Mechanical Integrity Report for the CURI Pierside Stainless Diesel Tank at 208 North Palmetto Boulevard Clemson, South Carolina 29631 Inspection: 26 September 2012 Prepared by: George E. Matthews, E.I.T. Senior Consultant Reviewed by: Jeremy M. Orr, P.E., C.W.I. Principal Engineer - Manager Purchase Order Number: CU00134445 ATS Job Number: 187436 Page 1 of 10
Table of Contents Table of Contents General Information, Background, Equipment Orientation and Access Page 3 Present Condition and Analysis Page 4 Action Items Page 6 Future Inspections, Personnel Qualifications and Reference Industry Codes and Standards Page 7 Photographs Page 8 Appendix A: NDE Report Appendix B: Calculations Page 2 of 10
General Information, Background, Equipment Orientation and Access Design Pressure Design Temperature Operating Pressure Operating Temperature Contents Specific Gravity Shell Height / Length Diameter Manufacturer Year Constructed Serial Number UL Number Material Previous Inspection Drawing(s) NDE Performed by Background Unknown Unknown Atmospheric Ambient Diesel Fuel 1.0 (Used for calculations) 4 feet 4 feet Unknown Unknown Not applicable Not applicable Unknown Stainless Steel None None George Matthews (VT) Peter Dudley / Joey Laprade (UTT) Overall View This report contains the results of the inspection, analysis and action items regarding the CURI Pierside Stainless Steel Diesel Tank. The inspection included an external visual inspection and applicable NDE to the accessible portions of the tank. Equipment Orientation The zero references as discussed in this report were as follows: The tank was oriented beginning with 0 at the top of the shell as viewed from the North Head and progressing to 360 in a counter-clockwise direction (refer to the roll-out in Appendix A). All nozzles and manways were individually oriented with 0 at the top of the individual nozzle and manway necks (towards the top of the tank) and progressed to 360 in a counterclockwise direction. Equipment Access No access equipment was required for the inspection. Page 3 of 10
External Present Condition Present Condition and Analysis Minor mechanical damage and staining near the weld seams was observed throughout. Minor general surface corrosion was observed at areas of coating failure on the support system. No visible deterioration or damage was observed on the normal vent at nozzle N4. The normal vent was observed to be necked down to 1/2 from the 2 threaded connection. An emergency vent was not observed. A possible leak was observed at the threaded connection of nozzle N2. A grounding cable was not located. Analysis The tank was analyzed as STI SP001 Category 3 for the operating parameters as provided by the client. A possible leak was observed at nozzle N2. Emergency venting provisions were not met. The existing normal vent does not satisfy the normal venting requirements of UL 142. The tank required a NPS 3 or larger emergency vent, per UL 142. A summary of the ultrasonic thickness measurements is located in the Summary of Measurements table that immediately follows. The completed NDE Report is located in Appendix A. The calculations summary is located in Appendix B. Calculated minimum required thicknesses are exclusive of any corrosion allowance. Page 4 of 10
Summary of Measurements Present Condition and Analysis Component East Head Shell West Head Previous Average Minimum Minimum Required Corrosion Rate (inches/year) Remaining Life (years) 0.109 0.109 0.107 0.082 0.109 0.104 0.090 0.082 0.109 0.109 0.108 0.082 Assumed, per STI SP001 7.2.4 Stainless steel - no generalized corrosion rate in this service. Legend > 10% Above Minimum Required Within 10% of Minimum Required At Minimum Required or Below Page 5 of 10
