Neil Henry, ABB Consulting, January 2013

European Oil Storage Conference

Managing and Maintaining Tank Integrity

ABB Group
January 22, 2013 | Slide 1
Maintaining tank integrity- overview

Life extension and maintenance:

managing the assets

Concerns about ageing storage tanks

What causes storage tanks to deteriorate?
- how this influences integrity
- specific and proven case studies
Types of storage tank and materials of construction
Practical advice on how can integrity be managed

ABB Group
January 22, 2013 | Slide 2
Introduction
Tanks are in all shapes and sizes
Most are of carbon steel (some stainless steel)
Certain duties are pressurised (eg liquified gas)
Can be very large inventory of hazardous fluid
Service life can be very long (over 70 years)
May have very limited inspection
Large numbers manufactured of non-metallic
materials

An ageing forgotten asset?

ABB Group
January 22, 2013 | Slide 3
Ageing tanks a riveting subject

ABB Group
January 22, 2013 | Slide 4
Why is there a concern?
COMAH Competent Authority Priority area for UK (Seveso
directive)

50% of European major hazard losses of containment

are primarily due to ageing plant mechanisms
(Ageing Plant Operational Delivery Guide June 2010)
30% of potential major accident incidents associated with
ageing of one type or another
(HSE Research Report 823)
ABB experience - there is often limited knowledge of
condition of storage tanks (and other COMAH equipment)
to assess if deterioration is a problem.
(ABB contributed to the HSE Research Report 509)

There is a need to understand the potential for

deterioration and the stage of life that the item is at.
ABB Group
January 22, 2013 | Slide 5
 Ageing Plant Not us?

The quotes below are typical examples from organisations and individuals
that are not recognising or not acting on the signs of ageing

There havent been any problems up to now, so the equipment is

safe, isnt it?
We dont have any drawings for this vessel; and we dont know what
the material is.
Its only been in service for two years so it cant be ageing.
The integrity of our equipment is separate from our safety
management.
Our equipment does not contain defects.
We maintain and inspect only equipment to meet the PED (UK
Pressure Systems Safety Regulations) and usually stock tanks are
not pressure vessels.

Ref: HSE RR 509 Plant Ageing Management of equipment containing hazardous fluids or pressure

ABB Group
January 22, 2013 | Slide 6
 Current Performance on Ageing Plant

Ref: IChemE Loss Prevention Bulletin 224, April 2012 - Management of Ageing Plant, S Pointer HSE

ABB Group
January 22, 2013 | Slide 7
 Management of Life
For ageing and vulnerable items do we recognise the potential for defects?

Identify potential failure scenarios based on condition eg. base leak, hole in shell.

Contingency plan for leaks / defects to manage safety:

Transfer of inventory
Temporary repair
Continue operation and manage leak / defect
Shutdown

Condition assessment
Materials and deterioration modes
Operating conditions
Recognition of change

Plan for business requirements

Funding
Resources / contracts
Planned outage

ABB Group
January 22, 2013 | Slide 8
Why does equipment fail? Investigation Data.

ABB Group
January 22, 2013 | Slide 9
Failure patterns of 40 years ago

ABB Group
January 22, 2013 | Slide 10
What affects asset life?
Life-limiting factors assumed at design stage
Design quality
Design
Quality of original fabrication & installation
Construction Operating within design limits

Suppliers Knowledge of equipment condition e.g.

Inspection of static equipment

Operation Condition Monitoring of rotating equipment

Obsolescence of equipment

Inspection

Maintaining equipment in fit for service condition Maintenance

Quality of spare parts and repairs
Modifications
Change of equipment or operating procedure that
negates original design assumptions

Asset Life Factors Across the Life Cycle

ABB Group
January 22, 2013 | Slide 11
Is integrity managed?

Application of an RBI process (typically API 571)

Describes 60 plus deterioration mechanisms
(refinery bias)
Is a guide to deterioration (recommends
specialist assistance)
Significant resource / time commitment
Not always considered for storage

ABB Group
January 22, 2013 | Slide 12
Fuel storage problems
Corrosion of tank shell is usually localised
Tank base particularly vulnerable:
External deterioration (Kerosene)
Internal corrosion / microbiological action
Corrosion of roof occurs (diesel & fuel oil duties)
Hydrogen sulphide (H2S)
Water vapour
Floating roof location most vulnerable (petrol storage)

ABB Group
January 22, 2013 | Slide 13
Fixed roof tanks - Tank uplift

Although low pressure, there are significant loads from the pressure
on the roof
If force up > weight of roof + shell, tank needs hold down

Small pressure LARGE area

LIQUID
TYPICALLY
1/4" THICK WELD
TEARS

1/4" THICK

ABB Group
January 22, 2013 | Slide 14
Frangible roof design

Tanks are weakest at the shell-to-base weld

Light seal weld in roof designed to protect against
catastrophic failure at base from overpressure
See EEMUA 180 for guidance on design specification
Ensure relief devices are correctly sized and maintained

ABB Group
January 22, 2013 | Slide 15
Floating roof problems
Vulnerable to poor water drainage
Pontoons can corrode and sink
Seals deteriorate (fire potential)
Corrosion to walkway causing it to seize
Corrosion to roof support leg housings

Sunken roof
Poor water
drainage
Rim Seal

ABB Group
January 22, 2013 | Slide 16
External corrosion - Shell, roof and base
External corrosion / pitting to shell and roof paint system breakdown

Corrosion / pitting to under-side of base plate

Seal lost at base-plate edge corrosion up to 1m in from edge
Corrosion also seen randomly across the base

