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To keep up with the increasing demand for LNG and for effective practical use, Osaka Gas started to demolish
the two conventional LNG storage tanks in 2011, and now a large LNG storage tank of 230,000m3 has been
under construction since September 2012.
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 tanks material and its thermal insulation material jointly with IHI as the constructor
and Nippon Steel & Sumitomo Metal Co., LTD (NSSMC) as the supplier of tanks steel products. Moreover, we
examined the steel pipe piles and the instrumentation devices from Osaka Gass 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)
5)
Deterioration of concrete
6)
7)
Internal liquid
Capacity
Type
LNG
45,000KL
single containment type with double steel walls
Dimensions
inner tank
outer tank
Diameter
44,600mm
46,400mm
Height
28,820mm
31,850mm
Roof radius
35,700mm
36,600mm
-162
ambient temp.
0.12kg/cm2
50mmH2O
carbon steel
Design temp.
Design pressure
Main material
Insulation
Thickness of insulation
10
Foundation slab
thickness ;800mm
reinforced concrete
11
Dike
12
Earthquake history
13
Commercial operation
Sampling Part
Chemical
Component
Analysis
Tensile Test
Charpy
Impact Test
CTOD Test
Duplex
Esso
Test
K31
(A5083)
1st Course
13th Course
Annular Plate
Bottom Plate
K11
(9%Ni-Steel)
1st Course
13th Course
Annular Plate
Bottom Plate
Si
Fe
Cu
Mn
Mg
Zn
Cr
Ti
0.08
0.10
0.01
0.67
4.51
<0.01
0.10
0.01
<0.005
0.08
0.12
0.01
0.65
4.39
<0.01
0.10
0.01
<0.005
0.11
0.13
0.01
<0.005
0.1
0.10
0.05
~0.25
0.01
0.4
4.44
4.0
~4.9
<0.01
0.4
0.67
0.3
~1.0
0.15
0.25
Si
Mn
Ni
0.09
0.30
0.59
0.006
0.005
8.76
0.08
0.28
0.59
0.004
0.002
8.80
0.09
0.28
0.62
0.0054
0.004
8.67
0.09
0.26
0.55
0.009
0.008
8.80
1)
Rolling
Direction
L
C
L
C
L
C
-
0.2% Proof
Stress [MPa]
136
139
153
139
160
139
125 (0.8<t40)
120 (40<t80)
Tensile
Stress [MPa]
297
303
304
302
299
303
Elongation
[%]
23
24
20
21
18
22
275 (0.8<t80)
Rolling
Direction
L
C
L
C
L
C
0.2% Proof
Stress [MPa]
708
706
722
719
723
714
Tensile
Stress [MPa]
761
762
767
767
776
769
Elongation
[%]
36
36
29
27
28
28
723
779
35
590
690
Sampling Part
Weld Joint
Chemical
Component
Analysis
Tensile
Test
Charpy
Impact Test
CTOD Test
Wide Plate
Test
Bending
Fatigue
Test
K31
(A5083)
1st Course
1st&2nd Course
13th Course
Annular Plate
Vertical
Horizontal
Vertical
Fillet
K11
(9%Ni-Steel)
1st Course
1st&2nd Course
13th Course
Annular Plate
Vertical
Horizontal
Vertical
Fillet
Process
K31 (Aluminum)
Material
Groove
Process
K11 (9%Ni-Steel)
Material
Groove
JIS Z 3224
ENi 6133
(AWS 5.10
ER5183)
(AWS 5.11
ENiCrFe-2)
MIG
Bottom Plate
One Side
Lap Weld Joint
Table 3.8. Macro Structure of Vertical Weld Joint of Shell Plate 1st Course
K31
Aluminum Tank
K11
9%Ni-Steel Tank
Si
Fe
Cu
Mn
Mg
Zn
Cr
Ti
0.08
0.10
0.01
0.67
4.51
<0.01
0.10
0.01
<0.005
0.09
0.11
<0.01
0.66
4.35
<0.01
0.10
0.01
<0.005
0.08
0.12
0.01
0.65
4.39
<0.01
0.10
0.01
<0.005
0.11
0.13
0.01
0.67
4.44
<0.01
0.10
0.01
<0.005
0.40
0.40
0.10
0.50
~1.0
4.3
~5.2
0.05
~0.25
0.25
0.15
Si
Mn
Cu
Ni
Cr
Mo
Nb
Al
Fe
0.06
0.26
1.79
0.010
0.0032
0.05
63.9
13.6
0.69
2.18
0.098
Bal.
0.08
0.26
1.89
0.009
0.0028
0.10
67.0
15.7
0.73
2.17
0.105
Bal.
0.07
0.22
1.77
0.009
0.0028
0.05
62.5
12.2
0.65
1.90
0.102
Bal.
0.08
0.28
1.90
0.010
0.0023
0.00
66.7
15.0
0.73
2.20
0.091
Bal.
0.05
0.29
1.92
0.008
0.010
68.3
15.5
0.73
2.29
(+ Ta)
10.8
[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 doesnt across the ages.
[K11]
The same as K11 tank, these results conform to the specs of JIS Z 3224 (AWS 5.11 ENiCrFe-2).
(b) Tensile properties
Tensile tests were carried out using specimens: a full thickness specimen taken from different parts of the
welded joints in accordance with JIS Z 3121 No.1A, but the excess weld metal was not ground. Each tensile
test was performed at room temperature in accordance with JIS Z 2241.
