ASSESSMENT OF OUT OF SERVICE INSPECTION FOR

Chevron Tank No.T-102

Inspection and evaluation

According to API 653

Prepared By: Eng. Osama Zeyada

Approved By: Eng. Adel Omar

Report revision: 0

Report date: Jan., 5th, 2016

Inspection and assessment, out of service inspection of Tank T-102 Page 1

Contents

1. Introduction

2. Tank Data

3. Applicable Codes and Standards

4. Reference documents

5. Scope of work

6. General observations /findings

7. Suitability for service

8. Findings summary and Recommendations

9. Appendix

- Ultrasonic thickness measurement reports.

- Vacuum box test report.

- Magnetic particle inspection report.

- Painting inspection report.

Inspection and assessment, out of service inspection of Tank T-102 Page 2

 1- Introduction

At the request of CHEVRON, the undersigned Bureau Veritas API 653 Inspector and BV team
attended the out of service inspection for tank T-102 From Dec.16 to 21, 2015

2- Tank Data: The tank data collected as per tank nameplate and CHEVRON tank
Drawing (DWG. No. TC-102-1100-REV. 0)
Tank Name plate T-102

Tank Manufacturer EL NOOR TRADING& CONTRACTING Co.

Designed By ECG. Engineering Consultants Group

Construction Material Carbon Steel ,DIN 17100,RST 37-2

Applicable Tank Standard API 650, Appendix E&M, Ed. Nov.1988, Rev.08

Year Completed 1994

Nominal Diameter (D) 9.007 M

Tank Nominal Height 9.005 M

Design liquid level (H) 8.100 M

Nominal Capacity (M3) 515 M3

Product Base Oil

Design Specific Gravity 1.00

Design Pressure ATM.

Max. Oper. Temperature 65 ̊C
Tank surrounding wall No
Roof Type Fixed Conical Roof

Access to roof Helical Stairway

No. of Roof Man ways 1

Inspection and assessment, out of service inspection of Tank T-102 Page 3

 3- Applicable Codes and Standards

 API Standard 653API 653 fourth edition, April 2009, Addendum 2012

Tank Inspection, Repair, Alteration, and Reconstruction

 API Standard 650TWELFTH EDITION, March 2013

Welded Tanks for oil storage.

 ASME Section V,2013

Nondestructive test examination

4- Reference Documents

 General Tank layout, Drawing No. TC-102-1100, Rev. 0

 Tank Design Data sheet Rev.0 dated 4.4.2015
 Tank Nameplate.
 Previous Ultrasonic Thickness Gauging dated from 27.06.2012 to 26.07.2012

5- Scope of work

BV scope of work is limited to out of service inspection of the tank No.102 according to API 653
FOURTH EDITION, Addendum 2, 2012.
1- Review of tank drawings, previous inspection histories and all submitted documents.
2- Bottom inspection.
- Visual inspection of all existing welds and plates.
- Random thickness measurements for bottom.
- Vacuum box test of bottom overlap joints.
- 100% Magnetic particle inspection on Shell-to-bottom “zero welds”.
- Hammer tests of bottom plates. 3-
Shell inspection.
- Visual inspection of all existing welds and plates as accessible for the first course of shell.
- Random thickness measurement of shell plates.as accessible for the first course of shell.
- Magnetic particle inspection of shell nozzles and manhole.
- Check for tank verticality and roundness. 4-
Roof inspection
- Visual inspection of all existing welds and plates (external) as accessible.
- Random thickness measurement of roof plates and roof nozzles and manhole.
- Vacuum box test of roof overlap joints. 5-
Tank appurtenances inspection
Visual inspection of stairs, ladders, manholes, handrails, grating…etc

Inspection and assessment, out of service inspection of Tank T-102 Page 4

 6- General Observations/Findings

Tank Out-of-service Inspection Checklist

Item Observation / Completed

.1 Overview
a) Check that tank has been cleaned, is gas free, and safe for entry. OK
b) Check that the tank is completely isolated from product lines, all electrical OK
power, and steam lines.
c) Check that roof is adequately supported, including fixed roof structure OK

d) Check for presence of falling object hazards, such as corroded- through

roof rafters, asphalt stalactites, and trapped hydrocarbons in unopened or OK
plugged equipment or appurtenances, ledges, etc.
e) Inspect for slipping hazards on the bottom and roof decks.. OK
The steps of helical stair was
f) Inspect structural welds on access ways and clips. welded directly to shell
g) Check surfaces needing inspection for a heavy-scale buildup and check No internal scaling is noted
weld seams and oily surfaces where welding is to be done.
Note areas needing more cleaning, including blasting.
h) Review cathodic protection potential readings. No cathodic protection
.2 Tank Exterior
a) Inspect appurtenances opened during cleaning such as lower floating swing sheave N/A
assemblies, nozzle interiors (after removal of valves).

b) Hammer test for roof. No detected thin area

.3 Bottom Interior Surface
a) Using a flashlight held close to and parallel to the bottom plates, and using Noted Some areas need to be
the bottom plate layout as a guide, visually inspect and hammer test the
entire bottom. ground flush and There are voided
areas under the bottom plates
b) Measure the depth of pitting and describe the pitting appearance No pitting are noted
(sharp edged, lake type, dense, scattered, etc.)
c) Mark areas requiring patching or further inspection. The fillet weld of wear plate to
bottom is not completed.
d) Mark locations for turning coupons for inspection. N/A
e) Inspect all welds for corrosion and leaks, particularly the shell-to- bottom No significant corrosion and
weld. leakage are noted

f) Inspect sketch plates for corrosion. No corrosion

g) Check condition of internal sump, if applicable. Standing liquid should be
removed from the sump to allow for complete inspection and vacuum testing All welds inspected visually and
of weld seams as appropriate. Sump bottom and sidewall plate and seams
need to be evaluated using MT.
for both product-side and soil-side corrosion.

