STATUTORY INTERNAL

INSPECTION OF PENTANE
BULLETS & NAPTHA STORAGE
TANKS

PREPARED BY: MANISH SINGH

 Why Internal Inspection is Required :

 For ensuring operational safety requirements as well as to comply with the statutory
requirements (including Gujarat Factories Rules- 1963 and OISD Std -129), the
internal inspection consisting of various NDT tests needs to be done.
 What is NDT?

 Nondestructive testing is a wide group of analysis techniques used

in industry to evaluate the properties of a material, component
or system for discontinuities, or differences in characteristics
without destroying the serviceability of the part or system.
 Non-Destructive Testing (NDT) is proving to be an extremely
effective way for businesses to save time and money. These
types of testing technologies help companies test for quality
assurance and identify areas of risk or corrosion before they
become problematic.
 Why NDT?

NDT does not directly measure Mechanical properties but they are used to locate defects or
flaws in the component to prevent premature failure even with a sound design and proper
selection of materials.
 To obtain high level of reliability. To achieve this, defects should be or at minimum level.
 Leak detection. Hence minimizing chances of catastrophic failure.
 Dimensional measurements.
 Estimation of Mechanical and Physical properties.
 Stress and dynamic responses measurements.
 Material Chemical composition determination
 MAJOR TYPES OF NDT

DETECTION OF INTERNAL FLAWS

DETECTION OF SURFACE FLAWS
 Radiography
 Visual Inspection
 Ultrasonic Testing
 Magnetic Particle Inspection
 Eddy Current Testing
 Fluorescent Dye Penetration Inspection
 VARIOUS NDT TECHNIQUES TO BE USED AS
PER OISD-129 FOR INTERNAL INSPECTION
OF STORAGE VESSELS/TANKS
S/N EXAMINATION TYPE OF DEFECTS EXAMINED AREAS COVERED
TYPE
1 Visual Examination Corrosion, Pitting, Cracks, External under 100% Surface from Inside & Outside
Insulation (Fireproofing)
2 UT Thickness Significant thickness degradation All Petals, Dished End & Nozzles, Shell,
Measurement (As per (Corrosion allowances in Naptha Tank, Bottom Plate, Deck Plate, Drain Piping,
ASTM-A-455-89) For Shell Plate is 1.5 mm Nozzle
Annular & Bottom Plate is NIL
Roof Plate is 0.5 mm)
3 Dye Penetrant Test Significant linear defects (Surface cracks) Nozzles fillet weld joints, Fillet joints of
(ASTM-E-165-80) Support, Staircase joint, wind gutter & any
other area not covered by MPI

4 Hardness Measurement Significant Hardness Deviation Random- All circular & vertical welds and
(ASTM-E-110) its corresponding HAZ including Bottom
plate and Annular Plate
S/N EXAMINATION TYPE TYPE OF DEFECTS EXAMINED AREAS COVERED

5 Wet Fluorescent Magnetic Particle Significant linear defects (Surface & sub- 100% of all weld joints from Inside and
Test (ASTM E-709) surface cracks) Weld joints of Top deck from outside

6 Ultrasonic Flaw Detection (ASTM Internal Defects On weld not less than 25% of weld
A-522-89) seams including all ‘T’ joints of middle
circumferential seams, Nozzle joints

7 Vacuum Box Test Leak from Weld joint All weld joints of Bottom Plate and
annular plate

8 Hydrotest or Water fill test Leak from Weld joint/Parent material All External surface, flange joints
VISUAL INSPECTION

Area to be covered

Protective Coatings

Roof Plates

Ladders, Stairways, Platforms
and Structure

Tank Pads

Anchor Bolts

Fire Fighting System

Vents & Pressure Relieving Devices

Insulation

Grounding Connections

Leaks

Roof Drains
 APPLICATIONS OF VISUAL INSPECTION

Remote visual inspection using a

robotic crawler : It permits
observations in Hazardous or
tight areas such as air ducts, Portable video inspection unit with zoom: It allows
reactors, Pipelines. inspection of Gas Turbines, Compressors, Tubing's.
 ADVANTAGES LIMITATIONS

 Limited to only surface

 Cheapest NDT method
inspection
 Applicable at all stages of  Require good lighting
construction or manufacturing
 Require good eyesight
 Do not required extensive training
 Capable of giving instantaneous
results
 UT MEASUREMENT

