Overview

MISTRAS Overview

Overview

Improved RBI Analysis of Above Ground

Storage Tanks Through the Use of On
Stream Inspections
Sam Ternowchek
Mistras Group

Overview

Internal Inspections of Tank Floors is Expensive

Overview

Inspection Frequency Considerations

a) the nature of the product stored;
b) the results of visual maintenance checks;
c) corrosion allowances and corrosion rates;

d) corrosion prevention systems;

e) conditions at previous inspections;
f) the methods and materials of construction and
repair;

Overview

Inspection Frequency Considerations

g) the location of tanks;
h) the potential risk of air or water pollution;
i) leak detection systems;

j) change in operating mode

k) jurisdictional requirements;
l) changes in service

Overview

Determine Internal Inspection Interval

O
Interval Based on Fixed
Time and/or Corrosion
Rate

OR

Risk Based Inspection

Internal Tank Assessment

Overview

API 653 Inspection Interval

Determined using the corrosion
rate procedures

6.4.2.3

Or, using the RBI procedures

6.4.2.4

Overview

Comparison
Direct Measurements in API 653: Based on the sum of the product
side and soil side bottom corrosion rates

Traditional approach for determining inspection

intervals in API 653

Tends to be a conservative approach because it is

based on the sum of corrosion rates

Inspection Interval Shorter then Necessary

False Sense of Security

Overview

Comparison
RBI Assessment with 10-Year Update Assessments based on
API 580/581 as implemented in API 653: Based on direct
measurements or conservative-provided estimates of the
bottom corrosion rates

Tends to be considered realistic estimates because

it is based on the maximum corrosion rate of the
bottom

Provides a More Optimal Inspection Intervals

Assessments performed more often

Overview

API 653 Inspection Interval

If an RBI (Risk Based Inspection) assessment has
been performed the maximum initial internal interval
does not apply to tanks
An owner/operator can establish the subsequent
internal inspection interval using risk based inspection
(RBI) procedures in accordance with API RP 580 and
the additional requirements of API 653

Overview

Factors to Consider in a RBI Assessment

The tank design and material of construction

Details about the foundation and surrounding
area
Operational history
Inspection history
On Stream Inspections
Product characteristics
Etc.

Overview

On Stream Tank Inspections

API 653 In-Service Inspection Appendix C1.1
Advance NDT Techniques
Acoustic Emission to identify active corrosion on tank floor

Automated UT for corrosion mapping on tank shell (Liquid to

air preferential pitting)
Bulk wave UT for corrosion detection in critical zone

Pulsed Eddy Current and MWM for CUI

ADVANCE NON-INTRUSIVE SOLUTIONS

TO TANK INSPECTION
Overview

What is Acoustic Emission (AE)

Overview

Passive Listening Technique using Piezo Electric

Transducers

AE AE Sources from Corrosion

Overview

AE
Sensor

Active Corrosion
process

ACOUSTIC
EMISSION
Fracture Decohesion of
precipitation
Metal Dissolution
Thick oxide breakdown
Hydrogen evolution
Corrosion products
spalling

Overview

16

Acoustic Sources Detected

Overview

Sources of interest:

Spalling of corrosion products.

Leak noise: flow interruption, or turbulence.

Extraneous noise to be removed:

Roof and structural movement.

External and pipe-borne noise.
Condensation, particle impacts and valve
leakage.

Corrosion of Internal Zinc Anodes

Overview

Internal sacrificial anodes

corrode in place on tank
floor.
Zinc blocks can be large.
Oilfield production tanks use
sacrificial anodes-very
active when coating has
failed, until zinc used, then
floor corrodes.
Emission from active anodes in a
180 foot diameter tank, 6 ft. x 3 ft. in
size, (30 in tank, 4/10/16)

Overview

Recommendations Matrix
Overall Grade A

PLD Grade

(2)

(2)

.5

.5

.5

.5

.5

.5

.5

.5

Clearly leaking tanks often unable to grade, (should be opened anyway).