Inspection and assessment, out of service inspection of Tank T-102 Page 5

 h) Locate and mark voids under the bottom. The bottom has voids

i) Record bottom data on a layout sketch using the existing bottom plates Some areas need to be ground
as a grid. flush
j) Vacuum test the bottom lap welds. See attached vacuum box report
k) Hammer test or ultrasonically examine any slightly discolored spots OK
l) Check for reinforcing pads under all bottom attached clips, brackets, N/A
m) Inspect floating roof leg pads for pitting or cutting, and excessive dimpling N/A
(indicating excessive loading).
n) Check the column bases of fixed roof supports for adequate pads and N/A
o) In earthquake Zones 3 and 4, check that roof supports are not welded N/A
down to the tank bottom, but are only restrained from horizontal
movement.
p) Check area beneath swing line cable for indications of cable cutting N/A
q) Mark old oil and air test connection for removal and patching. N/A
r) Identify and report low areas on the bottom that do not drain Some areas in bottom has voids
s) Inspect coating for holes, disbonding, deterioration, and No noted internal coating

Tank Out-of-service Inspection Checklist (Continued)

Ite Observation / Completed

m
.4 Shell Seams and Plate
a) On cone up bottoms, closely inspect and gauge the depth of metal loss The shell Seams and Plate
on the lower 2 in. to 4 in. of the shell (area of standing water). generally in good condition and
Details in thickness
b) Measure the depth of pitting on each course. No pitting in 1st course and
random thickness check for other
course, see shell thickness
c) Inspect and estimate the amount of metal loss on the heads of N/A
d) Inspect shell-to-bottom riveted lap joints. N/A
e) Inspect for vertical grooving damage from seal assembly N/A
f) Inspect existing protective coatings for damage, deterioration, and Externally Noted and proposed
g) Check for areas of rubbing (indicating too much pressure by the seal assembly N/A
shoes or inadequate annular space).
h) Visually inspect the shell plates and seams for indications of No leakage noted in shell.
leakage.
i) If the shell has riveted or bolted seams, record the leak locations by film or N/A
chart in case the locations are lost during surface
j) Measure annular space at 40-ft intervals. N/A
k) Survey the shell to check for roundness and plumb. OK
.5 Shell-mounted Overflows
a) Inspect overflow for corrosion and adequate screening. Nozzle N8 is equipped with high
level switch and has general
b) Check location of overflow that it is not above any tank valves or N8 location is adequate

Inspection and assessment, out of service inspection of Tank T-102 Page 6

.6 Roof Interior Surface
.6.1 General
a) Visually inspect the underside surface of the roof plates for holes, scale No access to under side surface
buildup, and pitting.
b) Hammer test or ultrasonically examine to check for thin areas, particularly in Conducted hammer test and UT
the vapor space of floating roofs and at edge of roof thickness externally and no thin
c) Check all clips, brackets, braces, etc., welded to the roof deck plate for No access to under side surface
welded reinforcing pads and see that they have not broken free.
d) If no pad is present, penetrant test for cracking of the weld or deck N/A
e) Inspect for protective coating for breaks, disbondment, and See attached inspection coating
.6.2 Fixed Roof Support Structure
a) Inspect the support columns for thinning in the upper 2 ft. No column
b) On API columns (two channels welded together) check for corrosion scale N/A
breaking the tack welds, unless the joint between the channels
c) Check that the reinforcing pad on the bottom is seal-welded to the tank N/A
bottom with horizontal movement restraining clips welded to
d) Determine if pipe column supports are concrete filled or open pipe. If open N/A
pipe, check for a drain opening in the bottom of the pipe.
e) Inspect and gauge rafters for thinning, particularly near the center of the No access to under side surface
roof. Report metal loss.
f) Check for loose or twisted rafters. No access to under side surface
g) Inspect girders for thinning and check that they are attached securely to the No access to under side surface
top of the columns.

Tank Out-of-service Inspection Checklist (Continued)

Ite Observation / Completed

m
h) Report if the columns have cross bracing in the area between the low pump N/A
out of the top of the shell (for future internal floating roof
installation).
i) Inspect and report presence of any roof-mounted swing line N/A
j) Photograph the roof structure if no rafter layout drawing exists. layout drawing exists but not
.7 Fixed Roof Appurtenances
.7.1 Breathers and Vents
a) Inspect and service the breather. There is general corrosion on
b) Inspect screens on vents and breathers. The screen is in good condition
.7.2 Emergency P/V Hatches
a) Inspect and service pressure/vacuum hatches. (Setting should be high
enough to pre- vent chattering of breather during normal operation. See N/A
breather manufacturer’s guide.)
b) Inspect liquid seal hatches for corrosion and proper liquid level in N/A
.7.3 Sample Hatch
a) Inspect sample hatch for corrosion. Uniform corrosion
b) Check that the cover operates properly. The cover operates properly

Inspection and assessment, out of service inspection of Tank T-102 Page 7

 .8 Common Tank Appurtenances
.8.1 Gauge Well N/A
.8.2 Sampling Systems: Roof Sample Hatches N/A

a) Inspect roof-mounted sample hatches for reinforcing pads and In good condition
b) Inspect cover for operation. The cover operates properly
c) For tanks complying with Air Quality Monitoring District rules, inspect N/A
sample hatch covers for adequate sealing.
d) Check horizontal alignment of internal floating roof sample hatches N/A
under fixed roof hatches.
e) Inspect the sealing system on the internal floating roof sample hatch N/A
f) Inspect floating roof sample hatch cover recoil reel and rope. N/A
.8.3 Shell Nozzles
a) Inspect shell nozzles for thinning and pitting. See attached thickness report
b) Inspect hot tap nozzles for trimming of holes. N/A
c) Identify type of shell nozzles. As per construction drawing
d) Identify and describe internal piping, including elbow-up and elbow- down Pipe 2” including elbow –down
types. to withdraw from sump

Tank Out- of- service Inspection Checklist

(Continued)
Observation /
Item
Completed
.8.4 For Nozzles Extended Into the Tank
a) Inspect pipe support pads welded to tank bottom. Nozzle N3 with diameter 2”
b) Inspect to see that pipe is free to move along support without strain or extended to sump as a draw off
tearing action on bottom plate. without any support and fixed
c) Inspect nozzle valves for packing leaks and damaged flange faces. to sump bottom

d) Inspect heater stream nozzle flanges and valves for wire cutting. N/A
e)Report which nozzles have thermal pressure relief bosses and valves. N/A
f) In internal elbow- down fill line nozzles, inspect the wear plate on the N/A
g) On elbow-up fill lines in floating roof tanks, check that opening is directed N/A
against underside of roof, not against vapor space. Inspect
.8.5 Diffusers and Air Rolling Systems N/A
.8.6 Swing Lines N/A
.8.7 Man way Heater Racks N/A
.8.8 Mixer Wear Plates and Deflector Stands N/A
.9 Access Structures
.9.1 Roof Handrails
a) Identify and report type (steel pipe, galvanized pipe, square tube, angle)and size of The roof handrail is angle
handrails.
b) Inspect for pitting and holes, paint failure. See attached painting report