 Wall thickness measurements are especially important in corrosion

studies where corrosion can cause a uniform reduction in wall
thickness over a period of time.
 When an electrical pulse is applied for a short period, a piezoelectric
element in the transducer generates a burst of ultrasonic waves which
passes through a test piece. Transducers convert sound energy into
electrical energy when the sound energy returns to them.  The time
taken for a sound pulse to be reflected from a test piece’s inner or
outer wall is measured by an ultrasonic transducer. The sound waves
are reflected off the edges of dissimilar materials, resulting in a
“pulse/echo” mode for this type of measurement.
 ADVANTAGE LIMITATIO
S NS

 Requires calibration for each

 Does not require access to both sides of the sample material
 Can be engineered to cope with coatings, linings, etc.  Requires good contact with the
 Good accuracy (0.1 mm and less) can be achieved using material
standard timing techniques  Requires coupling material
 Can be easily deployed at site, does not require laboratory between the measured surface and
conditions the probe. (Does not apply to
EMAT)
 Relatively cheap equipment
 Needs experienced operator
 EMAT does not require the use of couplant.
 EMAT can conduct thickness measurements through corrosion
and other surface coatings on metals
 DYE PENETRANT TEST

DPT is an NDT method that utilizes the principle of Capillary action in which liquid of suitable physical properties can penetrate
deep into extremely fine cracks or pitting that are opened to the surface without being affected by the gravitational force.
 LIMITATIO
ADVANTAGES NS

 Limited to detection of surface

 Simple to perform
breaking discontinuity
 Can be applied to almost  Not applicable to porous
any type of material. material and Powder
 Applicable to materials metallurgical components
with complex geometry  Require access for pre and
 Inexpensive post cleaning
 Fast interpretation of  Irregular surface may cause
results the presence of non-relevant
indication
 MAGNETIC PARTICLE INSPECTION

 It utilizes the Principle of Magnetization

 Magnetic field is established within and in the vicinity of the material.
 Finely milled iron particles coated with dye are applied to specimen.
These magnetic particles are attracted to magnetic fields and will
cluster to form an indication directly over the discontinuity.
 The presence of surface breaking and subsurface discontinuity on the
material causes the magnetic field to leak and travel through air.
 In wet MPI, liquid carrier allows small magnetic particles to flow
easily to small leakage fields and detect very small discontinuity.
 This indication can be visually detected under proper lighting
conditions
EXAMPLES OF VISIBLE MAGNETIC PARTICLE
INDICATION
 LIMITATIO
ADVANTAGES NS

 Inexpensive  Applicable only to

ferromagnetic materials
 Equipment's are portable
 Insensitive to internal defects
 Equipment’s are easy to
operate  Require magnetization and
demagnetization of materials
 Sensitive to surface and
to be inspected
sub-surface discontinuities
 Require power supply for
 Provide instantaneous
magnetization
results
 ULTRASONIC FLAW DETECTION

 High frequency sound waves are introduced into a material and they are reflected back from surface or
flaws
 Reflected sound energy is displayed versus time, and operator can visualize a cross section of the
specimen showing the depth of features that reflect sound.
 LIMITATIO
ADVANTAGES NS

 Require highly skilled and experience

operator
 Required only one side accessibility  Require use of couplant to enchance sound
 High Sensitivity, better accuracy and transmission
reliability  Require calibration blocks and reference
 Capable of detecting internal defect standards
 Applicable for Thickness measurement,  Not so reliable for surface and sub-surface
detection of discontinuity discontinuity due to interference between
 Can provide size of discontinuity initial pulse and signal due to discontinuity
 Non-hazardous and mostly portable  Irregular shaped and rough parts are very
difficult to examine.
 RADIOGRAPHY TEST

 It utilizes X-Rays or Gamma radiation to detect discontinuities in materials and to present their image
on recording medium.
 The source of radiation can be from radioactive sources like Ir-192, Cobalt-60, Cs-137, which emit
gamma rays or from specially built machine that can emit X-rays.
 The radiation used in radiography testing is a higher energy (Shorter wavelength) version of the
electromagnetic waves that we see as visible light. The radiation can come form an X-Ray generator or
a radioactive source.
 Rays are absorbed by the materials through which they are passed in the proportion of their density.
After passing through the components, show a picture on a fluorescent screen or on a photographic
plate.
 The cracks, blow holes and cavities appear lighter, whereas inclusions of impurities appear darker than
the metal component.
 LIMITATIO
ADVANTAGES NS

