TE6 FEI FII Guide Lines.pdf

AST INSPECTION STANDARD 12 September 2011 COPYRIGHT© 2011 Steel Tank Institute

SP001 Portable Container Monthly Inspection Checklist each month for containers onsite for 91 days or more. Take note of the instructions on the checklist. Note special conditions.

6.8 Additional requirements for field-erected tanks are included in Appendix B.

6.9 Refer to Section 10.0 for conditions that warrant immediate action.

6.10 By removing water or taking other corrective action on a regular basis, harmful MIC is prevented.

Monitor for water accumulation monthly. If corrosion is found due to MIC, treat the AST with a proper biocide or otherwise sterilize the AST. In addition, take necessary steps to repair or remove the AST from service if warranted by the extent of the corrosion, per Section 10.0.

7.0 FORMAL EXTERNAL INSPECTION (FEI) GUIDELINES

7.1 GENERAL

7.1.1 Formal External Inspections are to be performed by Certified Inspectors, per paragraph 4.2.

7.1.2 These Guidelines are minimum inspection requirements. There are numerous AST configurations and components and it is the responsibility of the Certified Inspector to identify and properly inspect them to conform to the owner’s requirements and/or industry standards. The inspector or the inspection company shall develop detailed checklists that identify, record and document all aspects of each inspection.

7.1.3 Review prior formal and periodic inspections, repair and alteration data before each inspection.

7.1.4 Record AST nameplate data, if available, and check the information included for accuracy against actual conditions. Record AST data, inspection findings, and problems identified.

7.1.5 Inspect the fabrication of the AST against applicable industry standards.

7.1.6 Inspect the AST foundations for indications of settlement, cracking, exposed rebar or general disrepair. Inspect for areas of wash-out and voids under the AST. Confirm that the ground is sloped away from the AST and that there is no soil resting against the side of the AST, covering parts of the shell or bottom extension. Inspect for standing water against the AST or the indication of drainage problems.

7.1.7 Visually inspect the condition of the AST’s supports. Severe cracking or spalling of concrete supports shall be noted and evaluated. If there are pad plates between the supports and the shell, inspect the condition. Inspect the supports to be sure that they are sitting securely on the foundation or grade. If the supports are welded to the shell, inspect the welds for visible signs of stress or deterioration.

7.1.8 Identify and record the type and condition of the secondary containment, spill control and CRDM, if present.

7.1.8.1 Visually inspect the general condition of the containment area to be sure that it is in good condition and that there is not a breach in the containment structure. Note changes from the original design and installation information if available.

7.1.8.2 Inspect for foreign materials in the containment area. Inspect for liquid in the containment system and CRDM. If liquid is present, find the source and report findings. Record other ASTs or containers within the same containment area.

7.1.8.3 Make sure that the drain valves are operable and in good condition. Report penetrations through the secondary containment that may compromise the integrity of the containment area. Report penetrations that are likely to lead to failure of the secondary containment should the liquid level of water or liquid rise to these penetrations.

7.1.9 Inspect and verify the operability of ancillary equipment including the following items:

7.1.9.1 Inspect piping and piping connections for visible signs of stress or leakage, such as severe corrosion, rusted bolted connections or other severe degradation.

7.1.9.2 Inspect normal and emergency vents and pressure/vacuum devices. Verify that the devices are of adequate size and capacity, operable and in good condition. Refer to the device manufacturer’s literature, typical industry venting requirements and other appropriate resources. Record the types and locations of these devices.

7.1.9.3 Inspect primary tank level gauge and secondary tank interstitial gauge for free movement and to determine if the floats, guides and attachments are in working order. Check that the liquid level gauge length is sized correctly for the tank diameter. Inspect the alarms connected to the level gauge for operability and for a complete loop and circuit from the primary sensor to the final annunciation or alarm point.

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7.1.10 Inspect the bonding and grounding system of the AST, if present. (Refer to NFPA 780 Standard for the Installation of Lightning Protection Systems.)