Action Items Action Items The following are the prioritized action items based on the observations and findings at the time of the inspection: No. Item Priority 1 A 3 or larger emergency vent should be installed on the tank, per UL 142. 2 The normal vent at nozzle N4 should be replaced with a vent sized 1 ¼ inches or larger. 1 1 2 The leak at nozzle N2 should be verified and corrected as necessary. 2 Priority 1 Priority 2 Priority 3 Legend High likelihood and consequence of failure. Critical Code or Standard deficiency. May not be fit for continued service without repair. Medium likelihood and consequence of failure. Low likelihood and consequence of failure. Non-critical Code or Standard deficiency. Industry best practice or preventative maintenance. Housekeeping items. Page 6 of 10
Future Inspections, Personnel Qualifications and Reference Industry Codes and Standards Future Inspections Per STI SP001 Table 5.5 for Category 3 tanks, the tank should be externally re-inspected and leak tested in 10 years. The tank should be periodically inspected by a competent person, according to the guidelines in STI SP001 Section 6. According to the Clemson University Spill Prevention Control and Countermeasure (SPCC) Plan, the tank should be re-inspected within 10 years. Personnel Qualifications Jeremy M. Orr SC PE # 27219 GA, AL, ME, FL, LA, TX, SC, CA registered Professional Engineer; Mechanical Engineer with 13 years experience in inspection, evaluation, repair and design in various industries; AWS CWI, API 653 / 510 / 570 / 580 / 571/ 577 certified; STI certified inspector; NACE coating inspector level I certified; ASNT certified level II VT; SPRAT level I certified rope access technician; ATS certified Level II UTT, MT, PT, VT per SNT-TC- 1A; active member of TAPPI, AWS, NACE International, ASME George E. Matthews GA Registered Engineer-in-Training, Mechanical Engineer with 3 years experience in inspection, evaluation, repair and design in various industries Jesse B. Showalter GA Registered Engineer-in-Training, Mechanical Engineer with 3 years experience in inspection, evaluation, repair and design in various industries Peter Dudley Joey Laprade Reference Industry Codes and Standards ATS certified Level II UTT, MT, PT per SNT-TC-1A ATS certified Level II UTT, MT, PT per SNT-TC-1A Clemson University, Spill Prevention Control and Countermeasure Plan STI SP001, Standard for the Inspection of Aboveground Storage Tanks UL 142, Steel Aboveground Tanks for Flammable and Combustible Liquids Page 7 of 10
Photographs Photo 1: Overall view of the tank. Page 8 of 10
Photographs Photo 2: View of the East Head. Page 9 of 10
Photographs Photo 3: View of nozzle N2. Page 10 of 10
Appendix A: NDE Report External Visual Inspection: Component Condition / Comments East Head Minor mechanical damage was observed. Staining was observed near weld seams. Shell Minor mechanical damage was observed. Staining was observed near weld seams. Insulation / Coating None. West Head Minor mechanical damage was observed. Staining was observed near weld seams. Floor Plate Extension Not applicable. Nozzle / Manway / Repad Nozzle N2 was observed with a possible leak at the threads. Otherwise, no visible deterioration or damage was observed. Relief / Vent Jacket / Coils Weld Seam No visible deterioration or damage was observed. Not applicable. Minor staining near weld seams. Support System Minor general surface corrosion was observed at areas of coating failure. Anchor Bolt / Saddle / Lug Grounding Cable Minor general surface corrosion was observed at areas of coating failure. None located. Notes: ATS460, 4/18/12 Pierside Stainless Diesel Tank Calcs.xls