 Applicable to almost all materials due  Radiation used is Hazardous for living
to its adjustable energy level beings
 Highly sensitive  Expensive method
 Number of samples can be inspected at  Incapable of detecting laminar discontinuity
a time  Results are not instantaneous
 Produce permanent images that are  Require highly trained personnel
readily retrievable for future reference
 Capable of detecting surface, sub-
surface and internal discontinuities.
 Many equipment’s are portable
 HARDNESS TEST

 Hardness can be defined as the resistance of a material to an applied pressure

or force.
 The Brinell hardness number (BHN) is calculated by dividing the load applied
by the surface area of the indentation.
 The Brinell hardness test consists of applying a constant load, usually in the
range 500–3000 N, for a specified period of time (10–30 s) using a 5 or
10 mm diameter hardened steel or tungsten carbide ball on the flat surface of a
work piece.
 The standard ball for Brinell testing is 10 mm (±0.005 mm) in diameter and
should have a minimum hardness of 850 HV.
 Hardened steel balls can be used for testing material up to 444 HB, while
tungsten carbide balls are recommended for measuring hardness values
 beyond 444 HB and up to 627 HB.
 VACUUM BOX TEST

 Vacuum box testing is a non-destructive examination used when trying to locate weld seam leaks. A vacuum
box and a compressor create a high or low pressure vacuum while a detergent solution is applied to the test area.
The detergent bubbles, making leaks visible within the created pressure envelope.
 LIMITATIO
ADVANTAGES NS

 Size and orientation of any

 Provides an immediate leaks will have to be
visual indication of the analyzed with a secondary
location of any leaks NDT method
present
 For standard testing surface
 Can detect small leaks temperature of the test
within a given area material must be between
5°C and 50°C.  Otherwise, a
procedure effective at the
temperature range must be
demonstrated.
 HYDROTEST

 Hydro testing, more formally called hydrostatic testing, is a

type of test that is performed on pressure vessels to check
for leaks. It is a type of pressure test that works by
completely filling the component with water, removing the air
contained within the unit, and pressurizing the system up to
1.5 times the design pressure limit the of the unit. The
pressure is then held for a specific amount of time to visually
inspect the system for leaks. Visual inspection can be
enhanced by applying either tracer or fluorescent dyes to the
liquid to determine where cracks and leaks are originating.

 Although hydrostatic testing is considered to be a nondestructive testing method, equipment can rupture and fail
if the inspection exceeds a specified test pressure or if a small crack propagates rapidly.
S/N Description of Parameters Pentane Bullet Naptha Storage Tank
Major dimensions of the storage vessels
1 Shell Thickness (mm) 18 6
2 Dish end thickness (mm) / Floating Roof thickness (mm) 18 8 & 10 (Double deck floating roof)
3 Internal & Outer Shell diameter (mm) 3964 & 4000 10500 & 10512
4 Equipment length (mm) TL to TL/ Height  21000  7500

5 Overall length from Dish end to Dish end (mm) 23400  7500

6 Process Fluid Pentane Naphtha

7 Corrosion Allowance (mm) 1.5 1.5
Material of construction of storage vessels
8 Shell SA 516, GR- 70 IS : 2062 GR- A
9 Dish / head / Roof Plate SA 516, GR- 70 IS : 2062 GR- A
10 Nozzle Flanges SA 105 SA 105
11 Nozzle flange up to 250 NB SA 106, GR- B IS : 2062 GR- A
12 Pipe Fittings SA 234 WPB SA 234, WPB
13 External Studs / bolts / nuts SA 193, GR- B7 / SA 194, GR- 2H IS : 1367 CL 4.6 / CL4.0
14 Internal Studs / bolts / nuts SS 304 SS - 304
15 Internal Parts SA 516, Gr- 70/ SA 106, GR- B SA 106, GR- B / IS:2062 GR- A