7.1.11 Inspect stairways, handrails and platforms for broken welds, bent members and corrosion.

7.1.12 Inspect the coating on the AST shell, heads and supports for paint failure.

7.2 DETERMINE THE ORIGINAL SHELL THICKNESS OF THE AST. Suggested methods are:

7.2.1 Review the original tank documentation, such as drawings and packing lists.

7.2.2 Consult the tank manufacturer.

7.2.3 Examine the tank labels for evidence of a widely accepted tank standard, such as Underwriters

Laboratories Standard UL 142, etc. Consult the referenced standard to determine the minimum design shell thickness.

7.2.4 Measure the tank thickness of several areas of the tank that have no visible corrosion or pitting.

The average of these measurements will result in a minimum shell thickness measurement.

7.3 HORIZONTAL AST- Requirements in addition to the applicable items in 7.1:

7.3.1 Inspect shell plates and welds for indications of exterior corrosion, buckling or distortion, as well as for cracking, pinholes or mechanical damage. Inspect the shell of the AST and the ancillary equipment for signs of distortion and stress.

7.3.1.1 Take and record UTT readings and the location of the reading of each plate or shell course in areas accessible without entering the AST. Readings must be concentrated in areas where corrosion is likely to occur. If significant internal corrosion is detected, further investigation using ultrasonic testing scans (UTS) is required. If applicable, include areas marked from previous readings. Refer to Section 10.0.

7.3.2 Inspect shell attachments for changes made after the AST was fabricated. Refer to previous drawings or make new sketches that show all the appurtenances, attachments and nozzle locations on the AST shell and heads or roof. Record repads (reinforcing plates) and/or insert plates. Inspect attachment welds for signs of stress and corrosion.

7.4 VERTICAL OR RECTANGULAR AST - Requirements in addition to the applicable items in 7.1:

7.4.1 Shell surface – Refer to 7.3.1 and 7.3.2

7.4.2 Shell attachments – Refer to 7.3.2

7.4.3 Vertical AST roof - Inspect for low areas on the roof and standing water that may corrode the roof areas. Inspect for paint failure, holes and corrosion. Take UTT readings on the roof and record results. If possible, measure thicknesses in previously measured areas for corrosion rate determination. If significant corrosion is detected, further investigation using ultrasonic testing scans (UTS) is required. Refer to Section 10.0

7.5 DOUBLE-WALL AND DOUBLE-BOTTOM AST - Requirements in addition to the applicable items in 7.1:

7.5.1 Verify that the leak detection equipment or method is operating, if the tank is so equipped.

7.5.2 Check for leaks or the presence of liquid in the interstice.

7.5.3 Double-bottom ASTs require UTT readings of areas that are single-wall as described in paragraph 7.3.1.1 above. Double-wall ASTs do not require UTT readings.

7.6 INSULATED AST - Requirements in addition to the applicable items in 7.1 to 7.4:

7.6.1 Remove the insulation in areas where mold or moisture is present or points where moisture is likely to accumulate and examine the metal surface for signs of signification corrosion. Consider the wicking effect of water in the insulation, particularly in the lower exterior portion of the tank shell.

7.6.2 If insulation damage is suspected, remove sections of the insulation to check for corrosion.

Continue removing the insulation until the extent and nature of the corrosion has been established.

7.6.3 Take UTT readings of the shell and record results including, if applicable, areas marked from previous readings. If significant internal corrosion is detected, further investigation using ultrasonic testing scans (UTS) is required. Refer to Section 10.0

7.7 Additional requirements for field-erected ASTs are included in Appendix B.

7.8 In the final report, include field data, measurements, pictures, drawings, tables and an inspection summary. In the summary, identify unacceptable conditions and recommended corrective actions. Determine the suitability for continued service of the AST per Section 10.0. Include the next scheduled Formal External Inspection (FEI) or Formal Internal Inspection (FII), as applicable.

Include the inspector’s name and certification number in the report.