Inspection and assessment, out of service inspection of Tank T-102 Page 8

 c) Inspect attachment welds. the handrail is welded
directly to tank roof through
d) Identify cold joints and sharp edges. Inspect the handrails and mid rails. stiffener plate
e) Inspect safety drop bar(or safety chain) for corrosion, functioning, and length. No safety chain or bar
f) Inspect the handrail between the rolling ladder and the gagging platform for N/A
hazardous opening when the floating roof is at its lowest level.
.9. Platform Frame N/A
.9. Deck Plate and Grating N/A
.9. Stairway Stringers
a)Inspect spiral stairway stringers for corrosion, paint failure, and weld failure. The steps of stair were
Inspect attachment of stair way treads to stringer.
welded directly to shell
b) Inspect stairway supports to shell welds and reinforcing pads. without reinforcement pad,
c) Inspect steel support attachment to concrete base for corrosion.
NOTES

The lap-welded tank bottom joint converted to butt-welded bottom joints at distance from 0-10 cm from shell by cutting
strip from the top plate to be the edges of plates corresponding to each other and this is not according to API 650.

Inspection and assessment, out of service inspection of Tank T-102 Page 9

Photos

1-Roof Corroded 4"X3" adapter 2-Roof F.F not resting support

3-Nozzle N8, Level switch, corroded 4-Tank roof handrail, general corrosion

Inspection and assessment, out of service inspection of Tank T-102 Page 10

 5-Roof, general corrosion

6-Underneath Bottom with foundation

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 7- Tank bottom areas, to be flushed

Inspection and assessment, out of service inspection of Tank T-102 Page 12

8- Surface Crack in Shell nozzle N5 9- Surface Crack in Shell nozzle N1

Inspection and assessment, out of service inspection of Tank T-102 Page 13

7.0 Suitability for service
7.1 Tank Roof Evaluation

 Where the minimum measured thickness is 5.92 mm as per attached thickness measurements report
and as per API 653 , clause 4.2.1.2 the corroded areas of roof plates is acceptable as average thickness
is more than 0.09 in (2.286 mm) in any 100 inch ²
 The hammer test is conducted on roof plates and no thin areas are noted.
 The minimum thickness of roof nozzles
Nozzle Description Required
Min Reading
thickness evaluation
(mm)
(mm)
N6 Air vent with screen Dia. 12.45 7.112
6“not as Built, (4“) in DWG.
N4 Spare Dia. 6” 12.69 7.112 Satisfied as per
API 650 clause
N7 Gauge Hatch Dai. 8” 12.69 8.179
5.8.5.6
Not indicated Rader Gauges Dai. 4“ 8.44 6.02
in DWG. NR
N12 Roof manhole Dai. 20” 7.76 6
Satisfied as per
clause 5.8.4

7.2 Tank Shell Evaluation

Given Data:
 The plate width is 1.0m.
 The maximum design liquid level is 8.100 m from the tank bottom
The shell material type is RST 37-2, (S) is smaller of (0.8X235 or 0.429X340) then S=145.86 MPa
(21,155.20 psi) for 1st and 2nd courses, and smaller of (0.88 X 235 or 0.472 X 340) then S= 160.48
MPa (23,275.656 psi) for all other courses.
The construction standard of tank is API 650 and the joint efficiency (E) for welded joints is 0.85
as per drawing/datasheet.

Inspection and assessment, out of service inspection of Tank T-102 Page 14

 i. Minimum acceptable shell thickness:

According API 653 fourth edition, April 2009, Addendum 2012 (Para. 4.3.3.1 (a))

2.6 ( H -1 ) D G

SE
tmin =
tmin is the minimum acceptable thickness, in inches

D is the nominal diameter of tank, in feet (ft);

H is the height from the bottom of the shell course under consideration to the maximum liquid level
when evaluating an entire shell course, in feet (ft);

G is the highest specific gravity of the contents;

S is the maximum allowable stress in pound force per square inch (lbf/in.2);

E is the original joint efficiency for the tank.

H = 8.100 m (26.57 ft)

D = 9.007 m (29.55 ft)

G=1

S = 21155.20Ibf/in2 for lower two courses and is 23275.656Ibf/in2 for upper courses. E =

0.85

Inspection and assessment, out of service inspection of Tank T-102 Page 15

For 1st course
2.6 (26.57 - 1) x 29.55 x 1
tmin = = 0.11”
21155.2 x 0.85
For 2nd course
2.6 ( 23.29 - 1 ) x 29.55 x 1
tmin = = 0.095”
21155.2 x 0.85
For 3rd course

2.6 ( 20.01 - 1 ) x 29.55 x 1

tmin = = 0.05”

23275.656 x 0.85

And as per API 653 Fourth edition, April 2009 Addendum 2012(Para. 4.3.3.1 (b)) tmin
shall be not less than 0.1”, so the minimum thickness for courses from 2nd to 9th is 0.1” = 2.54mm.

Inspection and assessment, out of service inspection of Tank T-102 Page 16

 t actual t actual Corros Remaini
min min ion ng life
Course Allowable stress t required t min required
H (ft.) (mm)on (mm)on rate
order (psi) min (inch) (mm)
16/12/20 26/7/20 (mm/Y
15 12 RS)

1st 26.57 21155.20 0.11 2.8 6.05 6.20 0.043 75.58

2nd 23.29 21155.20 0.1 2.54 6.06 6.21 0.043 81.86

3rd 20.01 23275.656 0.1 2.54 5.93 6.26 0.094 36.06

4th. 16.73 23275.656 0.1 2.54 6.35 6.26 NA NA

5th. 13.45 23275.656 0.1 2.54 6.44 6.26 NA NA

6th. 10.17 23275.656 2.54 6.14 6.15 NA NA

7th. 6.89 23275.656 2.54 6.27 6.26 NA NA

0.1
8th. 3.61 23275.656 2.54 6.14 6.26 0.034 105.88

9th. 0.33 23275.656 2.54 6.30 6.26 NA NA

Calculating corrosion rate as per equation

−
( )=
( )

The shell condition is accepted as above maintained calculations. Next external ultrasonic thickness
inspection will be after 15 years if the same product will be stored, as per API 653 clause 6.3.3.2, the
maximum interval shall be the smaller of RCA/2N = (5.93-2.54)/2*0.094= 18 years (where RCA is
the difference between the measured shell thickness and the minimum required thickness in mils, and
N is the shell corrosion rate in mils per year) or 15 years

The next visual external inspection will be after 5 years, as per API 653 clause 6.3.2.1; All tanks
shall be given a visual external inspection by an authorized inspector. This inspection shall be called
the external inspection and must be conducted at least every five years or RCA/4N (where RCA is
the difference between the measured shell thickness and the

Inspection and assessment, out of service inspection of Tank T-102 Page 17

minimum required thickness in mils, and N is the shell corrosion rate in mils per year)
whichever is less. Tanks may be in operation during this inspection.

