Report No.: 11033.033.1 Inspector: Jeff Walling Employer: Eagle Inspection Inspection Date: 5/26/2011 ACME Energy Orlando, FL OUT-OF-SERVICE Inspection Report For Propane Tank 0480 Tank Farm An API Standard 510 Inspection based on client criterion for nondestructive examinations was conducted on vessel DA Unit 2 in the ACME Energy facility located at Orlando, FL on 5/26/2011. This vessel was originally built to AS E Section VIII Division 1. This inspection was conducted in accordance with requirements of the API-510 standard for inspections of Pressure Vessels. The following is a detailed report of the inspection including findings and recommendations. Inspector Signature API Certification No. 2782 Report No.: 11033.033.1 Page 1
1.0 EXECUTIVE SUMMARY INDEX 2.0 VESSEL DATA 3.0 INSPECTION RESULTS, 3.1 Foundation 3.2 Vessel Shell 3.3 Vessel Heads 3.4 Appurtenances IN-SERVICE 4.0 RECOMMENDATIONS 4.1 Foundation 4.2 Vessel Shell 4.3 Vessel Heads 4.4 Appurtenances 4.5 Next Inspection 5.0 ULTRASONIC THICKNESS MEASUREMENTS 5.1 Results 5.2 Recommendations APPENDICIES APPENDIX A APPENDIX B APPENDIX C APPENDIX D APPENDIX E APPENDIX F APPENDIX G Mechanical Integrity Calculations Thickness Measurement Records Inspection Drawings Inspection Checklist Manufacturers Data Sheets Inspection Photographs NDE Records Report No.: 11033.033.1 Page 2
1.0 EXECUTIVE SUMMARY An API Standard 510 inspection of pressure vessel 0480 located at Orlando, Florida was conducted on 05/26/2011. This inspection was made to collect data in order to evaluate the mechanical integrity and fitness for service of the vessel. This inspection consisted of Internal and External VT and UT exams. No major problems were noted during this inspection. Minor discrepancies are listed in Section 3.0 Inspection Results and 4.0 Recommendations. TABLE A Component Nominal Design Thickness (in.) Actual Measured Thickness (in.) Minimum Required Thickness (in.) Design MAWP (psi) Internal Calculated MAWP (psi) Internal Remaining Life (years) Vessel Shell 0.938 0.938 0.937 250 250 >20 West Head 0.525 0.522 0.445 250 293 >20 East Head 0.525 0.532 0.445 250 299 >20 Next external inspection is due by: 5/25/2016 Next internal inspection is due by: 5/25/2021 Next UT inspection is due by: 5/25/2021 Report No.: 11033.033.1 Page 3
2.0 VESSEL DATA Main Vessel Data General Data: MAWP (psi): 250 Product: Propane Design Temp. F: 125 Build Date: 1966 MDMT F: -20 NB No.: None Oper. Press.(psi): 180 Const Code: ASME S8 D1 Oper. Temp. F: Ambient Material Type: Carbon Steel Inside Dia. (in.): 130 Length (in.): 1088.125 Vessel Config.: Horizontal Head Type: Hemispherical Insul. Type: None Insul. Thk (in.): N/A Chamber 2 Data - N/A MAWP (psi): Design. Temp. F: Material: Oper. Press.(psi): Oper. Temp. F: Medium: Report No.: 11033.033.1 Page 4
3.0 INSPECTION RESULTS, 3.1 Foundation: 3.2 Shell: 3.1.1 The vessel rests in two concrete foundation support saddles with rubber liners in between the tank and saddles. 3.1.2 The concrete saddles are in satisfactory condition. 3.2.1 The shell is carbon steel with 8 to 15 mil epoxy external coating and is un-insulated. 3.2.2 The external surface profiles of the shell appear to be smooth and clean and in satisfactory mechanical condition. The shell coating is in satisfactory condition. 3.2.3 The shell nozzle penetration welds appeared to be in satisfactory condition. 3.3 Head(s): IN-SERVICE The following results are the summarization of a field checklist that was utilized during the inspection of vessel 0480 3.3.1 The West and East heads are carbon steel with 8 to 15 mil epoxy external coating and are un-insulated. The West and East heads have a hemispherical design. 3.3.2 The external surface profiles of the West and East heads appear to be smooth and clean and in satisfactory mechanical condition. The coating on both heads is in satisfactory condition. 