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8.0 FORMAL INTERNAL INSPECTION GUIDELINES

8.1 GENERAL

8.1.1 Formal Internal Inspections (FII) are to be performed by Certified Inspectors per paragraph 4.2.

8.1.2 These Guidelines are minimum inspection requirements. There are numerous AST configurations and components; it is the responsibility of the Certified Inspector to identify and properly inspect them to conform to the owner’s requirements and/or industry standards. The inspector or the inspection company shall develop detailed checklists that identify, record and document all aspects of each inspection.

8.1.3 A Formal Internal Inspection includes the requirements of a Formal External Inspection with the addition of the requirements described below. Refer to paragraphs 7.1 to 7.7 for Formal External Inspection requirements.

8.1.4 Double-wall tanks and secondary containment tanks may be inspected by checking the interstice for liquid or by other equivalent methods.

8.1.5 For elevated ASTs where all external surfaces are accessible, the internal inspection requirements may be satisfied with an examination from the exterior by using such methods as UTS. For all other situations, entry into the interior of the AST is necessary to assess the condition of all surfaces.

8.2 HORIZONTAL AST INTERNAL INSPECTION

8.2.1 Identify, measure, inspect and record all AST internal appurtenances. Inspect for mechanical damage, corrosion, cracking, etc. Inspect for deteriorating or corroding internal attachments and piping. Take thickness readings of internal structures and record the readings.

8.2.2 Inspect the welds for cracking by visual inspection or, if necessary, by magnetic particle (MT) inspection or equivalent method.

8.2.3 Internal NDT Inspection

8.2.3.1 AST assessment:

8.2.3.1.1 Ultrasonic testing equipment that is capable of scanning the tank (UTS), rather than measuring only individual points (UTT), is the preferred method of testing. Personnel performing UTS are to be qualified per paragraph 4.3.2.

8.2.3.1.2 If ultrasonic testing equipment that is capable of scanning the tank (as described in 8.2.3.1.1) is not practical, use equipment that tests individual points. In this case, take UTT measurements of at least 15 points per each 12 inches x 12 inches (0.3 meters x 0.3 meters) square area of the shell that is in contact with the ground. Any questionable areas are to be assessed by UTS per 8.2.3.1.1.

8.2.3.2 Perform a vacuum box (VB) examination of questionable welds to check for leaks.

8.2.3.3 Refer to Section 10.0 for criteria for suitability for continued service.

8.3 VERTICAL AND RECTANGULAR AST INTERNAL INSPECTION

8.3.1 Identify, record, inspect and measure all AST internal surfaces and appurtenances. Inspect AST internals to check for mechanical damage, corrosion, cracking, etc. Check for deteriorating or corroding internal attachments and piping. Take thickness readings of internal structures and record the readings.

8.3.2 Inspect the welds for cracking by visual inspection or, if necessary, by magnetic particle (MT) inspection or equivalent method.

8.3.3 Internal NDT Inspection

8.3.3.1 AST floor thickness assessment is required as follows:

8.3.3.1.1 Complete coverage of the AST floor is recommended, due to random corrosion characteristics of metal in contact with the ground. Inspection of the AST floor is recommended using inspection methods capable of determining the underside floor condition, such as UTS, MFL followed by UTS of questionable areas, or other equivalent methods.

8.3.3.1.2 If ultrasonic testing equipment that is capable of scanning the tank (as described in 8.3.3.1.1) is not practical, use equipment that tests individual points. In this case, take UTT measurements of at least 15 points per each 12 inches x 12 inches (0.3 meters x 0.3 meters) square area of the shell that is in contact with the ground. Any questionable areas are to be assessed by UTS per 8.3.3.1.1.

8.3.3.2 Perform a vacuum box (VB) examination of questionable welds to check for leaks.

8.3.4 Refer to Section 10.0 for criteria for Suitability for Continued Service.

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8.4 Additional requirements for field-erected ASTs are included in Appendix B.

