Professional Documents
Culture Documents
Hiroshi Nishigami
Maki Yamashita
Shunsuke Ohnishi
Nobuhiro Wadama
Osaka Gas Co., Ltd
Hiroto Yamaoka
Tatsuo Tsuji, Yu Murakami
IHI Corporation
Takehiro Inoue
Naoki Saito
Motohiro Okushima
Nippon Steel & Sumitomo Metal Co., Ltd
ABSTRACT
In 2011, Osaka Gas commenced the dismantlement of two aboveground LNG storage tanks with a storage
capacity of 45,000 m3 each at the Senboku 1 terminal. The said LNG storage tanks had been in commercial
operation for approximately 40 years, and were the first to be dismantled in Japan. Concurrent with the
dismantlement of the said LNG storage tanks, Osaka Gas also began the research on the deterioration due to
their aging. Aging evaluation of the said LNG storage tanks will contribute to the LNG industry by not only
potentially increasing its lifetime, but by improving its functions and safety as well. In this paper, the method of
dismantling and the research results with regard to the aging for the two types of LNG storage tanks,
respectively made of 9% Nickel steel and Aluminum alloy are reported. The contents of the research will be of
the following criteria: (1) Mechanical properties of 9%Ni steel and Aluminum alloy (2) Thickness of steel pipe
piles (3) Deterioration of instrument devices (4) Deterioration of insulation materials. After dismantling of the
said LNG storage tanks, Osaka Gas decided to construct a large scale LNG storage tank applying newly
developed 7% Ni-TMCP steel for its inner tank. The storage capacity of the new LNG storage tank will be
230,000m3, and is scheduled to be completed by November, 2015. The present state of the construction of the
innovative LNG storage tank will be reported in this paper as well.
1. INTRODUCTION
Demolition of old LNG storage tanks was executed with paying sufficient attention to the safety in consideration
of the influences on the other facilities in operation and neighboring companies. Then, Osaka Gas investigated
the demolished LNG inner tank’s material and its thermal insulation material jointly with IHI as the constructor
and Nippon Steel & Sumitomo Metal Co., LTD (NSSMC) as the supplier of tank’s steel products. Moreover, we
examined the steel pipe piles and the instrumentation devices from Osaka Gas’s own point of view. This paper
describes the study on dismantling method of LNG storage tanks, the results of the investigations, and also
reports on the new material used for the LNG storage tank under construction.
Investigation items:
1) Base metal mechanical properties (chemical composition / macro-micro structure / tensile strength /
Charpy absorbed energy / retained austenite)
2) Weld metal mechanical properties (chemical composition / macro-micro structure / tensile strength /
Charpy absorbed energy)
3) Fracture toughness properties (CTOD test / duplex ESSO test / wide plate test)
4) Corrosion of foundation piles (steel pipe piles)
5) Deterioration of concrete
6) Deterioration of instrumentation devices
7) Deterioration of thermal insulation material
Table 2.1 and Figure 2.1 show the specifications of the two demolished tanks.
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Table 2.1 Specification of the tanks
1 Internal liquid LNG
2 Capacity 45,000KL
3 Type single containment type with double steel walls
Dimensions inner tank outer tank
Diameter 44,600mm 46,400mm
4
Height 28,820mm 31,850mm
Roof radius 35,700mm 36,600mm
5 Design temp. -162℃ ambient temp.
6 Design pressure 0.12kg/cm2 50mmH2O
7 Main material 9%Ni steel(Al alloy) carbon steel
8 Insulation perlite & perlite concrete
tank shell & roof; 900mm
9 Thickness of insulation
tank bottom ;1,100mm
reinforced concrete
10 Foundation slab
diameter :44,600mm thickness ;800mm
reinforced concrete
11 Dike height :4,000mm(3,000mm from the ground)
thickness ; 1,400mm
ground surface acceleration;
12 Earthquake history
178gal
13 Commercial operation Feb.1972.
Note; ( ) shows Al alloy tank
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2.2 Dismantling procedure
The LNG tanks were demolished through the following procedure in Figure 2.2.
1. Setting of entering road into the dike 5. Removal of the inner tank roof
2. Perlite extraction from the annular space 6. Removal of the outer tank shell plate
3. Removal of the pipe, pipe frame etc. 7. Removal of the inner tank shell plate
4. Removal of the outer tank roof 8. Removal of the outer tank bottom plate
& bottom insulation
Step 2 Perlite extraction from the annular space Step 4 Removal of the outer tank roof
Step 6 Removal of the outer tank shell plate Step 7 Removal of the inner tank shell plate
4
Figure 2.3. The examples of the strain diagram
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3.2.1 Base Metal of Inner Tank
Table 3.1 shows sampling parts and investigation items of each tank. Details are given as follows.