3.3.3 The nozzle penetration welds through the both heads appeared to be in satisfactory condition. 3.4 Appurtenances: 3.4.1 The shell and head nozzles appear to be clean and in satisfactory mechanical condition. There are areas scattered throughout the relief valve vent piping with coating failure and surface oxidation. 3.4.2 The four (4) pressure relief valves do not have data tags attached specifying certification date or set pressure. 3.4.3 The flange on shell nozzle K (24" Manway) has visible corrosion in the flange gap. 3.4.4 The ASME dataplate is attached and in an easily accessed location. The plate is faded and barley readable. A data plate is affixed to the vessel. 3.4.5 The pressure and temperature gauges do not have calibration tags. Report No.: 11033.033.1 Page 5
4.0 RECOMMENDATIONS 4.1 Foundation: 4.2 Shell: 4.1.1 None 4.2.1 None 4.3 Heads: 4.3.1 None 4.4 Appurtenances: 4.4.1 Remove manway, clean flanges of corrosion and coat. 4.4.2 Certify or replace the four (4) existing pressure relief valves. 4.4.3 The manufacturer should be contacted and a request made to replace the ASME dataplate. 4.4.4 Calibrate the pressure and temperature gauges (recommend calibrating on an annual basis). 4.5 Next Inspection: 4.5.1 Next external inspection is due by 5/25/2016 4.5.2 Next internal inspection is due by 4.5.3 Next UT inspection is due by 4.5.4 Governing component limiting life 5/25/2021 5/25/2021 West Head Report No.: 11033.033.1 Page 6
5.0 ULTRASONIC THICKNESS (UT) MEASUREMENTS 5.1 Results Summary: 5.1.1 UT measurement of accessible vessel components (shell and heads) found no significant material loss due to internal corrosion of the components. All of the vessel component thicknesses were nominal and acceptable for ASME calculations for minimum required thicknesses for internal pressure. 5.1.2 Calculations of all evaluated components resulted in greater than 20 years remaining life. 5.2 Recommendations: 5.2.1 Next UT inspection of the vessel may be scheduled in 10 years in accordance with maximum allowable intervals recommended by API-510. Report No.: 11033.033.1 Page 7
APPENDIX A Engineering Calculations 1) Cylindrical Shell Calculations 2) Formed Head Calculations 3) Horizontal Vessel Calculations Report No.: 11033.033.1 Page 8
API-510 PRESSURE VESSEL SHELL EVALUATION MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS Report No Client Inspector Vessel Date 11033.033.1 ACME Energy Jeff Walling 0480 5/26/2011 Vessel Shell Material CS - A212 B Material Temp MAWP SH SG D t nom Temp MAWP SH SG D t nom 125 250 0.0 0.59 130.000 0.938 Minimum Thickness Calculations Vessel Shell Internal PR/(SE-0.6P) = t min P 250.0 R 65.000 S 17500 E 1.00 t min 0.937 P Internal PR/(SE-0.6P) = t min R S E t min Remaining Life Calculations Vessel Shell t prev t act t min y t prev t act t min y 0.938 0.938 0.937 45.0 Ca = t act - t min = 0.001 (in) Ca = t act - t min = (in) Cr = t prev - t act / Y = 0.00000 (in/year) Cr = t prev - t act / Y = (in/year) RL= Ca / Cr = >20 (years) RL= Ca / Cr = (years) Next Inspection (Yn) 10.0 (years) MAWP Calculations Vessel Shell MAWP at Next Inspection MAWP at Next Inspection Where t = t act - 2YnCr = 0.938 (in) SEt/(R+0.6t) = P = 250.4 (psi) Where t = t act - 2YnCr = SEt/(R+0.6t) = P = (in) (psi) P-(SH*.433*SG) = MAWP = 250.4 (psi) P-(SH*.433*SG) = MAWP = (psi) Page 9