-The roundness of tank has been checked and it is within the radii tolerance (±13 mm, as per API 650
clause 7.5.3)
-The plumbness readings of tank have been checked and are inaccurate due to the existing deflector
which is installed around the top tank shell course to concentrate the cooling water on the tank shell.
However, The getting plumbness readings are within the acceptance tolerance of API 650 clause
7.5.2 (9000/200 = 45 mm)

-The minimum thickness of shell nozzles

Nozzle Description Min Required

Reading thickness evaluation
(mm) (mm)
N1 Inlet Dia. 4” 8.51* 8.56
N2 Suction high Dia. 6” 12.94 10.97 Satisfied as per
N3 Draw off Dai. 2” 5.25* 5.54 API 650 table
N5 Spare Dai. 4” 8.25* 8.56 5.6a
N10 Level Sensor Dia. 3” 7.92 7.62
N8 Level switch Dia.6” 13.05 10.97
N13 Shell Manhole 20” 8.25 6 Satisfied as per
table 5.4a
N14 Coil Inlet (Blind) Dia. 4” 8.74 8.56 Satisfied as per
N15 Coil Outlet (Blind) Dia. 4” 8.31* 8.56 API 650 table
N16 Temperature element Dia. 1” NA THREADED 5.6a
N17 Recycle Pump Dia. 4” 8.71 8.56
*Nozzles N1, N3, N5, and N15 have reached to the required thickness.

Inspection and assessment, out of service inspection of Tank T-102 Page 18

7.3 Tank bottom Evaluation

Minimum Thickness for Tank Bottom Plate

Quantifying the minimum remaining thickness of tank bottoms based on the results of measurement
can be done by the method outlined in API 653, 4.4.5.1. Other approaches such as the probabilistic
method in 4.4.5.2 may be used.
4.4.5.1 An acceptable method for calculating the minimum acceptable bottom thickness for the entire
bottom or portions thereof is as follows:
MRT = (Minimum of RTbcorRTip) – Or (StPr+ UPr)
Where
MRT is the minimum remaining thickness at the end of interval Or.
Or is the in-service interval of operation (years to next internal inspection) not to exceed that allowed by
6.4.2; (10 years after installing new bottom plates)
RTbc is the minimum remaining thickness from bottom side corrosion after repairs
RTip is the minimum remaining thickness from internal corrosion after repairs;
StPr is the maximum rate of corrosion not repaired on the top side. StPr = 0 for coated areas of the
bottom. The Expected life of the coating must equal or exceed Or to use StPr = 0; UPr is the
maximum rate of corrosion on the bottom side.

MRT=7.13– 10(0.094) = 6.19mm > 2.5 mm (0.1”) as per table 4.4

- The bottom should be re-evaluated after repair it.
- As per API 650 the bottom plate shall be welded lap welded bottom joints as per
5.1.5.4 or butt welded bottom joints as per 5.1.5.5, and incase lap-welded bottom joint
welds, the annular plate may be used as per 5.5.1 but in tank T-102 the lap- welded
bottom joint converted to butt-welded bottom joints at distance 0- 10 cm from shell and
not according to API 650.
- The seal weld of wear plate isn’t completed at location of lap-welded bottom joint
underneath it
- No leakage is noted during conducting vacuum box test for lap-welded bottom joint.

- No internal painting traces are noted inside the tank although item no. 32 in general
notes in drawing no.TC-102-1100, the tank outside and inside surface to be sand blasted
and painted as per ECG specification No.9900

Inspection and assessment, out of service inspection of Tank T-102 Page 19

8.0 Findings summary and Recommendations

1- Roof lap joints have spatters to be fully cleaned before sand blasting and painting.

2- The roof firefighting ring has 6 supports; 4 of them are not standing on the roof. Need to be rectified.

3- Longitudinal surface cracks have been discovered by MPI in two shell nozzles from internal 4”N1 and 4”N5.
Need to be repaired.

4- The lap-welded bottom joint converted to butt-welded bottom joints at distance 0-10 cm from shell by
cutting strip from the top plate to be the edges of plates corresponding to each other and this is not
according to API 650. Two proposals are offered;

A-Using annular bottom plates as per API 650, section 5 and clause 5.5

B-Replacement the whole bottom as per API 650, section 5 and clauses 5.1, 5.2, 5.3, 5.4 and 5.5

The second one is recommended to cover at least the rest bottom observations in points as below.

5-Some scattered areas in bottom need to be ground flush then perform visual and PT inspection

6-Remove the wear plate in bottom under gauge hatch to check the lap-welded bottom joint under it

7-Welding Spatters are noted around the longitudinal weld of draw off sump. Need to be cleaned

8- There are voids between bottom and tank foundation need grout or mastic seal material

9- As the Tank bottom has voids so, The foundation under bottom plates during repair works to be inspected
and re-compacting the soil under the tank bottom during installing new annular/bottom plates

10- The bottom slope to be inward the sump pit for better draining.

11-All removed gaskets shall be replaced by new correctly ones

12-Many bolts at roof nozzles have been corroded. To be replaced by new ones.

13-The tank drawings need to be as-built and completed.

14- The initial internal inspection after erecting new annular/bottom plates shall be after 10 years if the same
product will be stored as per API 653 clause 6.4.2.1.1, The interval from initial service date until the first
internal inspection shall not exceed 10 years unless a tank has one or more of the leak prevention,
detection, corrosion mitigation or containment safeguards listed in API 653 Table 6.1.