Chemical Duplex
Charpy
Tank Sampling Part Component Tensile Test CTOD Test Esso
Impact Test
Analysis Test
1st Course ○ ○ - - -
K31 13th Course ○ ○ - - -
(A5083) Annular Plate ○ - - - -
Bottom Plate - ○ - - -
1st Course ○ ○ ○ ○ ○
K11 13th Course ○ ○ ○ - -
(9%Ni-Steel) Annular Plate ○ - - - -
Bottom Plate - ○ - - -
Sampling
Si Fe Cu Mn Mg Zn Cr Ti B
Part
Shell Plate
0.08 0.10 0.01 0.67 4.51 <0.01 0.10 0.01 <0.005
1st Course
Shell Plate
0.08 0.12 0.01 0.65 4.39 <0.01 0.10 0.01 <0.005
13th Course
Annular Plate 0.11 0.13 0.01 0.67 4.44 <0.01 0.10 0.01 <0.005
Spec 0.3 4.0 0.05
≦0.4 ≦0.4 ≦0.1 ≦0.25 ≦0.15 -
JIS H 4000 ~1.0 ~4.9 ~0.25
Sampling Part C Si Mn P S Ni
Shell Plate
0.09 0.30 0.59 0.006 0.005 8.76
1st Course
Shell Plate
0.08 0.28 0.59 0.004 0.002 8.80
13th Course
Annular Plate 0.09 0.28 0.62 0.0054 0.004 8.67
Inspection
0.09 0.26 0.55 0.009 0.008 8.80
Certificate
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(b) Tensile Properties
Tensile tests were carried out by using specimens: a full thickness specimen in accordance with JIS Z 2201
No.1A. The tests were performed in both the L and C rolling directions at room temperature in accordance with
JIS Z 2241.
Table 3.4 shows the results of K31 tank, and Table3.5 shows that of K11 tank.
Figure 3.1 shows the results of Charpy impact tests. These values are lower than that of current 9%Ni steel, but
all plates conform to the requirements1), and as compared with inspection certification, it is apparent that the
base metal doesn’t deteriorate with age, too.
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Figure 3.1. Results of Charpy Impact Test (9%Ni-Steel Base Metal)
Test Temperature:-196℃
(d) Other
For the 1st shell courses of K11 tank, CTOD test and duplex Esso test were carried out and we make sure of
the soundness of material used in the construction days. The details are omitted due to space limitation.
Chemical Bending
Tensile Charpy Wide Plate
Tank Sampling Part Weld Joint Component CTOD Test Fatigue
Test Impact Test Test
Analysis Test
1st Course Vertical ○ ○ - - - -
K31 1st&2nd Course Horizontal ○ ○ - - - -
(A5083) 13th Course Vertical ○ ○ - - - -
Annular Plate Fillet ○ - - - - ○
1st Course Vertical ○ ○ ○ ○ ○ -
K11 1st&2nd Course Horizontal ○ ○ ○ ○ - -
(9%Ni-Steel) 13th Course Vertical ○ ○ ○ - - -
Annular Plate Fillet ○ - - - - ○
8
Table 3.7. Welding Procedure of Each Weld Joint
Bottom Plate
One Side
Lap Weld Joint
Table 3.8. Macro Structure of Vertical Weld Joint of Shell Plate 1st Course
K31 K11
Aluminum Tank 9%Ni-Steel Tank
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Table 3.9. Chemical Composition (K31 Aluminum Tank Weld Metal)
Sampling Part Si Fe Cu Mn Mg Zn Cr Ti B
Shell Plate 1st Course
0.08 0.10 0.01 0.67 4.51 <0.01 0.10 0.01 <0.005
Vertical Weld Joint
Shell Plate 1st&2nd Course
0.09 0.11 <0.01 0.66 4.35 <0.01 0.10 0.01 <0.005
Horizontal Weld Joint
Shell Plate 13th Course
0.08 0.12 0.01 0.65 4.39 <0.01 0.10 0.01 <0.005
Vertical Weld Joint
Shell Plate 1st Course
& Annular Plate 0.11 0.13 0.01 0.67 4.44 <0.01 0.10 0.01 <0.005
Fillet Weld Joint
Spec 0.50 4.3 0.05
≦0.40 ≦0.40 ≦0.10 ≦0.25 ≦0.15 -
JIS Z 3232 ~1.0 ~5.2 ~0.25
Sampling Part C Si Mn P S Cu Ni Cr Mo Nb Al Fe
Shell Plate 1st Course
0.06 0.26 1.79 0.010 0.0032 0.05 63.9 13.6 0.69 2.18 0.098 Bal.
