1.

General
This technical report summarizes design recommendations for the in-service API 650 tank
THF2 at CBG facility, Kamsar, Guinea. This tank is in continues services for over forty
years.
CBG has confirmed there are no regular inspection or monitoring program established for
the tanks and there are no inspection and monitoring records available. There is no
cathodic protection provided for this tank.
As per contract documents there is buildup of sludge and approximately 916 m of sludge
accumulation inside the THF2 tank. There is small percentage of water content in the tank
fluid.
ASC had carried out visual inspection of tank THF2 and submitted inspection report to
CBG in May 2016.

2. Tank Bottom Plate

The tank is in continuous service for an extended period and with the presence of sludge
and water inside the tank should have contributed in acceleration of corrosion and pitting.
The inside surface of tank bottom plate along with its lap weld joints would have lost
substantial amount of thickness due to corrosion & pitting caused by the sludge and water.
As there is not cathodic protection installed for this tank the underneath surface of bottom
plate also would have corroded and lost thickness due to continuous contact with the soil.
With the double impact of corrosion on the tank bottom plate inside and underneath
surfaces, there might be substantial loss of thickness and thinning and the bottom plate
might be at its end of life. The failure of bottom plate lap weld joints will lead to loss of tank
fluid and result in direct revenue loss. Also the leaked tank fluid will contaminate the soil
and eventually result in environmental impact.
Considering the above factors it is strongly recommended to replace the tank THF2
bottom plate.

3. Tank Foundation & Footing (Bottom Plate Support Soil)

The tank fluid leakage from the bottom plate weld joints into tank foundation will cause
partial settlement of the soil, apart from contaminating the soil. This localized settlement of
soil around the damaged weld joints will result in sinking and partial settlement of the tank
bottom plate.
It is recommended to remove the contaminated soil and replace with clean and fresh soil.

4. Tank Steam Coil

The entire circumference of the THF02 outer tank bottom was visually inspected. The tank
foundation is completely buried in the debris and dirt and inaccessible.
To complete the inspection of THF02 tank foundation ASC recommends removal of debris
and dirt from the bottom of the tank and exposing the tank foundation and make it
accessible for inspection.

5. Cathodic Protection
Due to the close proximity of the CBG plant at Kamsar to the sea coast and in particular
the tank farm area to the sea coast there is likely hood of sever soil salinity which will
contribute to acceleration of the corrosion in underneath surface of the bottom plate. It is
highly recommended to install the cathodic protection for the corrosion control of the THF2
tank. Also section I.3 of API Standard 650 and API RP 651 recommends strongly to install
the cathodic protection for extend the lift of tank and to maintain the integrity and avoid the
leakage.
contamination of the The entire circumference of the THF02 outer tank bottom was
visually inspected. The tank bottom plate is completely buried in the debris and dirt and
inaccessible to perform the inspection.
To complete the inspection of THF02 tank bottom plate ASC recommends removal and
clearing of the debris and dirt from the bottom of the tank and exposing the tank bottom
plate for inspection.
As per contract document the tank has about 916 m of sludge which will contribute in
acceleration of corrosion and pitting in tank bottom plates and the lap weld joints.
It is strongly recommended to perform a NDT examination to measure the thickness of
tank bottom plates to check plate wall thinning due to internal corrosion. And perform
vacuum box leak test and DP test for all lap weld joints to check the integrity of lap weld
joints and to detect leaks in the weld joints.
It is suspected the insider portion of the tank bottom plates will be extensively damaged
with corrosion and pitting and it is recommended to replace the bottom plates.

Materials for Replacement of Tank Bottom, Steam Coil and Tank Foundation
The entire circumference of the THF02 outer tank bottom was visually inspected. The tank
foundation is completely buried in the debris and dirt and inaccessible.
To complete the inspection of THF02 tank foundation ASC recommends removal of debris
and dirt from the bottom of the tank and exposing the tank foundation and make it
accessible for inspection.

Recommendations:

As per original contract the scope for tank rehabilitation project includes replacement of
tank conical roof. After initial field inspection ASCs observations and recommendations
were presented in the inspection report.

THF2 Tank Bottom Plate Material:

Material Specification: ASTM A283 Grade C
Plate Thickness = 3/8" (including corrosion allowance).
A corrosion allowance of 1.6 mm is assumed for the carbon steel bottom plates. If the
actual corrosion allowance requirement for the THF2 tank bottom plates is different, then
CBG shall provide the actual corrosion allowance.
A plate size of 72 width x 240 length is considered for the bottom plate layout
calculation and to estimate the number of plates. If the plate dimensions changes then I
have to rework the layout for tank bottom plate and reestimate the number of plates.
A total of 106 plates of 72" x 240" dimension are required for bottom plate replacement.
Steam Coil material requirement:
Steam coil pipe:
Material Specification: ASTM A106 Grade B
Pipe Size: 2-1/2 NB x Sch. 80 Pipe.
Pipe Length: 600 feet approx.
Pipe fittings:
Material Specification: ASTM A234 Grade WPB
Pipe Fitting Size: 2-1/2 NB x Sch. 80 Pipe
Number of elbows required: 8 pieces
Flanges:
Material Specification: ASTM A105N
Pipe Flange Size, Type & Rating: 2-1/2 NB x Slip-on x 150 pound
Number of flanges required: 8 pieces
Flanges Bolting:
Material Specification: ASTM A193 Grade B7H & ASTM A194 Grade 2H
Bolting: Stud with Heavy Hex Nuts
Number of flanges required: 32 sets + 10 % spare bolting
Flanges Gasket:

Material Specification: ASTM A240 Grade 304

Gasket type & size: Spiral wound with centering ring, 2-1/2 NB x 150 #
Number of Gaskets required: 8 pieces + 8 pieces spare
Pipe supports:
Approximately 30 pipe supports are required for the steam coil
ASTM A36 material spec. and approximately 0.75 tons

Removal and reinstate soil for the tank bottom plate:

Remove contaminated soil:
Approximate quantity = 22, 000 Cu feet considering a 2 feet depth of soil removal
Transport and dispose the soil in the designated area
Reinstating of the soil.
Fresh / clean soil material = 24,200 Cu feet
Labour and equipment cost for soil compaction.
For the replacement of the bottom plate and steam coil two large access openings are
required to be cut in the tank shell and the material required for opening and reinstating
the tank shell plates are:

Opening size 10 feet x 10 feet 2 required

Structural reinforcement shall be installed prior to cutting and opening the shell for
access:
W-beam of 16-W-45 size and ASTM A36 material specification and a length of 2 x 30
feet = 60 feet
Material required for reinstating the shell plates:
Shell plate material specification: ASTM A283 Grade C
2 x 10 x 10 Sq. feet = 200 Sq. feet of 14 mm thickness
To estimate the labour cost for fabrication, installation and civil works, please provide
hourly rates for the following labour, equipment and machinery: