Mock Report

Report :2016-10082-001
NDT Inspection and Complete Date: 03-08-2016

Suitability for Service Analysis Rev:00
of Tank XXXX
INSPECTEST SUBJECT GROUP DATE

REPORT NO. 2016-10082-001 II DIVISION 29-31 JULY, 2016
TITLE OF REPORT DEPARTMENT PROJECT NO.

NDT Inspection and Complete Suitability for Service Analysis INDUSTRIAL 483/10082
INSPECTION
APPROVED BY INSPECTEST
HAIDER RAZA
API 653 AUTHORIZED INSPECTOR
CERTIFICATE NO. 60190
CLIENT / SPONSOR OF PROJECT / ADDRESS CHECKED BY

XXXXXXX BASHARAT ALI
INSPECTION & INTEGRITY ENGINEER
XXXXXXX
WORK CARRIED OUT BY REPORTED BY

KAMAL AHMED NIAZI KAMAL AHMED NIAZI
BASHARAT ALI API 653 AUTHORIZED INSPECTOR
ZAKI AHMAD ZAKI CERTIFICATE NO. 60184
DISTRIBUTION STATEMENT:
NO DISTRIBUTION WITHOUT
X PERMISSION FROM THE
LOCATION RESPONSIBLE DEPARTMENT
XXXX
LIMITED DISTRIBUTION WITHIN
INSPECTEST
FREE DISTRIBUTION
NUMBER OF
SUBMISSION DATE OF REV. NO. 0 PAGES
22
The item/s described above was/were examined in prescribed manner. The information contains hereon reflects the companys finding at time of inspection only and
within clients instructions & premises. Inspection and certification becomes null and void if any changes made in equipment that alters safety features of above
described equipment. This inspection report does not relieve the contractor/user from his obligations to keep the equipment maintained and used safely.
Any unsanctioned alteration, forgery or falsification of the content or appearance of document is unlawful and delinquents may be prosecuted to the completest extent
of law.
Inspectest (Pvt.) Limited 18 km, Ferozepur Road, Lahore, Pakistan
T: + 92 42 3540 2053 -58 UAN: III-INSPEC I F: + 92 42 3540 2050 E: inspectest@inspectest.com.pk 1|P a g e
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TABLE OF CONTENTS
1 Executive Summary .............................................................................................. 4

2 Abbreviations .......................................................................................................... 4
3 Scope of Work ......................................................................................................... 5
4 Reference documents ............................................................................................ 5
5 Deliverables ............................................................................................................. 6
6 Tank Details ............................................................................................................ 6
7 Inspection Equipment .......................................................................................... 6
8 Visual Inspection ................................................................................................... 6
8.1 External Visual Inspection Shell........................................................................... 7
8.2 External Visual Inspection Shell Appurtenances ............................................. 8
8.2.1 Shell Manhole Dimensional Checks..................................................................................... 9
8.3 External Visual Inspection Tank Foundation ................................................... 9
8.4 External Visual Inspection Tank Roof Access Structure ..............................10
8.5 External Visual Inspection Tank Fixed Roof ....................................................11
8.5.1 Roof Manhole Dimensional Checks .................................................................................... 12
8.6 Internal Visual Inspection Tank Shell................................................................12
8.7 Internal Visual Inspection Tank Bottom ...........................................................13
9 Non-Destructive Testing ..................................................................................... 14
9.1 Ultrasonic thickness gauging................................................................................14
9.1.1 Required Minimum Thickness Calculation for Tank Shell plates ............................ 14
9.1.2 Corrosion Rate & Inspection Interval Calculation for Tank Shell plates and
Bottom ......................................................................................................................................... 15
9.2 Vacuum Box Testing ................................................................................................17
9.3 Magnetic Particle Inspection ................................................................................17
10 Root Cause Analysis of Sump Area Weld Failure ..................................... 17
11 Recommendations ............................................................................................... 19
11.1 Shell and Appurtenances ...................................................................................19
11.2 Foundation .............................................................................................................20
11.3 Tank Roof ...............................................................................................................20
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11.4 Tank Bottom ..........................................................................................................20
12 Repair Procedure for Drawoff Sump Area ................................................... 21
13 Conclusion.............................................................................................................. 21
13.1 Tank Shell...............................................................................................................21
13.2 Tank Roof ...............................................................................................................21
13.3 Tank Bottom ..........................................................................................................21
14 Attachments .......................................................................................................... 22
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1 Executive Summary
The NDT inspection and complete suitability for service analysis of NGL storage
tank XXX was carried out on July 29-31, 2016 at XXXX
Sump drawnoff weld located at bottom of above mentioned tank failed and leakage
was observed by the plant personnel, Tank when emptied, purged and properly
vented was initially inspected and failed corroded weld joint was evident. On the
work order issued by M/S XXX, Inspectest Private Limited mobilized its team for
subjected work completion and complete suitability for service analysis of Tank
and determination of root cause of failure as per API 653 section 4. Inspectest
team consisted of following personnel.
01 API 653 Authorized Tank Inspector

01 Inspection Engineer
01 ASNT Level 2 Examiner
2 Abbreviations
API : American Petroleum Institute
ASNT : American Society for Non-Destructive Testing
ASME : American Society for Mechanical Engineer
ASNI : American Standards National Institute
AC : Alternating Current
DPT : Dye Penetrant Testing
EKL : Engineering Kinetics (Pvt). Ltd
FFS : Fitness for Service Analysis
IPL : Inspectest Private Limited
JJVL : Jomshoro Joint Venture Limited
LPG : Liquefied Petroleum Gas
MPI : Magnetic Particle Inspection
MFL : Magnetic Flux Leakage
NGL : Natural Gas Liquid
NFPA : National Fire Protection Association
NDT : Non-Destructive Testing
NPS : Nominal Pipe Size
PAUT : Phased array Ultrasonic Testing
RP : Recommended Practice
TOFD : Time of Flight Diffraction Testing
UT : Ultrasonic Testing
UTG : Ultrasonic Thickness Gauging
VT : Visual Testing
VBT : Vacuum Box Testing
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3 Scope of Work
Scope of work for suitability for service analysis includes complete assessment of
following parts of Tanks.
Tank Shell including nozzles, shell to bottom joint, roof access structure and
appurtenances.
Tank Roof including opening, supporting structures and appurtenances.
Tank Bottom including bottom plates, critical zone, projection plate, bottom to
shell joint and sump drawoff area.
Tank Foundation including foundation plates and dike area.
Following Inspection and NDT techniques were used for assessment and
evaluation of above quoted Tank parts.
External Visual Inspection by API 653 Inspector

Internal Visual Inspection by API 653 Inspector
UTG of shell plates, bottom plates, nozzles openings, roof plates and sump
drawoff area.
VBT of bottom plates weld joints and shell to bottom joint.
MPI of tee intersection joints of shell course 1 and 2 and joint on course 1
adjacent to reinforcement joint of manhole.
Pit Depth measurement by pit gauge of scattered pits located at roof plates.
Fillet weld throat measurement by cam gauge of fillet weld of sump drawoff
plate.
Nozzle openings thickness and dimension measurements of flange diameter,
cover plate thickness and diameter, nozzle neck length measurement and bolt
circle diameter by vernier calliper.
4 Reference documents
Following international codes and standards were followed during inspection.
1. API 653 Tank Inspection Code

2. API 650 Welded Tanks for Oil Storage
3. API 575 RP for Inspection of Existing Tank
4. API RP 571 Damage Mechanisms
5. API RP 577 Welding Inspection & Metallurgy
6. ASME Section V Nondestructive Examination
7. ASME Section IX Welding and Brazing Qualifications
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5 Deliverables
The deliverables of the work assigned as per contract were follows:
1. A comprehensive report from API authorized inspector in hard form.

2. Soft copy of report in pdf format.
6 Tank Details
Following detail for this Tank was taken from available Inspection dossier and
Client;
Equipment Name : XXXX

Manufacturer : EKL Pakistan
Maximum safe fill Height : 12 feet
Specific gravity of NGL : 0.67
Tank diameter : 6 meter
Tank height : 4.5 meter
Tank roof type : Fixed cone
Material of construction : A-36 Structural Steel
Manufacture Year : 2004
7 Inspection Equipment
Following equipments were used for inspection;
Complete visual inspection kit

DMS-Go (Ultrasonic Thickness Meter)
MPI consumables
AC hand yoke
VBT equipment
Cam gauge
Pit depth gauge
Meter Tape
Vernier Calliper
8 Visual Inspection
Tank was properly purged and vented for entry and all the pre-requisites of
internal and external inspection were fulfilled. Platform was provide outside the
tank for external visual inspection and lighting and ladder was provided inside the
tank for internal visual inspection.
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8.1 External Visual Inspection Shell
Inspection Checklist
1. Coating or painting on shell plates (blisters, peeling, stains): 3
2. Insulation (cracks, leaks, moisture retention): NA
3. Shell pitted or corroded (API 653. 4.3): 1
4. Deformation of shell (banding, peaking) (API 653. 10.5.4, 10.5.5): 2
5. Bottom course deformation: 2
6. Shell lap patches (API 653. 9.3): NA
7. Indication of shell leaks: 1
8. Shell misalignment (API 650. 5.6.1.4): 2
9. Weld reinforcement (API 650. 5.7.2): 2
10. Riveted joint condition (worn, corroded): NA
11. Riveted vertical joints full fillet lap welded: NA
12. Tank roundness (API 653. 10.5.3): 2
13. Seam weld undercut (API 653. 10.4.2.5): 1
14. Remnant welds (API650 3.8.1.2C)(API 652 4.3) (API 653 9.6.5): 1
15. Shell vertical seam weld spacing (API 650. 5.1.5.2): 1
16. Name plate attachment (API 650. 10.1, API 653. 13.1): NE
17. Check overflow slots for corrosion and screening: NA
18. Check overflow does not drain over valves or equipment: NA
19. Check autogauge system (C.1.1.3) NA
Comments
External visual Inspection of Tank shell was carried out and paint/coating, shell
out of roundness, out of plumbness, banding and peaking, signs of general
corrosion and localized corrosion and pits, dents and bulges were assessed.
Following are the evident discrepancies observed during inspection.
Sporadic and localized paint failure was observed on shell course 1. See
Appendix-B
Name Plate detailing design and as built parameters was not seen attached to
the Tank.
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Corrosion on Weld seam of shell course 2 and 3 at location above Manhole was
observed. See Appendix-B
8.2 External Visual Inspection Shell Appurtenances
1. Leakage around reinforcement plate welds: 1
2. Reinforcement telltale holes (API 650 5.7.5): 3
3. Reinforcement plate spacing (API 650 5.7.3): 3
4. Reinforcement plate size/thickness (API 650 5.7.2): 1
5. Two (2") inch nozzle reinforcement (API 650 5.7.2): 1
6. Nozzle weld corrosion/undercut (API 650 8.5.1): 2
7. Excessive dimpling of shell plate or bowing of piping: 1
8. Indications of leakage around manifolds, flanges, or valves 1
9. C.1.3.2:
Indications of leakage around manways and nozzles: 1
10. Indications of leakage around flange bolts and welds: 1
11. Tank mixer mounting base (weld failure, damage): NA
12. Leakage around mixer shaft seal: NA
13. Condition of welds on davit clips (valve, mixers, cleanouts): NA
14. Wind girder, supports, handrails (corrosion, weld failure): NA
15. Wind girder, (debris buildup, paint failure): NA
16. Leaks at sample connection C.1.3.2: NA
17. Visual check of fire equipment C.1.3.2: NA
18. Emergency overflow screens clean and free of debris: NA
19. Anchor bolt condition: NA
20. Independent level alarm system NA
Comments
External visual inspection of shell appurtenances (openings, nozzles and other

support structure) was done for assessment of its conditions. Following are the
evident discrepancies.
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Weld spacing between shell horizontal seam and manhole reinforcement pad
seam didnt comply with the requirement of API 650 figure 5.6 and 5.7.3
which states minimum spacing between weld seams shall be 3 inch minimum
however actual spacing between seams were 1.5 inch and 2.5 inch. See
Appendix-B
Telltale hole on manhole reinforcement pad was not found drilled as per API
650 5.7.2.10. If it was drilled at time of fabrication then it is most probable
that it must have been chocked and diminished underneath a thick layer of
paint. See Appendix-B
4 NPS nozzle installed in shell course 1 on LPG bullets side was found non
reinforced and it is critical because it is located near bottom which tends to
rotate with vertical bending under hydrostatic load. See Appendix-B
8.2.1 Shell Manhole Dimensional Checks
Manhole Size: 24 NPS

Parameter As Measured Required
Flange thickness API 650 table 5.6 a 20 mm 12 mm
Nozzle thickness API 650 table 5.4 a 5.71 mm 6 mm
Cover plate diameter API 650 table 5.5 a 813 mm 832 mm
Flange bolt circle diameter API 650 table 5.5 a 753 mm 768 mm
Cover plate thickness API 650 table 5.3 a 16 mm 11 mm
J (distance from reinforcement plate to 286 mm 300 mm
manhole flange face) API 650 table 5.6 a
As per above table citation and measured dimensions it is obvious that nozzle
neck thickness, cover plate diameter, flange bolt circle diameter and
parameter J doesnt meet the criteria set in API 650.
8.3 External Visual Inspection Tank Foundation
1. Level survey required (base on visual planar tilt) C.1.1 & C.1.1.1: 1
2. Foundation (cracks, breaks, spalling): NA
3. Foundation 300 mm above dike basin NA
4. Bitumen cover (cracks, washouts, erosion): NA
5. Foundation seal (deterioration, peeling): NE
6. Foundation (erosion, leaks, cond. API 650 5.3.1, API 653 10.5.6): 2
7. Water ingress/egress/vegetation against bottom C.1.1.1 2
8. Indications of bottom leaks: 1
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9. Bottom plate extension cond. (API 650 5.4.2, API 653 4.4.7.7): UA
10. Bottom plate extension welds (pitting, corrosion, undercut): UA
11. Earth grounding cables and connectors cond. (API 575. 7.2.5): NE
12. Cathodic protection NA
13. Tank settlement into pad C.1.1.2: 2
14. Does washout of pad reveal crushed rock under bottom C.1.1.4: NE
Comments
Tank bottom foundation was inspected for evidence of any deterioration in

foundation and any considerable settlement. Following are the evident
discrepancies observed during inspection, no concrete ring wall was present
around tank foundation.
Signs of settlement was observed around foundation on left side of manhole as
seen from plant which when surveyed by level was substantiated and
settlement is observed to be of minor nature. See Appendix-B
8.4 External Visual Inspection Tank Roof Access Structure
1. Ladder attachments to concrete base (corrosion, broken): 1

2. Bolts and fasteners on stairways and ladder stringers: 1
3. Welds on stairways and ladder stringers (corrosion, broken): 2
4. Stairways and ladders (corrosion, paint failure): 2
5. Tread attachments to stringers (corrosion, broken): NA
6. Safety drop bar or safety chain provides adequate protection: NE
7. Gauger platform frame and supports (corrosion, broken): NE
8. Gauger platform deck (corrosion, thinning, weld failure): NE
9. Gauger walkway for thinning and slots: NE
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Comments
Roof access structure of Tank (ladder) was inspected for any deterioration and its
suitability and following are the evident discrepancies.
Ladder attachment weld to shell course 3 plate was not properly seal welded
further corrosion was also observed on the same weld.
8.5 External Visual Inspection Tank Fixed Roof
1. Roof plate distortions: 2

2. Roof plates (corrosion, pitting, holes (API 653 4.2.1.2): 3
3. Roof plates (coating or paint failure): 2
4. Remnant welds (API 652 7.3)(API 653 9.6.5): NE
5. Roof plate lap joints (API 650 5.1.3.4, 5.1.3.5) NE
6. Indications of product staining: 1
7. External rafter condition (corrosion, broken, weld failure 3
8. Emergency venting (NFPA 30) NE
9. Rain water standing, sag of roof C.1.4.3: 1
Comments
Tank roof was subjected to visual inspection for assessment of condition of roof
structure, external rafter, tank roof appurtenances (nozzles, openings), pitting,
corrosion and other deterioration associated with roof plates. Following are the
evident discrepancies observed during inspection.
Roof plate was observed to be moderately corroded at one location and its paint
and coating was damaged just beside roof access ladder. See Appendix-B
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External roof rafter (angle iron) for structure adequacy of roof was in precarious
condition, its weld seam with roof plate was observed to be of poor
workmanship and separated from roof plate on at least 02 locations. See
Appendix-B
Scattered pitting was observed on roof plates, the deepest pit measured on roof
was 2.89 mm deep, details of measuring locations and pit depths are attached
herewith in Appendix-F
2 NPS water line at roof was open for inspection and heavily chocked. See
Appendix-B
8.5.1 Roof Manhole Dimensional Checks
Manhole Size: 20 NPS
Parameter As Measured Required

Diameter of nozzle neck API 650 table 5.13 a 508 mm 500 mm
Diameter of flange bolt circle API 650 table 5.13 a 597 mm 597 mm
Cover plate diameter API 650 table 5.13 a 660 mm 660 mm
Roof manhole dimensions comply with the requirements set in API 650 table
5.13 a.
8.6 Internal Visual Inspection Tank Shell
1. Shell internal coating condition: NA
2. Damages/dents/scratches on the shell plates present: 2
3. Shell corrosion (API 653 4.3.1.3): 2
4. Seam weld undercut (API 653 10.4.2.5): 2
5. Remnant welds (API 650 3.8.1.2C)(API 620 4.3)(API 653 9.6): 2
6. Gauge wells (corrosion, pitting): NA
7. Gauge wells attach to shell (weld corrosion, crack): NA
8. Gauge wells slotted properly: NA
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Comments
Tank shell was inspected internally for evidence and susceptibility of general
and localized corrosion, scars, built-up, pitting, bulge, and vapor to liquid
interface and other anomalies. Following are the evident discrepancies observed
during inspection.
Signs of built-up and gouges were observed at shell course 1 and 2 plates at
numerous locations. See Appendix-B
8.7 Internal Visual Inspection Tank Bottom
1. Tank bottom plate condition (corrosion, pitting): 2
2. Remnant welds (AP 620 4.3, 4.4)(AP 653 9.6): 2
3. Bulges/depressions (AP 653 B3.3): 1
4. Tank bottom coating condition: NA
5. Standing water: 2
6. Striker plate condition: NA
7. Bottom weld joints (AP 650 5.1.3.4, 5.1.3.5): 1
8. Edge settlement (AP 653 B3.4): 2
9. Three way joint spacing (AP 650 5.1.5.4): NA
10. Bottom/shell joggle joints (AP 650 5.1.5.4): NA
11. Annular plate width (AP 650 5.5.2): NA
12. Bottom plate patches (Type, location) (AP 653 9.10.1.1, 9.10.1.2): NA
13. Bottom plate joints from shell vertical joints (AP 653 Fig.9-1): 1
14. Shell-to-bottom fillet weld (AP 650 5.1.5.7): 2
15. Internal piping general (Coating, corrosion): 2
16. Inlet piping (Diffusor present, supports, corrosion): NA
17. Outlet piping (Main and low suction present, supports, corrosion): 2
18. Drainage piping (Corrosion, supports): 2
19. Shell-to-bottom HAZ (UT survey): NA
20. Sump condition (Visual, UT survey): 4
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Comments
Tank bottom plates including sump drawoff area and shell to bottom joint were
visually inspected for evidence of corrosion, pitting, weld seam deterioration
and edge settlement. Following are the evident discrepancies observed during
inspection.
Weld seam in Sump drawoff was observed to be fully corroded and failing due
to corrosion complete integrity assessment of sump draw off area and other
details can be found in root case analysis section of this report. See
Appendix-B
9 Non-Destructive Testing
NDT inspection of Tank was done as deemed appropriate for suitability for service
analysis. Following is the details of NDT inspection.
9.1 Ultrasonic thickness gauging
Ultrasonic thickness gauging of Tank Shell plates, Roof plates, Bottom plates,
Tank openings, Drawoff sump area and other appurtenances was done.
At Tank shell courses plates thickness reading were taken at 1 meter gap
horizontally and 1 feet gap vertically see details in attached sketch (Appendix-
C) and Appendix-A for detailed findings.
Thickness reading at Roof plates were taken as 03 readings in each 8 sections
formed by division of external rafters see attached sketches (Appendix-C) and
Appendix-A for detailed findings
Thickness reading at bottom plates were taken in same manner as of shell
thickness readings, see attached sketches (Appendix-C) and Appendix-A for
details.
Thickness readings on Sump drawoff area are taken as shown in attached
sketches (Appendix-C) and details of findings are in attached Appendix-A
9.1.1 Required Minimum Thickness Calculation for Tank Shell plates
The minimum acceptable shell plate thickness for tanks with a diameter equal
to or less than two-hundred (200) feet is calculated as follows (Ref API 653,
Para 4.3.3.1).
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Where
Design Liquid Level H=12 ft. Specified by Exterran
Diameter D= 6 meter (19.68 ft.)
Specific gravity G= 0.65
Material specification = A 36
Max allowable Shell Stress S=24,900 lbf/in2 (For lower two shell courses)
Max allowable Shell Stress S=27,400 lbf/in2 (For upper shell courses)
Joint efficiency E=1 (Ref. API-653 Table 4.2)
Year built: 2004
Minimum Required Thickness (tmin) for 1st Shell Course
tmin = 2.6(H-1) DG
SE
tmin = 0.015 inch (0.381 mm)
Minimum Required Thickness (tmin) for 2nd Shell Course

tmin = 2.6(H-1)DG
SE
tmin = 0.008 inch (0.212 mm)
Minimum Required Thickness (tmin) for 3rd Shell Course

tmin = 2.6(H-1)DG
SE
tmin = 0.0018 inch (0.045 mm)
Note: Since calculated value is less than 0.1 inch or 2.54 mm therefore tmin
should be considered max: 0.1 inch or 2.54 mm as per API-653.
9.1.2 Corrosion Rate & Inspection Interval Calculation for Tank Shell
plates and Bottom
Corrosion rate of tank shell can be calculated by using the following formulae:
Next visual inspection interval of tank shell can be calculated by using the
following formulae:
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Next thickness measurement interval of tank shell can be calculated by using
the following formulae:
Corrosion rate and inspection interval for bottom can be calculated by using
the following formulae:
Where
MRT is the minimum remaining thickness at the end of interval Or . This value
must meet the requirements of Table 4.4 and 4.4.5.4 and 4.4.6 of API 653.
Or is the in-service interval of operation (years to next internal inspection) not
to exceed that allowed by 6.4.2 of API 653.
RTbc is the minimum remaining thickness from bottom side corrosion after
repairs;
RTip is the minimum remaining thickness from internal corrosion after repairs;
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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. To calculate the
corrosion rate, use the minimum remaining thickness after repairs. Assume a
linear rate based on the age of the tanks. UPr = 0 for areas that have effective
cathodic protection.
Corrosion rate and inspection interval of tank shell and bottom cant be
determined as previous inspection record, thickness measurements are not
available for review and comparison.
9.2 Vacuum Box Testing
VBT of tank bottom plate weld seams and shell to bottom joint was carried out
as per API 650 section 8.6 and qualified procedure. For details see attached
Appendix-E
9.3 Magnetic Particle Inspection
MPI of 08 Tee joints of connecting shell course 1 and 2 from internal side vertical
seams to circumferential seams for assessments of any cracks surface or
subsurface in weld joints was done. MPI was also performed on tank shell course
1 circumferential seam opposite to shell manhole reinforcement pad. Details are
to be found in Appendix-D.
10 Root Cause Analysis of Sump Area Weld Failure

Weld seam in base plate of sump drawoff area was observed to be deteriorated
beyond any operational integrity. Root cause analysis for determination of failure
cause is described in this section. First the offhand information available about
the tank fabrication or erection was of minimal nature and second the detail
information to be found in Inspection Dossier of Tank doesnt provide any detail
understanding of sump area weld, its weld design, design of sump area, details of
any buffering medium meaning compacting sand, gravel or clay beneath bottom
plates. From the information available regarding sump drawoff area and details
gathered from inspection, findings are as below.
Design of drawoff sump area as visually observed and dimensionally measured is

given in below figure.
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While sump drawoff area as desired by the construction code API 650 is
From the comparison of above two figures some of the notable differences are
Drawoff sump area plates thickness is 5 mm for wall plates and 6 mm for
bottom plates as measured, details are to be found in attached Appendix-A
While the required thickness by API 650 Table 5.16 a is 8 mm minimum for 2
NPS nozzle opening.
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Design of drawoff sump area as desired by API 650 and actual design as shown
in above figure does not match in manners that in actual sump area is welded
to bottom plates and this weld is shielded by reinforcement pad and further the
sump area top plate offset with wall plates doesnt comply to as shown in above
figure.
Sump area bottom plate fillet weld with wall plates is measured by cam gauge
and its throat length is 5 mm however in above figure desired is 6 mm as
shown in detail b, c and d.
API 650 requires sump to be placed in area with at least 100 mm of thoroughly
compacted sand or other suitable material and in sump area there is no
evidence of any sand material present beneath it.
In light of above statements and inspection we are of opinion that weld in bottom
plate of drawoff sump area failed due to non-compliance of API 650 at time of
construction in regard that its thickness is 5-7 mm instead of 8 mm, fillet weld
joining bottom plate with wall has 5 mm throat length instead of 6 mm and there
is no evidence of compacted sand or buffer zone beneath sump area to fend of soil
corrosion attack, this will be further substantiated in repair of this area when
bottom will be excavated.
However that API 650 5.8.7 states drawoff sump area can be of any design
specified by purchaser but in this case there is no document present to support
that this failed design was specified by purchaser.
11 Recommendations
With respect to inspection findings described in previous section of this report
following are some salient recommendations part wise:
11.1 Shell and Appurtenances
Points at which paint failure or corrosion is observed shall be painted (it is

advised that PU paint shall be used). Previous layer of paint shall be thoroughly
removed and surface shall be prepared for repainting.
Name Plate detailing design and as built information of Tank shall be attached
to Shell.
4 NPS nozzle at backside of tank shall be reinforced to avoid any vertical
bending in accordance with API 653 9.7.
Telltale hole on manhole shall be drilled. API 65O, Para 5.7.2.1O indicates
reinforcing plates should be installed with telltale holes left open to the
atmosphere. It is recommended that the holes be drilled, but before the tank is
returned to service, the reinforcing plates shall be tested by applying up to 1OO
kPa gauge pneumatic pressure between the tank shell and the reinforcement
plate on each opening using the telltale. While each space is subjected to such
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pressure, a soap film, linseed oil, or another material suitable for the detection
of leaks shall be applied to all attachment welding around the reinforcement,
both inside and outside the tank (API 65O, Para 7.3.4). The telltale holes
should then be left open to the atmosphere.
Manhole doesnt comply with the requirement of API 650, it is recommended
that manhole shall be frequently monitored by NDT techniques such as PAUT
and TOFD while in service for evaluation of any corrosion or other damaging
mechanism.
It is recommended that routine in-service inspection of tank including a visual
inspection of the tanks exterior surfaces. Evidence of leaks; shell distortions;
signs of settlement; corrosion; and condition of the foundation, paint coatings,
insulation systems, and appurtenances shall be done by plant operating
personnel in time interval not more than one month and findings should be
documented for follow-up action by an authorized inspector as per API 653 6.3.
11.2 Foundation
Although minor tank settlement was observed in inspection but it is highly

recommended to subject foundation to complete civil survey for complete
settlement assessment of tank.
11.3 Tank Roof
Roof plates which are corroded and paint failure is observed shall be repainted
in manner described in shell recommendation section.
Roof access structure meaning ladder was not seal welded at one location, it is
recommended to seal weld it properly.
Scattered pitting on roof plates needs to be monitored frequently in order to
access their growing depths.
Roof external rafters (iron angle) weld with plates were significantly deteriorated
and needs to be properly welded.
2 NPS water line at Roof manhole was found to be fouled, it should be cleaned
before bringing the tank in service.
11.4 Tank Bottom
Tank bottom plates shall be frequently monitored for assessment of corrosion

rate by suitable UT and MFL technique. It is recommended to re inspect tank
bottom internally after 01 year by UT and MFL for determination of corrosion
rate.
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12 Repair Procedure for Drawoff Sump Area
Damaged Sump area should be replaced and designed in accordance with API 650
5.8.7 and figure 5.21 and table 5.16 a. A buffer zone of 4 in (100 mm) thoroughly
filled with compacted sand or other suitable material shall be provided before
placement of sump area. Suitable NDT techniques shall be employed for fillet weld
after placement of sump area e.g. MPI or DPT. Welding Procedures used for sump
area replacement shall be prepared and qualified in accordance with API 653
Section 11.
13 Conclusion
In light of our inspection and NDT techniques applied, NGL storage tank TK-861
after suitability for service analysis being done API 653 section 4 is fit for service
provided sump area is repaired in accordance with section 12 of this report and
recommendations given in section 11 of this report are heeded in proper way. Part
wise conclusion of tank TK-861 is given below.
13.1 Tank Shell
Tank shell thickness as measured during inspection satisfies the requirement of