Appendix A: NDE Report Rollout / Nozzle Locations (NOT TO SCALE): End View: (AS SEEN FROM THE SIDE) East Head: West Head: Shell: Plan View: ATS460, 4/18/12 Pierside Stainless Diesel Tank Calcs.xls
Appendix A: NDE Report Ultrasonic Measurements: East Head: Distance Across (feet) Minimum Required 0 to 180 Minimum 90 to 270 Minimum 3.8 0.082 0.109 0.107 3.0 0.082 0.107 2.0 0.082 0.109 1.0 0.082 0.109 0.2 0.082 0.109 0.108 0.109 0.109 0.109 Legend > 10% Above Minimum Required Within 10% of Minimum Required At Minimum Required or Below ATS460, 4/18/12 Pierside Stainless Diesel Tank Calcs.xls
Appendix A: NDE Report Ultrasonic Measurements: West Head: Distance Across (feet) Minimum Required 0 to 180 Minimum 90 to 270 Minimum 3.8 0.082 0.109 0.109 3.0 0.082 0.109 0.109 2.0 0.082 0.111 0.110 1.0 0.082 0.109 0.110 0.2 0.082 0.108 0.110 Legend > 10% Above Minimum Required Within 10% of Minimum Required At Minimum Required or Below ATS460, 4/18/12 Pierside Stainless Diesel Tank Calcs.xls
Appendix A: NDE Report Shell Ultrasonic Measurements: Elevation (feet) Minimum Required 0 Minimum 90 Minimum 180 Minimum 270 Minimum 3.8 0.082 0.109 2.9 0.082 0.114 2.0 1.1 0.082 0.082 0.112 0.109 0.2 0.082 0.109 0.090 0.099 0.099 0.099 0.098 0.100 0.099 0.099 0.100 0.098 0.113 0.111 0.111 0.107 0.108 Legend > 10% Above Minimum Required Within 10% of Minimum Required At Minimum Required or Below ATS460, 4/18/12 Pierside Stainless Diesel Tank Calcs.xls
Appendix A: NDE Report Nozzles / Manways / Reinforcement Ultrasonic Measurements: Notes: A Threaded Nozzle NPS Elevation Nozzle 0 Scan 180 Reinforcement Pad Width Internal Projection N1 0.5 2 A A A None N/A Unknown N2 0.5 2 A A A None N/A Unknown N3 2 48 A A A None N/A Unknown N4 2 48 A A A None N/A Unknown N5 2 48 A A A None N/A Unknown N6 2 0 A A A None N/A Unknown N7 2 0 A A A None N/A Unknown ATS460, 4/18/12 Pierside Stainless Diesel Tank Calcs.xls
APPLIED TECHNICAL SERVICES, INCORPORATED Corporate Headquarters 1049 Triad Court, Marietta, Georgia 30062 770.423.1400 Fax 770.514.3299 www.atslab.com APPENDIX B: CALCULATIONS SUMMARY UL 142: MINIMUM THICKNESS (s.g. less than or equal to 1.0) Horizontal Construction (with flat heads) Actual Capacity = 376 U.S. gallons (calculated) Minimum Design = 0.093 in. (per UL 142, Section 13) STI Min. Required = 0.082 in. (per STI SP001, Section 10) Per STI SP001 10.0, the minimum required thickness for Category 3 tanks is 75% of the original construction thickness. The original construction thickness for this tank was assumed to be 0.109" (12 gauge) based on measuring an uncorroded area per STI SP001 7.2.4. The minimum required thickness was calculated as 75% of that value. Where: D = Diameter of Tank (ft.) = 4.00 L = Length of the Tank (ft.) = 4.00 (cannot be greater than 6 times D) UL 142: VENTING Actual Capacity = 376 U.S. gallons Wetted Surface Area (horizontal) = 57 ft 2 (assumes flat heads) Normal Venting Minimum Opening = 1 1/4 NPS (per Table 8.2) A vent opening must be in addition to the fill, withdrawal and liquid level gauge openings. The normal vent must be at least as large as the filling or withdrawal connection, whichever is larger. Emergency Venting Horizontal Minimum Opening = 3 NPS (per Table 8.1) Emergency vents are not prohibited from use for normal venting. The pipe size applies to lengths of not more than 12 in. Page 1 of 2
APPLIED TECHNICAL SERVICES, INCORPORATED Corporate Headquarters 1049 Triad Court, Marietta, Georgia 30062 770.423.1400 Fax 770.514.3299 www.atslab.com APPENDIX B: CALCULATIONS SUMMARY UL 142: SADDLES The tank was supported by non-standard saddles. The geometry of the saddles could not be analyzed without performing a finite element analysis (FEA). No damage to the tank shell was observed at the saddle attachment locations. Page 2 of 2