15- Flange adapter 4" X 3" for radar at roof is corroded and need to rehabilitation or replaced.

Inspection and assessment, out of service inspection of Tank T-102 Page 20

16- It is noted that, the sprinklers of fire fighting at roof are not

installed. 17-It is noted that, No cathodic protection is installed.

18- Generally, the Tank with all related attachments needs to be sand blasting and painting. The tank outside
and inside surface to be sand blasted and painted as per the available Tank drawing note No. 32.

19-Rehabilitation of all valves is recommended.

20- After approve the repair works, the next visual external inspection and external ultrasonic thickness
inspection shall be conducted by Authorized API Inspector 653 after 5 years. That, in case there is a planned
routine inspection otherwise visual inspection to be done annually.

21- Nozzles N1, N3, N5, and N15 have reached to the required thickness. It’s recommended to be
monitored with thickness gauging after 6 months to stand on the remedial action.

Inspection and assessment, out of service inspection of Tank T-102 Page 21

 9.0 Appendix

Inspection and assessment, out of service inspection of Tank T-102 Page 22

 Ultrasonic Examination
Thickness Report CLIENT : Chevron
Area: 6th of October city
ITEM :TANK No 102

for Shell Tank 102 Issue Date: 16-12-2015

Equipment : SIUI-CTS-30A Couplant type : Grease

Serial No : 546311131121 Surface condition : As Welded
Search unit : Normal prob Material : C.Steel
Angle : 0 Thickness : mm
Frequency : 5 MHz Working Pressure :NA
Applicable Code : ASME SEC V, 2013

Point Location Measurement (mm)

No
1st 2nd 3rd 4th 5th 6th 7th 8th Min Reading
1 S1(P1) 6.63 6.77 6.72 6.60 6.61 6.50 6.49 6.66 6.49
2 S1(P2) 6.65 6.75 6.32 6.41 6.54 6.15 6.14 6.66 6.14
3 S1(P3) 6.48 6.23 6.14 6.41 6.35 6.27 6.17 6.05 6.05
4 S1(P4) 6.43 6.32 6.69 6.68 6.69 6.30 6.32 6.27 6.27
5 S1(P5) 6.44 6.41 6.54 6.32 6.61 6.38 6.17 6.20 6.17
6 S2(P1) 6.80 6.81 6.93 6.80 6.84 6.85 6.87 6.86 6.80
7 S2(P2) 6.95 6.32 6.54 6.78 6.41 6.64 6.52 6.66 6.32
8 S2(P3) 6.06 6.90 6.29 6.33 6.40 6.20 6.55 6.57 6.06
9 S2(P4) 6.64 6.47 6.54 6.38 6.32 6.49 6.50 6.60 6.32
10 S2(P5) 6.60 6.78 6.48 6.41 6.23 6.30 6.30 6.54 6.23
11 S3(P1) 6.44 5.93 6.57 6.60 6.79 6.60 6.56 6.43 5.93
12 S3(P2) 6.60 6.57 6.55 6.72 6.47 6.63 6.60 6.23 6.23
13 S3(P3) 6.60 6.61 6.72 6.65 6.82 6.41 6.54 6.64 6.41
14 S3(P4) 6.80 6.82 6.60 6.52 6.50 6.83 6.38 6.68 6.38
15 S3(P5) 6.32 6.23 6.68 6.36 6.41 6.66 6.35 6.40 6.23
16 S4(P1) 6.39 6.35 6.52 6.44 6.48 6.52 6.54 6.42 6.35
17 S5(P1) 6.54 6.50 6.45 6.44 6.54 6.49 6.57 6.47 6.44
18 S6(P1) 6.21 6.30 6.23 6.36 6.14 6.33 6.30 6.26 6.14
19 S7(P1) 6.27 6.55 6.69 6.57 6.67 6.54 6.50 6.54 6.27
20 S8(P1) 6.49 6.37 6.44 6.19 6.27 6.14 6.38 6.38 6.14
21 S9(P1) 6.69 6.66 6.41 6.32 6.50 6.30 6.55 6.70 6.30

EXAMINTION QUALIFICATION DATE :

LEVEL Π
LEVEL 16/12/2015

Name Kadry Nabil

SIGNTURE

1|Pag
 Ultrasonic Examination
Thickness Report CLIENT : Chevron
Area: 6th of October city
ITEM :TANK No 102

for Shell Tank 102 Issue Date: 16-12-2015

Tank No 102
UT Thickness examination for Shell Tank

Notes:
1. S = Course of plates & P = Plate.
2. The Course consists of (5) plates where plates P4, P5 in every course are hidden in the back of shell tank as
shown in the DWG above.
3. We measured all plates thickness in Courses S1, S2, and S3.
4. We measured only one plate thickness in Courses S4, S5,..............., S9 because one plate only can be measured.
5. The smallest reading in every plate is present in the table with yellow color where the red one is the smallest all
over the Shell Tank 102 & the black one is the highest reading all over the shell Tank 102.

EXAMINTION QUALIFICATION DATE :

LEVEL Π
LEVEL 16/12/2015

Name Kadry Nabil

SIGNTURE

2|Pag
 Ultrasonic Examination

Thickness Report CLIENT : Chevron

Area: 6th of October city
for Bottom Tank 102 ITEM :TANK No 102
Issue Date: 21-12-2015

Equipment : SIUI-CTS-30A Couplant type : Grease

Serial No : 546311131121 Surface condition : As Welded
Search unit : Normal prob Material : C.Steel
Angle : 0 Thickness : mm
Frequency : 5 MHz Working Pressure :NA
Applicable Code : ASME SEC V, 2013

Point Location Measurement (mm) Point Location Measurement (mm)