Vertical Welded Joint
Shell Plate 1st&2nd Course
0.08 0.26 1.89 0.009 0.0028 0.10 67.0 15.7 0.73 2.17 0.105 Bal.
Horizontal Welded Joint
Shell Plate 13th Course
0.07 0.22 1.77 0.009 0.0028 0.05 62.5 12.2 0.65 1.90 0.102 Bal.
Vertical Welded Joint
Shell Plate 1st Course
& Annular Plate 0.08 0.28 1.90 0.010 0.0023 0.00 66.7 15.0 0.73 2.20 0.091 Bal.
Fillet Weld Joint
Inspection Certification 2.29
0.05 0.29 1.92 0.008 0.010 - 68.3 15.5 0.73 - 10.8
of Electrode (+ Ta)
[K31]
As the base metal, these results conform to the specs of JIS Z 3232 (AWS 5.10 ER 5183). It is apparent that
the weld metal doesn’t across the ages.
[K11]
The same as K11 tank, these results conform to the specs of JIS Z 3224 (AWS 5.11 ENiCrFe-2).
Table 3.11 shows the results of K31 tank, and Table3.12 shows that of K11 tank.
Table 3.11. Results of Tensile Test (K31 Aluminum Tank Weld Metal)
Tensile Fracture
Sampling Part
Stress [MPa] Location
Shell Plate 1st Course Fusion Line
297
Vertical Welded Joint ~HAZ
Shell Plate 1st&2nd Course Fusion Line
303
Horizontal Weld Joint ~HAZ
Shell Plate 13th Course
298 Base Metal
Vertical Welded Joint
1)
Requirement 275 -
10
Table 3.12. Results of Tensile Test (K11 9%Ni-Steel Tank Weld Metal)
Construction
Test after Dismantling
Management Test
Sampling Part
Tensile Fracture Tensile
Stress [MPa] Location Stress [MPa]
Shell Plate 1st Course
756 Weld Metal 761
Vertical Welded Joint
Shell Plate 1st&2nd Course
756 Base Metal 767
Horizontal Weld Joint
Shell Plate 13th Course
781 Base Metal 788
Vertical Welded Joint
1)
Requirement 655 (at 20 deg C) - -
[K31]
These results on tensile strength at room temperature satisfy the requirements1), and fracture locations are not
particular. It is apparent that soundness of tank was kept.
[K11]
The same as K31 tank, all results satisfy the requirements1), it is apparent that soundness of tank was kept.
Figure 3.2 shows the results of Charpy impact tests. All plates conform to the requirements1). Those
results have indicated that the weld joints don’t deteriorate with age.
Figure 3.2. Results of Charpy Impact Test (K11 9%Ni-Steel Tank Welded Joint)
11
(d) Other
For the vertical weld joint of 1st shell courses of K11 tank, CTOD test and wide plate test were carried out and
we make sure of the soundness of welded joints. The details are omitted due to space limitation.
The corrosion condition has been judged according to the thickness measurement which is executed by
remote field testing and actual pile investigation by excavating the upper portion of piles. Based on the
evaluation in this way indicated that there was no necessity of corrosion countermeasure for the next 50 years
at least. Because actual measurement data is still not enough, we conducted a survey on actual piles that
pulled out on this occasion of tank demolition in order to make up for scant data of actual corrosion condition.
Figure 3.3 shows the section view of the LNG tank. There were 496 foundation piles in total that driven with
steel pipe piles; length 25m, outer diameter 406.4mm, thickness of upper pile 12.7mm and lower pile 9.5mm.
As shown in Figure 3.4, the survey was conducted with 31 piles among all foundation ones of LNG storage
tank. The thickness of pile was measured down to 6m below pile head, where the lateral bearing force is
susceptible due to corrosion. In addition, 5 piles among them were measured over the entire length of pile.
The measurement of thickness was carried out after removing extraneous matters such as corrosion products
and residual material. Then the averages of pile thickness were calculated from measured thickness and
weight for each 1m.
Also note that the cathodic protection of impressed current method had been applied to the removed tank from
one year after start-up.
