Pores on shell vertical butt weld joint
on shell horizontal joint (internal) (internal)

Pitting corrosion on shell horizontal butt

weld joint (internal)
 Pitting corrosion on shell vertical weld joint (internal)

Pitting corrosion on shell horizontal weld joint (internal)

Lack of Fusion on shell horizontal weld Under cut on shell horizontal weld joint
joint (internal) (internal)

Localized corrosion in over flow nozzle (Nozzle TP)

 Localized corrosion around the vent hole of inlet piping (Nozzle A)

Mechanical damage, Arc strike and

Localized corrosion on shell manhole
spatters on shell internal
cover plate
Distortion on shell plate at pipe support locations

Peaking inspection from shell external

 Banding inspection from shell external

7.2 Ultrasonic Thickness Gauging (UTTG).

7.2.1 UTTG reports for shell plates and shell nozzles don’t show any mechanical degradation or metal
loss (Report No. 5111FA/ FTNDT/UTG/SHELL-01 & 02).
7.2.2 UTTG reports for external piping spool connecting shell nozzle D to over flow pipe shows that
metal loss, min. wall thickness is 4.26 mm out of 6.02 mm.
7.3 Dimensional Inspection
Plumbness inspection, Peaking and banding inspection shows that the shell distortion is not within the
acceptable limit. (Refer attached Drawing J198-5111FA-017 & 002E)

8 Repair Methodology

The purpose of any repair or replacement of shell and its component is to maintain the tank
shell integrity and their fitness for continuous service up to next shutdown (internal inspection)
after10 years, without any perceived potential risk to the assets or operators.

The repair of shell plates will be as follow:

8.1 Replace the external spool pipe connected to nozzle D in kind using approved WPS#
01, ø4” SCH. 40 pipe of ASTM A 106 Gr B, and SCH. 40 elbow of ASTM A 234 Gr
WPB. The final weld shall be examined by WVMT.
8.2 Pitting and localized corrosion on shell internal vertical and horizontal butt weld joints
shall be repaired by weld build up using approved WPS# 08 and the entire repaired area
will be examined using WVMT.
8.3 Localized corrosion on shell manhole cover plates (H3 & H4) shall be repaired by weld
build up using approved WPS # 08, machined and inspected visually followed by WVMT.
 8.4 Arc strikes and mechanical damages on shell plate shall be ground flush to the same original
plate surface / contour, then any surface flaw has a depth of 1.0 mm or more could be repaired
by buildup welding using the approved WPS#08 and examined by WVMT for external repairs
and WFMT for internal repairs.
8.5 Open to surface pore observed on shell horizontal and vertical butt weld joints shall be
repaired by welding using the approved WPS#08 and examined by WFMT.
8.6 Lack of side wall fusion and continuous undercut observed on shell horizontal butt weld joint
from tank inside shall be ground up to the sound weld metal and repaired by welding using
approved WPS#08 and examined by WFMT.
8.7 Localized corrosion observed on over flow nozzle TP and around the vent hole of inlet piping
shall be repaired by weld build up using approved WPS#08 and examined by WFMT.
8.8 Shell distortion observed on Exciting shell plates at inlet nozzle pipe support and over flow
pipe support location, should be repaired by one of the following repair options:
 Replace the shell courses which suffer from rejected peaking & banding areas, this solution
ensure that all peaking and banding areas will be eliminated OR
 Remove the shell sections which suffer from rejected peaking & banding areas, but this
solution can’t ensure that all peaking and banding areas will be eliminated, only will reduced
its’ values to be within the acceptable tolerances OR
 Adding additional Compression Ring (75x75x7mm) at outside the Shell with stretch weld
by welding using approved WPS#08 and examined by WVMT, but this solution can’t ensure
that all peaking and banding areas will be eliminated, only will reduced its’ values to be within
the acceptable tolerances.
QP Tank Authorized Inspector
Mohamed Ibrahim Amer
#42305