Other Design parameters of Vessels

17 Design code rules ASME Sec- VIII, Div- I, 1998 API- 650 (10th Edition, 1988)
18 Design pressure kg/cm2(g) 3.50 Full of liquid
19 Design Temp. (C) 55°C 65°C
20 Working pressure kg/cm2(g) 0.54 Atmosphere
21 Working Temp. (C) Ambient Ambient
22 Capacity (m3) 277.20 537
23 Hydro testing pressure kg/cm2 (g)  5.25  Water Filling Only
(EXTERNAL DOUBLE DECK FLOATING ROOF
TYPE)
DOUBLE DECK FLOATING ROOF
 WHY DOUBLE DECK FLOATING ROOF

 To protect the product inside the tank from evaporation to the atmosphere and contamination from the rain water.
 Double deck roof is much heavier than single deck one, hence it is more rigid. The air gap between the upper and
bottom plates of the deck has insulation effect which helps against the solar heat reaching the product during the
hot climate and preventing heat loss of the product during cold climate.
Advantages of floating roof tank
 Floating roof tank is the most economical and efficient solution for reducing emission and product loss by
evaporation.
 Floating roof tanks reduce the risk of explosion and fire in above ground storage tanks for extremely volatile
organic liquids.
 Protection against the possibility of implosion.
 Floating roof tanks keeps the stored oil pollution-free against rain, wind, sand, snow, or dust.
NAPTHA STORAGE TANK ROOF WITH TANK
APPURTENANCES
 TANK APPURTENANCES

 Rim Seal : In order to prevent costly and sometimes dangerous losses of volatile fractions of the stored
product, it is necessary to provide a seal in the space between the floating roof rim and the tank shell and
also to provide some means for maintaining the floating roof in a centered position within the tank shell.
 Rolling Stairway with track
 Wind Girder : The purpose of the stiffening ring (wind girder) is to maintain tank roundness when a
tank is subjected to wind load. The girder can also be used as an access and maintenance platform.
 Still well & Level Indicator (Floating Type): Stilling wells are cylinder-shaped chambers that are
connected to, but isolated from, a channel’s main flow of water. Capturing a portion of water inside of a
stilling well helps to quiet the interfering turbulence found in the main channel.   small connector links the
stilling well to the main channel, which allows it to rise and fall at the same rate (minus the turbulence).
 TANK APPURTENANCES

 Tank Auto Bleeder Vent : Comes into operation either when the
floating roof is being landed, and the tank is drained down, or when an
empty tank is being filled. This is the only device responsible for
Inbreath/ Outbreath venting (caused both by liquid movements
and thermal effects)
 RIM vent with pressure relief valve : There are instances where
entrained vapour may be released into the tank from the filling pipeline.
This surge of vapour would seek release from the tank via the rim gap
and the resulting build-up of pressure could cause damage to the sealing
fabric. To prevent this, a vent tube may be fitted between the outer rim
and the upper deck of
 Emergency drains & Roof Drain Sump
 RIM SEAL OF A FLOATING ROOF TANK

 To allow the roof to rise and fall, both internal and external floating roof
tanks are built with a circumferential seal.
 It basically runs against the side of the tank and as the liquid level moves
up and down, it maintains constant contact with the tank wall to ensure that
the liquid does not flow past the seal.
 A single seal is usually enough to allow some vapors to escape. Yet, the
typical practice is to provide a secondary seal over the first seal.
 This is done to prevent the release of most gases and vapors, thereby
protecting the environment and increasing safety.
 Floating roof seals shall be visually inspected every year. All seals shall be
inspected visually for corroded, eroded or broken parts and deteriorated
sealing materials.
 RIM SEAL FIRE PROTECTION SYSTEM

 It is designed to detect and extinguish fire in the Rim Seal area of the Floating Roof Tank at the incipient
stage. The system is fully automated in operation and uses the latest state of the art technology based on Hollow
Metallic Tube for early detection.
 ROOF SUPPORT LEGS

 Support Legs : Floating roofs are provided with pipe support

legs. These support legs support the roof when the roof is not
floating and landed. During normal operation pipe support legs
are kept in low leg position. When the roof is landed for repair or
cleaning, the support pipes are kept in high leg position to
provide more head room for persons working inside the tank.
ROOF DRAIN ROLLING
STAIRWAY
THANK YOU