API-510 PRESSURE VESSEL SHELL EVALUATION MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS Report No Client Inspector Vessel Date 11033.033.1 ACME Energy Jeff Walling 0480 5/26/2011 Variable Definitions for Shell Calculations: Ca = remaining corrosion allowance of the vessel part under consideration, in inches. Cr = corrosion rate of the vessel part under consideration, in inches per year. D = inside diameter of the shell course under consideration, in inches. E = (E Internal) lowest efficiency of any joint in the shell course under consideration. For welded vessels, use the efficiency specified in UW-12. MAWP = the design maximum allowable internal working pressure of component of interest at the upper most section of the vessel, (P - static head pressure), in psi. P = MAP = the maximum allowable internal pressure of component of interest, including static head pressure, in psi. R = inside radius of the shell under consideration, in inches. RL = estimated remaining life of the vessel part under consideration, in years. S = maximum allowable stress value, in psi. SH = static head of water, in feet t = thickness of the vessel part under consideration, variable related to applicable calculation used therein, in inches. t act = actual thickness measurement of the vessel part under consideration, as recorded at the time of inspection, in inches. t min = nominal thickness minus the design corrosion allowance or the calculated minimum required thickness of the vessel part under consideration at the design MAWP at the coinciding working temperature, in inches. t nom = design nominal thickness of vessel part under consideration, in inches. t prev = previous thickness measurement of the vessel part under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inches. Y = time span between thickness readings or age of the vessel if t nom is used for t prev, in years. Yn = estimated time span to next inspection of the vessel part under consideration, in years. Page 10
API-510 PRESSURE VESSEL HEAD EVALUATION MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS Report No Client Inspector Vessel Date 11033.033.1 ACME Energy Jeff Walling 0480 5/26/2011 Vessel Head(s) West Head and East Head MAWP D T E SG1 SG2 MAWP D T SH SG3 E 250 130.000 125 1.00 0.59 0.59 Head ID Head Type t nom Head ID West Head Hemispherical 0.525 East Head Material CS - A455-B Head Type t nom Head ID Head Type t nom Hemispherical 0.525 S SH P Material S SH P Material S P 18300 0.0 250.0 CS - A455-B 18300 0.0 250.0 For Torispherical Heads L = r = M = L = r = M = L = r = M = Minimum Thickness Calculations Internal Hemispherical Head 2:1 Ellipsoidal Head Torispherical Head PL/(2SE-0.2P) = t min PD/(2SE-0.2P) = t min (knl) PLM/(2SE-0.2P) = t min (knl) P0.9D/(2S-0.2P) = t min(crwn) PL/(2S-0.2P) = t min (crwn) (reference supplemental calcs for other head type formulas) West Head East Head Hemispherical Hemispherical t min = 0.445 (in) t min = 0.445 (in) t min = (in) Page 11
API-510 PRESSURE VESSEL HEAD EVALUATION MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS Report No Client Inspector Vessel Date 11033.033.1 ACME Energy Jeff Walling 0480 5/26/2011 Remaining Life Calculations West Head t prev 0.525 t act 0.522 t min 0.445 y 45.0 t prev t act t min y Ca = t act - t min = 0.077 (in) Cr = t prev - t act / Y = 0.00007 (in/year) RL= Ca / Cr = >20 (years) Ca = t act - t min = Cr = t prev - t act / Y = RL= Ca / Cr = (in) (in/year) (years) East Head t prev 0.525 t act 0.532 t min 0.445 y 45.0 Ca = t act - t min = 0.087 Cr = t prev - t act / Y = 0 (in) (in/year) Next Inspection (Yn) 10.0 (years) RL= Ca / Cr = >20 (years) MAWP Calculations (reference supplemental calcs for other head type formulas) Hemispherical Head MAP 2SEt/(R+0.2t) = P Internal Where t = t act - 2YnCr 2:1 Ellipsoidal Head Torispherical Head 2SEt/(D+0.2t) = P (knl) 2SEt/(LM+0.2t) = P (knl) 2St/(0.9D+0.2t) = P (crwn) 2St/(L+0.2t) = P (crwn) Where P = MAP at the Next Inspection Where MAWP = P-(SH*.433*SG) West Head Hemispherical t = 0.521 (in) P = 292.7 (psi) MAWP = 292.7 (psi) East Head Hemispherical t = 0.532 (in) P = 299.1 (psi) MAWP = 299.1 (psi) t = (in) P = (psi) MAWP = (psi) Page 12