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Steel pipe pile
Length: 25.0m
Outer diameter: 406.4mm
Diameter of base slab: 48.0m Thickness: (Upper part) 12.7mm
(Lower part) 9.5mm
Number: 496
(Measurement range)
From pile head to 6m below
Whole length
Figure 3.4. Framing plan of piles and the measured piles in corrosion survey
3.3.2 Result
Observing the appearance of piles, corrosion is found on the outside surface evenly, where local corrosion of
particular part is not found, nor rust inside of the steel pipe. Therefore, the corrosion content is estimated from
the outer wall of a pile by reducing the measured value from the initial thickness of a pile. Figure3.5 shows the
corrosion content according to the depth. The corrosion content is about 0.6mm at a maximum, so it is kept
within 2.0mm margin. Also, no specific difference is found in the corrosion conditions between each depth.
The averaged corrosion rate is obtained as 0.014mm/year at a maximum. It also stays within the confines of
normal corrosion rate that reported various research literatures. The evaluation criterion is estimated at up to
0.073mm/year before this corrosion survey; the total corrosion rating was calculated from adding
0.042mm/year as macro-cell corrosion rate of steel in concrete to 0.031mm/year as maximum natural
corrosion rate. However, the corrosion rate obtained from this survey resulted in far below the conventional
value we estimated.
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The effective range of cathodic protection related to the arrangement of foundation piles could not be
ascertained because there was no specific difference found between the outer and the center piles due to the
too small corrosion content.
Depth(m)
Corrosion allowance
Measure points are selected at the marked point in Figure 3.6; 5 points on underside of base slab, 4 points on
side surface of base slab, each 4points on outer and inner side of dike.
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3.4.2 Result
Carbonation depth
(mm)
15
(c) Compressive strength
Figure 3.9 shows the measurement result of compressive strength. The survey of compressive strength shows
that all the specimens satisfy the design compressive strength of 24.0N/mm2.
The following are the report of deterioration investigation of instrumentation devices. The devices below are
selected as objectives for investigation among the instrumentation devices mounted on the tank.
These devices have not renewed since the construction of the tanks, and they have been in service without
any failure. However, major renovation work including hot-up and opening of LNG tank would be necessary if
these devices had failure and needed to be repaired. Also, operation of the entire LNG terminal might be
interrupted. Therefore, it is important to investigate the deterioration of these devices for better approach to
future construction and maintenance of LNG tanks.
This thermometer has a very important role in monitoring LNG stratification that is considered as a warning
symptom of roll-over phenomenon.
As shown in Figure 3.10, 15 thermometers are arranged at intervals of 2m from the top of LNG tank.
According to the indicated values of the thermometers, supervised computer system (hereafter SCS) judges
the occurrence of LNG stratification. When SCS detects stratification, it sends an alert signal to the center
control room (hereafter CCR) and requires the operator to take measures, such as sending out, transfer or
circulation.
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Figure 3.10. Arranged thermometers
Region of insulation
Insulation resistance
Thermometer No. degradation [m]
[MΩ]
(distance from the head)
1 1 1
3 6 1
No.1 LNG tank
5 2 1
12 11 1
No.3LNG tank 1 0.1 1
(e) Conclusion
The insulation degradation was found on 5 thermometers among all 30 objective thermometers. However,
they did not have severe degradation to the extent of influencing the measuring ability of thermometers. The
degradation occurred within 1m from the thermometer’s head according to the investigation of region. It is
assumed that the cause of insulation degradation was the influent water from the terminal area covered with
epoxide resin. The epoxide resin used for insulating the terminal area had deteriorated.
The insulation degradation was solved by cutting off the deteriorated region in upper 1m. We conclude that
the thermometer should be installed with extra length to deal with insulation degradation.
Figure 3.12 shows the float type level meter removed from the tank on this occasion. It is used to measure the
liquid level according to the length of the tape that goes up and down depending on the float on the liquid
surface. The float moves along the guide wires. Therefore, friction arises between the float and the guide
wires every time when the float moves. In this investigation, the deterioration condition of guide wires were
inspected for taking into account the risk of broken guide wires.
2) Tensile test
We implemented tensile test of sample wires if these wires satisfy the breaking force specified in JIS G
3550; for tensile test, both edges of wires were bonded by white metal.
We picked up 1 strand of each 6 strand excluding the core as objectives for tensile test of wire, and
implemented tensile test if these wires satisfied the breaking force specified in JIS G 4314 under the
condition; length of specimen between grips 100mm, tension rate 50mm/min.