3-D View of a Bad - E Grade

and a Good A Grade
Overview

FOLLOW UP INTERNAL INSPECTION

Overview

What is the Reliability: *

Overview

Follow-up results versus AE-grades, normalised per AE-grade

population of 157 tanks (Shell, Dow-Stade, DSM,
120

Relative

100
80
60
40
20
0
A

AE-grade
FU 1/2 Minimal damage: no repairs

FU 3 Damage: some repairs

FU 4 Significant damage: major repair/new floor

* P.van de Loo/Shell, B.Hermann/Dow, ECNDT 1998

Annular Ring UT Inspection

Overview

Long-Range Automated Ultrasonics

(LRUT) Annular Ring Test for Tanks
Overview

Gives condition
information about
critical annular area.
Test with Bulk Wave
Ultrasonic
In-service test.
Manual or semi
automatic

Targets

500m
m

LRUT Annular Ring Test

Overview

SHELL:

LRUT

Inspects critical area,

~20-30 cm.
Automated UT, Plan
image.
Detects first edge of
corrosion
40 m/day.
Indicative, not
quantitative.

PLAN VIEW IMAGE SHOWING

SEVERE UNDERSIDE CORROSION

Tank Shell Surveys

Overview

CUI Corrosion Under Insulation

MR-MWM-Array
Inspection of Corrosion
Through Protective
Barriers
JENTEK Sensors, Inc.
110-1 Clematis Avenue, Waltham, MA 02453-7013

www.jenteksensors.com

Slide

27

Copyright 2014 JENTEK Sensors

All Rights Reserved.

CUI - Technology Summary / Overview

1. Sensors: MR-MWM-Arrays

Paradigm shift in sensor design (first priority is

predictable response based on physics-based
modeling)

2. Next Generation 8200 GridStation

Electronics

Very low frequencies (deep penetration)

High data rates
Minimal drift

Scan
Direction

l /4

3. GridStation Software using Hyperlattices

Analysis
MWM sensor

Rapid, autonomous data analysis

Performs multivariate inverse method
(MIM) using precomputed databases

Defect Images
Performance Diagnostics
Noise Suppression

Lift-Off

Thickness

Images

h (lift-off)

m
(permeability)

Solve Multiple Unknown Problems

MIM

D (Thickness)
Imaginary (Im)

Real (Re)

Slide

28

Copyright 2014 JENTEK Sensors

All Rights Reserved.

Overview

An Example Tank Management Program

Plant Condition Monitoring Software - PCMS

29

Overview

Background
PCMS Captures all operating and design information as it
relates to facility tankage
PCMS evergreens the RBI process per tank circuit, taking
into account
Operating information
Current corrosion rates
Historical Inspections
On Stream Inspections
API 653 Visual Inspections recorded within PCMS
Scheduling Flexibility (RBI/Corrosion/Fixed Based Interval)

Overview

TANK RBI SCREENING

PCMS defines tank damage
mechanisms per mode
PCMS automatically
screens which damage
mechanisms the tank is
susceptible to.
PCMS calculates both base
and current Probability of
Failure

Overview

TANK RBI SCHEDULING

PCMS will notify inspector what damage mechanisms to inspect for
PCMS generates an inspection plan per intrusive/extrusive inspection
types, and effective techniques to use to detect potential damage
mechanisms (customizable)
User has option to schedule by fixed /corrosion/RBI based intervals

Overview

RBI MATRIX
Tank circuits are plotted in the
RBI Matrix
Plotting takes into
consideration POF and COF
(Probability and Consequence of
Failure)
Consequence values are
configured per facility
RBI Matrix is customizable

Example - Initial Internal Inspection Interval

Original Design

life > 10 years

25 years max
20 years max

for original High

rank

Risk Assessment
2012 MISTRAS GROUP, INC. ALL RIGHTS RESERVED. DISSEMINATION, UNAUTHORIZED USE AND/OR DUPLICATION NOT PERMITTED.

Extensions
Overall
Grade

(2)

.5

.5

.5

.5

.5

.5

.5

.5

PLD Grade

2012 MISTRAS GROUP, INC. ALL RIGHTS RESERVED. DISSEMINATION, UNAUTHORIZED USE AND/OR DUPLICATION NOT PERMITTED.

Benefits of RBI
Overview

Identify tanks which do not require immediate

internal inspection and repair Saving MONEY

Determine the condition of damaged floors so that a

correct priority for internal maintenance may be set

Better scope of work when planning tank opening

Reduce down time when out of service

Do the above with little or no disruption to operations

Help prevent tank leakage

Overview

In Conclusion - RBI Assessments

May lengthen or shorten the inspection interval

May result in additional focused inspections

Allows a company to focus its resources

On Stream Inspection Improve the accuracy of RBI

Overview

QUESTIONS ????

Overview

MUCHAS GRACIAS
Sam.Ternowchek@mistrasgroup.com