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)
Sampling Part
Tensile
Stress [MPa]
297
303
Fusion Line
~HAZ
298
Base Metal
275
Requirement
1)
10
Fracture
Location
Fusion Line
~HAZ
Table 3.12. Results of Tensile Test (K11 9%Ni-Steel Tank Weld Metal)
Tensile
Stress [MPa]
Fracture
Location
Construction
Management Test
Tensile
Stress [MPa]
756
Weld Metal
761
756
Base Metal
767
781
Base Metal
788
Requirement
1)
[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.
(c) Charpy Impact Properties
Charpy impact tests were carried out on weld joints of K11 tank, machining the notch at center of weld metal,
fusion line (FL: 50% weld metal + 50% heat affected zone), FL+1mm, FL+3mm, FL+5mm, using specimens in
accordance with JIS Z 2202 and 3128. Notch is 2mm depth, V shape. The central axis of the specimen was the
same as base metal. The tests were carried out at -196 deg C in accordance with JIS Z 2242.
Figure 3.2 shows the results of Charpy impact tests. All plates conform to the requirements1). Those
results have indicated that the weld joints dont 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.
3.3 Corrosion survey on corrosion of foundation piles
3.3.1 Purpose and method
Corrosion countermeasure for foundation piles is important for maintenance of LNG tank substructure. Osaka
Gas adopts a corrosion allowance by adding 2mm margin to the specification of foundation piles in
construction design as a corrosion countermeasure. Meanwhile, heads of piles are bonded in advance during
construction so that a cathodic protection can be applied in preparation for significant corrosion progression in
service. Moreover, the installation method of electrodes using a horizontal boring technique for cathodic
protection has been developed, and the corrosion condition has been monitored in order to judge the necessity
of cathodic protection.
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.
12
(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.
13
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
Corrosion content (mm)
Figure 3.5. Corrosion content
3.4 Deterioration survey for concrete
3.4.1 Purpose and scope
Diagnostic evaluation for concrete structure used for 40 years was undertaken based on chloride ion content,
carbonation depth and compressive strength of concrete used for the base slab and dike of LNG storage tank.
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.
Underside of base slab
Side surface of base slab
3.4.2 Result
(a) Chloride ion content
Chloride ion content as measured at each 20cm depth for 7 measuring points at t underside of base slab and
for 5 measuring points at each side surface of foundation slab and dike. Figure 3.7 shows the chloride ion
content. The covering depth of base slab and dike is 85~105mm, and the chloride ion content at the reinforcing
steels was lower than 2.5kg/m3 that specified as criteria of corrosion durability. Also, it shows that almost no
chloride ion content made inroad into the underside of base slab.
Carbonation depth
(mm)
Underside
of base slab
Side surface
of base slab
Dike
Compressive strength
(N/mm2)
Underside
of base slab
Side surface
of base slab
Dike
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.
3.5.1 Thermometer for Roll-over
(a) Outline of Thermometer for Roll-over
Here is the detail of Thermometer for Roll-over.
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.
16
Sheath material
: SUS316
: 4.8mm
Sheath length
Classification
: 0.5
Detection element
: Platinum resistor
(Standard resistance value : Pt100 at 0 (JPt100))
Conductor
: 3-wire type
Table 3.13. The result of insulation resistance test and region of insulation degradation
Insulation resistance
Thermometer No.
No.3LNG tank
[M]
Region of insulation
degradation [m]
(distance from the head)
12
11
0.1
(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 thermometers 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.
3.5.2 Guide wire for Float type level meter
(a) Outline of Float type level meter
Here is the detail of Float type level meter.
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.
Applied standard
: JIS G 3550
Material
: SUS304
Product name
Constructive number
: 719
Length
: approx. 37.5m
Diameter of wire
: 10mm
Diameter of strand
: 0.67mm
Total times of
tank [m]
round-trip [time]*
Sample 1 (upper)
33
Sample 2 (middle)
17
1,000
Sample 3 (lower)
200
* Total times of round-trip after the installation are estimated from liquid level change for a year in 2010.
1) Observation of appearance / gauging of diameter
We inspected the worn volume of sampled wires and their strands by visual and a digital microscope.
Also, we gauged the diameters of each sample to compare the values to the standard criterion of JIS
and among the samples obtained from each position.
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.
(d) Result of inspection
1) Observation of appearance / gauging of diameter
Figure 3.13 shows the pictures of wires appearance and their diameters. There was no thinner wire
than 10mm (the criterion specified in JIS G 3550) and no difference was found among each position.
Red rust was found on some wires however it could be wiped off easily (it is supposed that this red rust
adhered at the removing work).
Figure 3.14 shows the pictures of strands 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.
19
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.
Table 3.15. The result of tensile test for wires
Breaking force of wire [kN]
Standard breaking
force of wire [kN]
Upper
61.8
Middle
Lower
64.0
68.2
64.8
71.4
66.8
72.2
Upper
Middle
Lower
Upper
Middle
Lower
2037
2036
2009
2102
2179
2169
2030
1996
2044
2089
2185
2094
2100
1962
2052
2089
2127
2149
1996
2000
2016
2169
2146
2163
2038
1978
2036
2137
2194
2135
2056
1989
1990
2143
2165
2114
Average
2043
1994
2025
2121
2166
2137
Standard breaking
force of strand [MPa]
1850~2100
(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.
20
Thermal conductivity(T.C.)
W/mK)(at 0
Ratio
*1
0.0433
0.98
0.0429
0.97
0.0391
0.88
0.0399
0.90
specification
0.0442
1.00
21
*1
specification (N/cm )
Ratio
1470
1955
1.33
Specification (W/mK)
Ratio
0.93
0.309
0.33
Specification (W/mK)
Ratio
0.1163
0.10028
0.86
22
Ratio*1
0.1163
0.10782
0.93
23
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
tanks 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
24