No No
1st 2nd 3rd 4th Min Min
1st 2nd 3rd 4th
Reading Reading
1 C1(P1) 8.16 8.00 7.92 7.97 7.92 15 C5(P2) 8.22 8.50 7.81 7.86 7.81
2 C1(P2) 7.88 7.99 8.10 8.06 7.88 16 C6(P1) 7.96 7.53 8.14 8.17 7.53
3 C1(P3) 7.95 8.06 7.73 7.99 7.73 17 C6(P2) 8.05 7.99 7.66 8.00 7.66
4 C1(P4) 7.91 7.20 8.10 7.91 7.20 18 C7(P1) 8.17 7.74 8.30 8.16 7.74
5 C1(P5) 7.60 7.31 8.00 8.03 7.31 19 C7(P2) 7.53 7.96 8.11 8.01 7.53
6 C1(P6) 8.06 8.13 8.00 7.95 7.95 20 C8(P1) 8.36 7.59 8.40 7.92 7.59
7 C1(P7) 8.06 8.22 8.03 8.19 8.03 21 C8(P2) 7.81 7.73 8.16 8.11 7.73
8 C2(P1) 7.50 7.19 8.08 8.02 7.19 22 C9(P1) 8.20 8.00 7.66 7.90 7.66
9 C2(P2) 7.22 7.95 8.17 8.12 7.22 23 C9(P2) 7.94 8.00 7.39 8.08 7.39
10 C3(P1) 7.95 7.57 7.13 7.17 7.13 24 C9(P3) 7.92 7.80 8.10 7.76 7.76
11 C3(P2) 8.02 8.00 7.99 8.30 7.99 25 C9(P4) 7.79 8.00 8.06 7.95 7.79
12 C4(P1) 7.60 7.17 8.25 8.27 7.17 26 C9(P5) 8.06 8.06 7.94 7.70 7.70
13 C4(P2) 8.24 8.11 8.05 8.28 8.05 27 C9(P6) 8.25 8.20 8.50 8.31 8.20
14 C5(P1) 8.17 8.40 7.84 7.93 7.84 28 C9(P7) 7.82 7.82 8.03 7.82 7.82
Notes:
1. C = Refers to a Cell of Plates & P = Refers to a Plate.
2. We taked 4 readings in every plate.
3. The smallest reading in every plate is present in the table where the yellow ones are the smallest reading in
every cell and the red one is the smallest all over the bottom and the black one is the greatest all over the
bottom.
4. Thickness of the bottom plates in the 1st 8cm from shell (4cm inside & 4cm outside the tank) also the same
as the bottom readings where the smallest reading in such area is 7.20 mm.

DATE :
EXAMINTION QUALIFICATION LEVEL LEVEL Π
21/12/2015

Name Kadry Nabil

SIGNTURE

1|Pag
 Ultrasonic Examination

Thickness Report CLIENT : Chevron

Area: 6th of October city
for Bottom Tank 102 ITEM :TANK No 102
Issue Date: 21-12-2015

Tank No 102
UT Thickness examination for Bottom Tank 102

DATE :
EXAMINTION QUALIFICATION LEVEL LEVEL Π
21/12/2015

Name Kadry Nabil

SIGNTURE

2|Pag
 Ultrasonic Examination

Thickness Report CLIENT : Chevron

Area: 6th of October city
ITEM :TANK No 102

for Roof Tank 102 Plates Issue Date: 17-12-2015

Equipment SIUI-CTS-30A Couplant type Grease

Serial No 546311131121 Surface condition As Welded
Search unit Normal prob Material C.Steel
Angle 0 Thickness mm
Frequency 5 MHz Working Pressure NA
Applicable Code ASME SEC V, 2013

Point Location Measurement (mm) Point Location Measurement (mm)

No 1 st
2nd 3rd 4th Min No 1st
2nd 3rd 4th Min
Reading Reading
1 C1(P1) 6.26 6.47 6.50 6.39 6.26 17 C5(P2) 6.15 6.05 6.50 6.40 6.05
2 C1(P2) 6.60 6.20 6.12 6.32 6.12 18 C6(P1) 6.25 6.41 6.17 6.35 6.17
3 C1(P3) 6.26 6.26 6.11 6.50 6.11 19 C6(P2) 6.38 6.40 6.41 6.10 6.10
4 C1(P4) 6.26 6.38 6.50 6.12 6.12 20 C7(P1) 7.36 7.55 7.15 7.33 7.15
5 C1(P5) 6.25 6.15 6.44 6.25 6.15 21 C7(P2) 7.55 7.50 7.36 7.23 7.23
6 C1(P6) 6.07 6.05 6.33 6.11 6.05 22 C8(P1) 6.08 6.06 6.17 6.05 6.05
7 C1(P7) 6.12 5.92 6.05 6.24 5.92 23 C8(P2) 6.43 6.40 6.69 6.23 6.23
8 C2(P1) 6.26 6.02 6.02 6.50 6.02 24 C9(P1) 6.26 6.29 6.39 6.34 6.26
9 C2(P2) 6.18 6.33 6.11 6.29 6.11 25 C9(P2) 6.50 6.44 6.14 6.32 6.14
10 C3(P1) 6.08 6.05 6.27 6.05 6.05 26 C9(P3) 6.35 6.20 6.41 6.30 6.20
11 C3(P2) 6.29 6.14 6.39 6.32 6.14 27 C9(P4) 6.28 6.13 6.14 6.57 6.13
12 C4(P1) 6.20 6.30 6.18 6.47 6.18 28 C9(P5) 6.35 6.23 6.70 6.61 6.23
13 C4(P2) 7.47 7.64 7.43 7.55 7.43 29 C9(P6) 6.08 6.50 6.29 6.10 6.08
14 C5(P1) 6.02 6.50 6.13 6.30 6.02 30 C9(P7) 6.14 6.38 6.38 6.60 6.14

Notes:
1. C = Refers to a Cell of Plates & P = Refers to a Plate.
2. We taked 4 readings in every plate.
3. There are 3 plates with defrent thickness from the rest plates of the roof plates ( pink ones in the table).
4. The smallest reading in every plate is present in the table where the yellow ones are the smallest reading
in every cell and the red one is the smallest all over the Roof plate and the black one is the greatest all
over the Roof plate.

DATE :
EXAMINTION QUALIFICATION LEVEL LEVEL Π
17/12/2015

Name Kadry Nabil

SIGNTURE

Page 1 of
 Tank No 102
UT Thickness Examination for Roof Tank 102 Plates.