API-510 PRESSURE VESSEL HEAD EVALUATION MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS Report No Client Inspector Vessel Date 11033.033.1 ACME Energy Jeff Walling 0480 5/26/2011 Variable Definitions for Head Calculations: Ca = remaining corrosion allowance of the vessel part under consideration, in inches. Cr = corrosion rate of the vessel part under consideration, in inches per year. D = inside diameter for the head skirt, in inches. E = (E Internal Calculations) lowest efficiency of any joint in the vessel part under consideration. For welded vessels, use the efficiency specified in UW-12. h = inside height for the head, in inches. H = inside head height from tangent, in inches. K = factor depending on head proportions D/2h and determined as 1/6[2+(D/2h)^2] L = Hemi. Hds - inside spherical or crown radius of the head under consideration, in inches,. Elip. and Tor. Hds - inside spherical or crown radius, in inches, M = a factor used in the formulas for torispherical heads where M= 0.25(3+(L/r)^.5) MAWP = the design maximum allowable internal working pressure of component of interest at the upper most section of the vessel, (P - static head pressure), in psi. P = MAP = the maximum allowable internal pressure of component of interest, including static head pressure, in psi. r = inside knuckle radius, in inches. R = inside radius of the shell under consideration, in inches. RL = estimated remaining life of the vessel part under consideration, in years. S = maximum allowable stress value, in psi. SH = Static Head, in feet t = thickness of the vessel part under consideration, variable related to applicable calculation used therein, in inches. t act = actual thickness measurement of the vessel part under consideration, as recorded at the time of inspection, in inches. t min = nominal thickness minus the design corrosion allowance or the calculated minimum required thickness of the vessel part under consideration at the design MAWP at the coinciding working temperature, in inches. Page 13
API-510 PRESSURE VESSEL HEAD EVALUATION MINIMUM THICKNESS, REMAINING LIFE, PRESSURE CALCULATIONS Report No Client Inspector Vessel Date 11033.033.1 ACME Energy Jeff Walling 0480 t nom = design nominal thickness of vessel part under consideration, in inches. 5/26/2011 t prev = previous thickness measurement of the vessel part under consideration, as recorded at last inspection or nominal thickness if no previous thickness measurements, in inches. Y = time span between thickness readings or age of the vessel if t nom is used for t prev, in years. Yn = estimated time span to next inspection of the vessel part under consideration, in years. Page 14
HORIZONTAL TANK EVALUATION (Based on Zick Formula for Two Saddle Tanks) Date 5/26/2011 File No Report No Client Initials Tank No Temp. F 3 11033.033.1 ACME Energy JLW 0480 125 Service Propane SG FH (in.) 0.59 117.00 Material Catagory CS/Crom. Stl wt 0.2833 (PCI) 17500 30000 29000000 132 tn Shell Prod # in L limit Mtl # in L limit Head Type tn Head CuFt in Head Mtl # in Head Other Weight, lbs 1.000 243469 110727 Hemispherical 0.525 348.5 5427 1000 ts th D R A H E L P Q a b 0.937 0.525 130.000 65.000 118 65.252 1.00 957 250 188803 120 18.000 Temp. Total # Material S Y ME K1 K8 125 377607 CS - A212 B 17500 5 30000 29000000 0.335 0.603 LONGITUDINAL BENDING STRESS Stiffening Rings? No STRESS IN TENSION Stress in Saddle (SS+) 3301 =([Q]*[A]*(1-((1-([A]/[L])+(([R]^2-[H]^2)/(2*[A]*[L])))/(1+((4*[H])/(3*[L]))))))/([K1]*[R]^2*[ts]) Stress in Mid Span (SM+) 1538 =(([Q]*[L]/4)*((1+(2*(([R]^2-[H]^2)/[L]^2)))/(1+(4*[H])/(3*[L]))-((4*[A])/[L])))/(3.1416*[R]^2*[ts]) Stress due to Int Press (SP +) 8671 =[P]*[R]/2*[ts] Sum of Tensional Stress (S1 +): =SP+S 11972 Max Allow. Ratio ([S1+]/S*E) 0.68 Vessel Strength is adequate for Tension Loads 17500 STRESS IN COMPRESSION Ratio = [ts]/[r] > 0.005 0.014 Compression Stress not a Factor Stress in Saddle (SS - ) Stress in Mid Span (SM - ) NA NA =([Q]*[A]*(1-((1-([A]/[L])+(([R]^2-[H]^2)/(2*[A]*[L])))/(1+((4*[H])/(3*[L]))))))/([K8]*[R]^2*[ts]) =(([Q]*[L]/4)*((1+(2*(([R]^2-[H]^2)/[L]^2)))/(1+(4*[H])/(3*[L]))-((4*[A])/[L])))/(3.1416*[R]^2*[ts]) Allowable Compressive Stress 1: NA =([ME]/29)*(([ts]/[R])*(2-((2/3)*100*([ts]/[R])))) Allowable Compressive Stress 2: NA =[Y]/2 Sum of Compress. Stress (S1 - ): NA =SP-SM Max Allow. NA Ratio ([S1-]/Mx Alw) NA NA Page 15