API 653 determined in section 9.1.1 of this report. Measured minimum value of
shell courses is greater than minimum required thickness of 2.5 mm. Next
inspection interval for UTG of shell is 5 years as corrosion rate is not known per
API 653 6.3.3.
13.2 Tank Roof
Thickness measurement, visual inspection and pit depth measurement all

corresponds to minimum required thickness of roof meeting the criteria set in
API 653 section 4.
Minimum thickness measured on roof is 6.27 mm and deepest pit measured is
2.89 mm henceforth remaining minimum thickness after pit depth exclusion is
3.38 mm which is greater than minimum required thickness of 2.286 mm set in
API 653 4.2.1.2.
13.3 Tank Bottom
As per thickness measurement in bottom plate and visual inspection, tank

bottom plates meet the criteria set in API 653 Section 4.
Minimum thickness measured in bottom plates is 5.42 mm which is greater
than minimum required thickness of 2.5 mm set in API 653 table 4.4.
of law.
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Report :2016-10082-001
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For determination of corrosion rate bottom plates shall be assessed and
inspected by suitable MFL and UT or other technique for not more than 01
years.
14 Attachments
Appendix-A Ultrasonic Thickness Measurement Reports
Appendix-B Photographic Presentation
Appendix-C Conceptual Sketches
Appendix-D Magnetic Particle Inspection Reports
Appendix-E Vacuum Box Testing Reports
Appendix-F Pit Depth Measurement Report
of law.
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Report :2016-10082-001

NDT Inspection and Complete Date: 03-08-2016

INSPECTEST SUBJECT GROUP DATE

TITLE OF REPORT DEPARTMENT PROJECT NO.

CLIENT / SPONSOR OF PROJECT / ADDRESS CHECKED BY

WORK CARRIED OUT BY REPORTED BY

1 Executive Summary .............................................................................................. 4

01 API 653 Authorized Tank Inspector

External Visual Inspection by API 653 Inspector

1. API 653 Tank Inspection Code

1. A comprehensive report from API authorized inspector in hard form.

Equipment Name : XXXX

Complete visual inspection kit

8.2 External Visual Inspection Shell Appurtenances

External visual inspection of shell appurtenances (openings, nozzles and other

8.2.1 Shell Manhole Dimensional Checks

Manhole Size: 24 NPS

8.3 External Visual Inspection Tank Foundation

Tank bottom foundation was inspected for evidence of any deterioration in

8.4 External Visual Inspection Tank Roof Access Structure

1. Ladder attachments to concrete base (corrosion, broken): 1

8.5 External Visual Inspection Tank Fixed Roof

1. Roof plate distortions: 2

8.5.1 Roof Manhole Dimensional Checks

Manhole Size: 20 NPS

Parameter As Measured Required

8.6 Internal Visual Inspection Tank Shell

8.7 Internal Visual Inspection Tank Bottom

9.1 Ultrasonic thickness gauging

9.1.1 Required Minimum Thickness Calculation for Tank Shell plates

Minimum Required Thickness (tmin) for 1st Shell Course

Minimum Required Thickness (tmin) for 2nd Shell Course

Minimum Required Thickness (tmin) for 3rd Shell Course

9.2 Vacuum Box Testing

9.3 Magnetic Particle Inspection

10 Root Cause Analysis of Sump Area Weld Failure

Design of drawoff sump area as visually observed and dimensionally measured is

11.1 Shell and Appurtenances

Points at which paint failure or corrosion is observed shall be painted (it is

Although minor tank settlement was observed in inspection but it is highly

11.3 Tank Roof

11.4 Tank Bottom

Tank bottom plates shall be frequently monitored for assessment of corrosion

13.1 Tank Shell

Tank shell thickness as measured during inspection satisfies the requirement of

13.2 Tank Roof

Thickness measurement, visual inspection and pit depth measurement all

13.3 Tank Bottom

As per thickness measurement in bottom plate and visual inspection, tank

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