DATE :
EXAMINTION QUALIFICATION LEVEL LEVEL Π
17/12/2015

Name Kadry Nabil

SIGNTURE

Page 2 of
 Ultrasonic Examination

Thickness Report For CLIENT : Chevron

Area: 6th of October city
Shell Nozzles and Bottom Sump (BS) ITEM :TANK No 102
Issue Date: 16-12-2015
of Tank 102

Equipment : SIUI-CTS-30A Couplant type : Grease

Serial No : 546311131121 Surface condition : As Welded
Search unit : Normal prob Material : C.Steel
Angle : 0 Thickness : mm
Frequency : 5 MHz Working Pressure :NA
Applicable Code : ASME SEC V, 2013

Nozzle Nozzle name Measurement (mm)

ID
1st 2nd 3rd 4th Min
Reading
N 13 Shell Man Hole 20" 8.34 8.34 8.45 8.25 8.25
N 14 Coil Inlet (Blind) 4" 9.29 9.58 9.20 8.74 8.74
N 15 Coil Outlet (Blind) 4" 9.82 9.14 9.02 8.31 8.31
N1 Inlet 4" 9.38 9.35 8.66 8.51 8.51
N 10 Level Sensor 3" 8.86 8.95 7.92 8.50 7.92
N2 Suction Pump 6" 13.63 13.12 12.94 13.45 12.94
N5 Spare 4" 9.11 9.23 9.08 8.25 8.25
N3 Draw off 2" 5.95 5.66 5.25 5.75 5.25
N 17 Recycle Pump 4" 9.42 9.63 8.71 9.27 8.71
BSS Sump (shell) 24" 8.66 7.22 6.95 7.84 6.95
BSB Sump (bottom) 24" 7.44 8.05 8.00 8.17 7.44

Notes .
1. We taked 4 readings in every Nozzle.
2. We taked 4 readings in the Sump 24" (BS) for the shell sump (BSS) & the sump bottom (BSB).
3. The smallest reading in every Nozzle is present in the table.

DATE :
EXAMINTION QUALIFICATION LEVEL LEVEL Π
16/12/2015

Name Kadry Nabil

SIGNTURE

Page 1 of
 Ultrasonic Examination

Thickness Report For CLIENT : Chevron

Area: 6th of October city
Shell Nozzles and Bottom Sump (BS) ITEM :TANK No 102
Issue Date: 16-12-2015
of Tank 102

Tank No 102
UT Thickness Examination for Shell Nozzles and Bottom Sump (BS) 24"

DATE :
EXAMINTION QUALIFICATION LEVEL LEVEL Π
16/12/2015

Name Kadry Nabil

SIGNTURE

Page 2 of
 United for Quality Engineering
‫ة‬ works

20-12-
Visual & Vacuum Test

Client: Chevron Item No: Tank No

Material: carbon Steel Date:

Vacuum Testing
1- Acceptance Criteria : API 4-The Range Of vacuum box gauge : (0-100)
2- Surface temp: 5-Over lab :
3- Surface condition : 6-Holding Time : Min 15

Carried out visual inspection for the tank bottom and found the

Interpretati Rep
Ite
Descripti Materi Thickne Remar
N Acce Reje Acce Reje

1 Bottom C.STE 8 A - - -

Note
- Carried out visual check during a Vacuum Box Test for the bottom plate welds of tank 102
fou Acceptabl

Eng. Kadri Nabil Inspector: Mahmoud Abd moniem

‫ا‬
 United for Quality Engineering
‫ة‬ works

20-12-
Tank No

Vacuum test for welds of the Bottom

Notes .
1. Doubled red lines refers to places of Vacuum Examination.

2. Vacuum test carried out for Bottom Plate welds and shows

Eng. Kadri Nabil Inspector: Mahmoud Abdelmoniem

‫ا‬
 Ultrasonic Examination

Thickness Report For CLIENT : Chevron

Area: 6th of October city
Roof Nozzles of Tank 102 ITEM :TANK No 102
Issue Date: 17-12-2015

Equipment : SIUI-CTS-30A Couplant type : Grease

Serial No : 546311131133 Surface condition : As Welded
Search unit : Normal prob Material : C.Steel
Angle : 0 Thickness : mm
Frequency : 5 MHz Working Pressure :NA
Applicable Code : ASME SEC V, 2013

Nozzle Nozzle Name Measurement (mm)

No
1st 2nd 3rd 4th Min
Reading
N 12 Roof Manhole (20") 7.76 7.89 7.95 8.05 7.76

N7 Gauge Hatch (8") 12.69 13.09 12.69 13.18 12.69

N6 Air Vent (6") 13.00 12.45 12.77 12.91 12.45

N4 Spare Blind (6") 12.69 12.72 12.80 12.69 12.69

N8 Level Swich (6") 13.05 13.60 13.87 13.28 13.05

NR Rader Gauge (4") 8.50 8.44 8.48 8.45 8.44

Notes:
1. We assumed (NR) for Rader Gauge (4") Nozzle.
2. Level Swich (6") Nozzle (N8) is located in the last Shell Course S9.
3. We taked 4 readings in every Nozzle & the smallest reading in every Nozzle is present in the table.

DATE :
EXAMINTION QUALIFICATION LEVEL LEVEL Π
17/12/2015

Name Kadry Nabil

SIGNTURE

Page 1 of
 Ultrasonic Examination

Thickness Report For CLIENT : Chevron

Area: 6th of October city
Roof Nozzles of Tank 102 ITEM :TANK No 102
Issue Date: 17-12-2015

Tank No 102
UT Thickness Examination for Roof Tank 102 Nozzles.

DATE :
EXAMINTION QUALIFICATION LEVEL LEVEL Π
17/12/2015

Name Kadry Nabil

SIGNTURE

Page 2 of
 MAGNETIC PARTICLE

REPORT FOR TANK

Date:

Client Chevron Job # 4

Date 21 / 12 / 2015 Report # 4
Project Tank No 102 DWG # Attached
Site 6 October PAGE # 1 of 4
Test Piece ident. Nozzels, Manholes and Shell to Bottom weld (Zero Weld) of Tank No 102
Surface Condition Magnetic Particle
Exam Method
As Welded Time of (Color)
 Visible Fluorescent
Exam N/A
Dry  Wet BLACK
Applicable Code Metal Type Temperature: Procedure & Examined
ASME SEC V 2013 C.Steel Ambient temp Revision Available area
MT-1
Equipment:  Yoke  AC  DC Calibration Verified  10 Ibs 40 Ibs
Part /weld no. ACC () REJ () IND Code REMARKS
Nozzel (N th)  No sign of defects scanned area is cleaned and available area
Nozzel (N 1)  C (3 cm) Found a crack with 3 cm length in the left side of the Nozzle
Nozzel (N 2)  No sign of defects scanned area is cleaned and available area
Nozzel (N 3)  No sign of defects scanned area is cleaned and available area
Nozzel ( N 5)  C Found two cracks one with 3 cm length in the left side of
(3cm,6cm) Nozzle & the other 6 cm length in the right side of Nozzle.
Nozzel (N 10)  No sign of defects scanned area is cleaned and available area
Nozzel (N 14)  No sign of defects scanned area is cleaned and available area
Nozzel (N 15)  No sign of defects scanned area is cleaned and available area
Nozzel (N 16)  No sign of defects scanned area is cleaned and available area
Nozzel (N 17)  No sign of defects scanned area is cleaned and available area
Man Hole (N13)  No sign of defects scanned area is cleaned and available area
Sump (24") (BS)  No sign of defects scanned area is cleaned and available area
Shell to Bottom weld  No sign of defects scanned area is cleaned and available area
INDICATION No Indications Under cut Porosity Crack Spatter
*INDICATION
CODE NI UN P C S

EXAMINTION QUALIFICATION LEVEL LEVEL Π DATE : 21/12/2015

Name Kadry Nabil

SIGNTURE

1|Pag
 MAGNETIC PARTICLE

REPORT FOR TANK

Date:

Tank No
MT Examination for Shell to Bottom weld (Zero Weld)& welds of
Holes in the Bottom plate

Notes .
1. Heavey lines refers to places of MT Examination.
2. MT Examination carried out for Shell to Bottom weld (Zero Weld) & welds of Bottom
Sump 24" (BS) in the bottom plate and shows no signs of defects.

EXAMINTION QUALIFICATION LEVEL LEVEL Π DATE : 21/12/2015

Name Kadry Nabil

SIGNTURE

2|Pag
 MAGNETIC PARTICLE

REPORT FOR TANK

Date:

Tank No
MT Examination for welds of
Nozzels in the 1st Course(S1).

1. Heavey lines refers to places of MT Examination.

2. N = Nozzel, S1 = 1st Course & P = Plate
3. We assumed Nth for the thermo couple Nozzle (1").
4. MT Examination done for all 1st Course Nozzles where we found three Cracks in Nozzles
N1, N5 one crack in Nozzle N1 with length 3cm in the left side of the Nozzle & two cracks
in Nozzle N5 with lengthes 3cm in the left side, 6cm in the rigth side of Nozzle (pics of the
tow cracks attached in page 4 below).

EXAMINTION QUALIFICATION LEVEL LEVEL Π DATE : 21/12/2015

Name Kadry Nabil

SIGNTURE

3|Pag
 MAGNETIC PARTICLE

REPORT FOR TANK

Date:

Nozzle (N1) 4" (Inlet) Nozzle (N5) 4" (Spare)

EXAMINTION QUALIFICATION LEVEL LEVEL Π DATE : 21/12/2015

Name Kadry Nabil

SIGNTURE

4|Pag
 INSPECTION REPORT

COATING OF TANK

Date:

Inspection Repot for Coating

Client : CHEVORN

Side: 6th October City

Serial No: T-102

Inspected item: outside for Oil Tank

Painting system: unknown

Another protection system: no

Production date of tank: 1994

Working environment classification according to ISO 12499- part 2: C3 – C4

EXAMINTION QUALIFICATION LEVEL C.SWIP B.GAS DATE : 21/12/2015

Name Mostafa Abd El-fatah

SIGNTURE

1|Pag
 INSPECTION REPORT

COATING OF TANK

Date:

Inspection
Wearing
Rough Surface Scratch
No Testing To Rust DFT
Chalking (Contamination Blister Flaking And
Position Finish ( µm )
Under The Mechanical
Coat
Pain) Damage
1 Two meters 100% Almost the ………. Few ………. Small Many
from the surface spot,
shell above density 150 - 450
zero plat little
(around
the seam
weld)
2 Zero plat, 100% Almost the Many Many ………. Many Many
fixed surface
support and
bolts
3 Flanges , 100% ………. Little Many ………. Many Many 50 - 250
manhole and
pipes
4 Two meters 100% Almost the ………. Few ………. Very Many
above ladder surface small
spot, 150 - 300
density
little
(around
the seam
weld)
5 Ladder A lot of Around Many
Galvanized ………. ………. ………. ………. wearing the seam 50 - 150
coated weld
6 Ladder ………. ………. ………. ………. ………. Almost ……….
Attachment the
surface

EXAMINTION QUALIFICATION LEVEL C.SWIP B.GAS DATE : 21/12/2015

Name Mostafa Abd El-fatah

SIGNTURE

2|Pag
 INSPECTION REPORT

COATING OF TANK

Date:

Rough Surface Wearing

Scratch
Testing (Contaminatio To Rust DFT
No Chalking Blister Flaking And
Position n Under The Finish ( µm )
Mechanical
Pain) Coat
Damage
7 Handrail 100% Few few ………. Few Many Little
8 Roof 100% Many ………. ………. Almost Around Many 50 -250
the the
surface seam
weld
9 Flanges and ………. Many Many Many ………. Many Many 100 -250
pipes at roof
10 Pipes of fire ………. ………. ………. ………. ………. Few ………. 150 -250
fighting
11 Angle beam ………. ………. ………. ………. ………. Almost ……….
to fixing the
the fire surface
fighting

Finally:
1- The durability of coating for Tank 102 had finished.
2- Generally the coating enough to protect the tank 2-3 years with repair the defected areas.
3- But the corrosion not strong (uniform corrosion) because the classification of environment is
C3 – C4 according to ISO 12944-2 and there is no pitting corrosion, bimetallic and crevice
corrosion.
4- So the coating enough to protect the tank 2-3 years with repair the defected areas by the
following painting system.
5- surface preparation Sa 2½ or ST2 according to ISO 8501-1
6- First coat 1-2 * coat Chlorinated rubber 80 µm ( Ex. Sigma vi coat 18)
7- Finished coat 2-3* coat Acrylic 80 µm ( Ex. Sigma ci coat 56)
8- According to ISO 12944-5 table A.3 system No. A3.05.
9- Re sand blasting and Re paint if you need to protect the tank more than 3 years.

EXAMINTION QUALIFICATION LEVEL C.SWIP B.GAS DATE : 21/12/2015

Name Mostafa Abd El-fatah

SIGNTURE

3|Pag