Severe corrosion to tank roof

Foliage growing at base-plate edge

ABB Group
January 22, 2013 | Slide 17
Corrosion Under Insulation (CUI)
Water enters damaged cladding at top and runs down tank walls
Accelerated corrosion occurs at hold-up points eg. Stiffening rings and base

ABB Group
January 22, 2013 | Slide 18
Internal corrosion - Shell, roof and base
Internal corrosion / pitting to shell at product / vapour interface
Corrosion / pitting to base - sludge
Internal corrosion to roof space, including structure members - condensation
Corrosion behind roof seals
Lining deterioration
Under deposit corrosion

Corrosion behind roof seal

Extensive corrosion to tank bottom

ABB Group
January 22, 2013 | Slide 19
External Corrosion

Design Temp : 100 Deg

Baseplate Nominal Thickness : 10.0mm
Depth of Corrosion Up to 8.0mm

ABB Group
January 22, 2013 | Slide 20
Damage Found on Inspection

Severe metal loss due to water pooling under tank base

ABB Group
January 22, 2013 | Slide 21
 Do inspection schemes include all damage mechanisms?

ABB Group
January 22, 2013 | Slide 22
Leaks from manways and branches
Use the correct gasket and fastener
specification

Only capable and experienced

personnel to make these joints

Consider Critical Joint management

system. ie. joint assembly witnessed
and logged

ABB Group
January 22, 2013 | Slide 23
 316 Stainless Steel on Warm Sulphuric Acid

Internal view as new; all damage originated from outside

Mechanism - chloride stress corrosion cracking (SCC)

ABB Group
January 22, 2013 | Slide 24
Failure Examples : Lack of weld fusion

Tank in service for over 20 years, without failure

Mechanism - flexing of weld with lack of root fusion
(Note most storage tanks have limited construction testing)
ABB Group
January 22, 2013 | Slide 25
 Bottom Plate Rotation Low Cycle Fatigue

ABB Group
January 22, 2013 | Slide 26
Tank failure example (background information)

Storage tank on liquid sulphur duty

Operating temperature = 120C
Operating pressure = a few mmHg or inches water gauge
The tank was insulated and heated by steam coils, 300mm
above the base of the tank.
The tank looked to be in good condition before the incident.
Inspection reports did not highlight any problems
Considered a none corrosive service (internal)
Temperature above serious concern range, for corrosion
under insulation (CUI)

ABB Group
January 22, 2013 | Slide 27
Extent of spillage

ABB Group
January 22, 2013 | Slide 28
Defect at base of tank

ABB Group
January 22, 2013 | Slide 29
Explanation of failure

Broken guttering allowed water behind insulation

Insulation

Water
accumulation
here
Corrosion band

The base of the tank had filled with

inert material insulating the lowest
section
ABB Group
January 22, 2013 | Slide 30
Inspection frequencies
Codes are not
Prescriptive. Only
guidance given

Example:- Table from

EEMUA 159

Other factors to consider,

listed in API 653:-
- nature of product
- corrosion rates
- operational regime
- prevention systems

ABB Group
January 22, 2013 | Slide 31
Non-metallic tanks

Non-metallic equipment offers cost effective long term service for many
process duties
Knowledge and experience are essential for assessment to maximise
service life
Ensure good design, fabrication and construction
Review operating regimes
Apply maintenance care, inspection and condition monitoring that are
appropriate to the duty, equipment type and age
Aim to have confidence in integrity of equipment for long term service
e.g. 10, 20 or 30 years, or more
Details guidance in HSE document PM75 (GRP), PM 86
(Thermoplastics)

ABB Group
January 22, 2013 | Slide 32
Typical results of Ageing Plant Study
Items need to be replaced Items need major repairs
within next 20 years within next 20 years
ALS Category
Items need further
evaluation
8% 7% 1%
11%
A
Items need minor repairs
B next 20 years
within
C
D
E

73%

Items can continue to be operated

for the next 20 years

ABB Group
January 22, 2013 | Slide 33
 Summary
Know and understand you assets and their ageing status

Identify and manage deterioration mechanisms and look to

minimise or eliminate as many as possible / practical

Have in place a sound integrity management system

Allocate responsibility for assets within your organisation

Use an experienced and capable inspection organisation

Use the standards and guidelines available (100 years experience)

Carry out regular visual checks with own staff

Act on any defects identified to prevent further damage

Ageing assets can be managed safely and effectively

providing the methodology is understood and applied.

ABB Group
January 22, 2013 | Slide 34
The conclusions & benefits
Identification of problems allows solutions to be found,
providing for:
Safe operations, for future service
Confidence in asset condition
Prevention or reduction of deterioration / failure
Improves management of total operating cost
Optimised life of equipment life
Regulatory compliance and improved corporate
reputation
Technical justification for continued service and
replacement planning (all critical equipment)
Makes safe, financial sense

ABB Group
January 22, 2013 | Slide 35
Information Sources
www.hse.gov.uk/comah/ca-guides.
(Ageing plant delivery guide contains eight links to relevant info).
HSE Doc SPC/Tech/Gen/35. Integrity of storage tanks
HSE RR 760. Mechanical Integrity of Storage tanks
HSE RR 509. Ageing Plant
HSE RR 823. Plant Ageing Study
HSE RR616. Fitness for Service Review
EEMUA Guide 159. Maintenance and Inspection of Storage
Tanks
www.chemical.org.uk/non_metallic_storage_tanks.
HSE PM 75 & PM 86. Non-metallic storage tanks
Corrosion of above ground storage tanks containing fuels
(NACE; Materials Performance, March 2012).

ABB Group
January 22, 2013 | Slide 36
 ABB Group
January 22, 2013 | Slide 37