Figure 3.14 shows the pictures of strand’s appearance and their diameters observed by a digital
microscope. There were small wears found at the parts marked with red arrows. However these wears
were not serious and the wires had enough diameters over the 0.67mm of regulation size. It can be
said that there was no wear on the wires.
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Figure 3.13. Wire’s diameters Figure 3.14. Strand’s diameters
2) Tensile test
Table 3.15 shows the result of tensile test for wires. All wires at each position satisfy the level of
standard breaking force 61.8kN for 10mm wire. Also, no difference was found among each position.
Therefore, it can be said that there was no deterioration of wires.
Table 3.16 shows the result of tensile test for strands. Some strands of No.3 LNG tank exceeded over
the maximum level of standard breaking force 1850~2100MPa for 0.67mm wire. However, no strands
exceeded the minimum level and no difference was found among each position. Therefore, it can be
said that there was no deterioration of strands.
(e) Conclusion
We investigated the deterioration condition of guide wires for Float type level meter that had been installed in
two LNG tanks. The guide wires have no specific wear and satisfy the standard specifications for both
diameter and breaking force. We conclude that the guide wires for Float type level meter have enough
properties that allow continuous use for 40 years.
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3.6 Thermal insulation material
The following thermal insulation materials (i.e. perlite, Mesalite (Mitsui Expanded Shell Light-Weight
Aggregate) concrete, perlite concrete block and cylindrical perlite concrete) were investigated (Figure.3.15).
3.6.1 Perlite
Perlite was sampled from the top, the middle, and the bottom of annular space, and also from inside of the
cylindrical concrete.
Thermal conductivity(T.C.)
*1
Sample Location Ratio
(W/mK)(at 0℃)
21
3.6.2 Mesalite concrete
(a) Compressive strength
The test was carried out in accordance with JIS A1108 (this standard follows ISO 1920-4). The test results are
shown in Table 3.18. Compressive strength of the samples satisfies the specification value at the time of the
construction. The specific gravity was almost the same as the value at the time of the construction.
The properties of Mesalite concrete have not been changed since the days of construction.
22
Table 3.21. Thermal conductivity of Cylindrical perlite concrete
The inner tank material for above ground LNG storage tanks has mostly been made of 9% Ni steel plate over
the 50 years as it has excellent mechanical properties under -160deg.C. During this period, the LNG storage
tanks made of 9%Ni steel plate have safety operated. It is known that 9%Ni steel has excellent cryogenic
fracture toughness due to the retained austenite and refinement microstructure obtained by nickel content and
heat treatment process.
NSSMC, Toyo Kanetsu K.K (TKK) and Osaka Gas jointly developed 7%Ni-TMCP steel having the comparable
performance to 9%Ni steel. Newly developed 7%Ni-TMCP is achieved 2% reduction of nickel content from the
conventional 9%Ni steel by adopting Thermo Mechanical Control Process (TMCP). Various basic performance
tests and fracture toughness tests in development process showed that the base metal and welded joints
satisfy the regulatory and technical requirements for LNG storage tanks. In 2010, Japanese Ministry of
Economy, Trade and Industry (METI) approved the use of 7%Ni-TMCP steel for newly-built tank of Osaka Gas.
The development of 7%Ni-TMCP steel realizes the reduction of rare metal nickel to be used. Therefore, not
only the cost of inner tank’s material but also the cost of nickel in rising market can be saved.
From September 2012, Osaka Gas started the construction of 230,000m3 full-containment tank in Senboku I
Terminal. Installation of steel pipe piles had been done at the time of October 2012 and the base slab is now
under construction (Figure4). The construction of the tank will be completed by November 2015.
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5. CONCLUSION
Osaka Gas demolished the two LNG storage tanks that had actually been used for about 40 years. On this
occasion, we assured the secure dismantling method and verified that the mechanical properties (including
chemical composition, tensile strength and Charpy absorbed energy) of 9%Ni steel and Al alloy used as inner
tank’s material satisfied sufficient levels. Thermal insulation material, steel pipe piles and instrumentation
devices have no significant deterioration. These investigations proved the high integrity of the LNG storage
tanks.
The results of these investigations obtained from the demolished LNG storage tanks that had been used for
about 40 years provide invaluable actual data and it contributes to the progress of LNG storage tank market in
the future.
REFERENCE
1) Recommended Practice for LNG Aboveground Storage; Japan Gas Association 2012
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