8.5 REPORT - In the final report, include field data, measurements, pictures, drawings, tables and an inspection summary. Identify in the summary unacceptable conditions and recommended corrective actions. Determine the suitability for continued service of the AST. Include the time until the next scheduled Formal External and/or Formal Internal Inspection, as applicable. Include the inspector’s name and certification number in the report.

9.0 LEAK TESTING METHODS (LTM)

9.1 SHOP-FABRICATED AST LEAK TESTING PROCEDURE.

9.1.1 Consult the Steel Tank Institute Recommended Practice R912, Installation Instructions for Shop

Fabricated Stationary Aboveground Storage Tanks for Flammable, Combustible Liquids. Air shall not be used for a pressure test and an inert gas shall be used instead. The introduction of a gas containing oxygen (such as air) to a tank that has previously held petroleum liquid can pose an explosion hazard.

9.1.2 Vacuum testing of the interstice of double-wall or double-bottom tanks is an option. Refer to the Steel Tank Institute Recommended Practice R912, Installation Instructions for Shop Fabricated Stationary Aboveground Storage Tanks for Flammable, Combustible Liquids.

9.2 PORTABLE CONTAINERS LEAK TESTING PROCEDURE. Refer to DOT Sections 49 CFR 173.28 (Reuse, reconditioning and remanufacturing of packagings - mainly for drums) and Part 178 - 49 CFR Subpart O - Testing of IBC's (section 178.803 Testing and certification of IBC's) and 49 CFR 180.605, or equivalent, for portable container testing and recertification.

9.2.1 See the definition of Leak Testing Methods for more information.

10.0 SUITABILITY FOR CONTINUED SERVICE

10.1 Evaluation for suitability for continued service is a result of Formal External and/or Internal Inspections performed by a Certified Inspector. This section describes the recommended actions to be taken by the owner as a result of these inspections. These conditions and others found during these inspections may require additional inspections or evaluations.

10.2 FORMAL EXTERNAL AND INTERNAL INSPECTIONS (refer to AST categories in Section 5.0)

10.2.1 MIC – For all tanks in Table 5.5, if evidence of MIC is found at any time, then corrections and repairs shall be promptly made to the AST. Refer to Steel Tank Institute SP031 Standard for Repair of In-Service Shop Fabricated Aboveground Tanks for Storage of Combustible and Flammable Liquids for alterations or repairs to an AST. Conduct the next Formal External or Formal Internal Inspection no more than two years after the discovery of MIC.

10.2.1.1 When Table 5.5 allows Formal External Inspections to be performed in lieu of Formal Internal Inspections, then conduct the next Formal External Inspection no more than two years after the discovery of MIC.

10.2.1.2 If the re-inspection confirms that MIC has been mitigated due to measures taken to eliminate it, such as regular and careful water removal and sterilization of the tank and piping systems, then the AST may be inspected according to Table 5.5.

10.2.2 Category 3 ASTs - If the shell thickness has been reduced to less than 75% of the original shell thickness, then the AST shall be taken out of service and repaired or replaced. Refer to Steel Tank Institute SP031 Standard for Repair of Shop Fabricated Aboveground Tanks for Storage of Combustible and Flammable Liquids for alterations or repairs to an AST. The Certified Inspector shall document in the report that the next Formal External or Formal Internal Inspection shall be within 5 years and each subsequent 5 years thereafter until the condition that caused the tank degradation has been fully corrected. When the tank degradation has been arrested or is in a steady-state condition, then follow the inspection intervals shown in Table 5.5 for subsequent inspections.

10.2.3 Category 2 ASTs – The AST shall be repaired or replaced if more than 3 square inches of any one square foot of the tank shell (i.e. approximately 2%) is found to be less than 75% of the original shell thickness or if the remaining shell thickness of an area is less than 50% of the original shell thickness at any point. Refer to Steel Tank Institute SP031 Standard for Repair of Shop Fabricated Aboveground Tanks for Storage of Combustible and Flammable Liquids for