HORIZONTAL TANK EVALUATION (Based on Zick Formula for Two Saddle Tanks) Date 5/26/2011 File No Report No Client Initials Tank No Temp. F 3 11033.033.1 ACME Energy JLW 0480 125 Service Propane SG FH (in.) 0.59 117.00 Material Catagory CS/Crom. Stl wt 0.2833 (PCI) TANGENTIAL SHEAR STRESS Stiffening ring at horn of saddle? No K2 1.171 NA Wear Plate? No NA NA ts 0.94 Stress in Shell (SS) 2507 =(([K2]*[Q])/([R]*[ts]))*(([L]-(2*[A]))/([L]+(4/3*[H]))) Stress in Head (SH) Not Required ([K4]*[Q])/([R]*[th]) Tangential Shear Stress (S2) 2507 Ratio 0.14 Vessel Strength is adequate for tangential shear stress (<0.80*S) Stress due to Int Press (SP). 15476 =[P]*[R]/2*[th] Sum of Stress in Head: (SH3) NA =([K5]*[Q]/[R]*[th])+[SP] Ratio NA NA CIRCUMFERENTIAL STRESS K6 0.053 K7 0.76 ts 0.94 Wear Plate Values NA NA NA ts2 0.878 [ts]^2 Stress in Horn of Saddle (S4) -18766 = -([Q]/(4*[ts]*([b]+1.56*([R]*[ts])^0.5)))-((3*[K6]*[Q])/(2*[ts2])) Ratio 1.07 Vessel strength is adequate for stress at the saddle horn (<1.50*S) Stress at Wear Plt Edge (S4) = -([Q]/(4*[ts]*([b]+1.56*([R]*[ts])^0.5)))-((3*[K6]*[Q])/(2*[ts]^2)) Ratio NA Stress in Bottom of Shell (S5) -5075 =-([K7]*[Q])/([ts]*([b]+1.56*([R]*[ts])^0.5)) Stiffening Ring(s) No Ratio NOTES: 0.17 Vessel strength is adequate for stress in shell bottom (<.50*Y) Page 16
File No 3 HORIZONTAL TANK EVALUATION (Based on Zick Formula for Two Saddle Tanks) Report No Client Initials 11033.033.1 ACME Energy JLW Date 5/26/2011 Tank No Temp. F 0480 125 Service Propane SG FH (in.) 0.59 117.00 Material Catagory CS/Crom. Stl wt 0.2833 (PCI) DEFINITIONS, Calculations based on L.P. Zicks analysis presentation in 1951 Variable = Definition A = distance from tangent line of the head to center of saddle, in. a = horn of saddle contact angle, degrees b = width of saddle, in. D = outside diameter of vessel, in. E = joint efficiency FH = fill height, in. H = outside depth of dish of head, in. K = constant from table L = length of vessel tan-tan, in. M = material ME = modulus if elasticity, psi P = vessel maximum allowable working pressure, psi PCI = pounds per cu. in. PSI = pounds per sq. in. Q = load on one saddle R = outside radius of component, in. S = allowable stress value, psi SG = specific gravity th = actual thickness of head, in. tn = nominal thickness, in. ts = actual thickness of shell, in. Wpa = wear plate contact angle, degrees WPL = wear plate length beyond horn of saddle, in. WPt = wear plate thickness, in. WPw = wear plate width, in. wt = weight, lbs Y = yield stress of material, psi. Page 17
APPENDIX B Thickness Measurement Records 1) Component Thickness Measurements Report No.: 11033.033.1 Page 18
API-510 PRESSURE VESSEL COMPONENT THICKNESS RECORD Inspection Data Report No Client Inspector Vessel Date 11033.033.1 ACME Energy Jeff Walling 0480 5/26/2011 Components with Vert. Axis: tml-1 N., tml-2 E., tml-3 S., tml-4 W. (Drawing N.) Components with Horz. Axis: tml-1 Top, tml-2 Side, tml-3 Bttm., tml-4 Side (Clock Wise) CML # 001 002 003 004 005 006 007 008 009 010 011 012 013 Comp ID Location Service tml-1 tml-2 tml-3 tml-4 t act West Head Crown Radius Propane 0.522 0.530 0.532 0.530 0.522 Vessel Shell Course 1 Propane 0.978 0.977 0.977 0.975 0.975 Vessel Shell Course 2 Propane 0.974 0.975 0.978 0.968 0.968 Vessel Shell Course 3 Propane 0.955 0.958 0.959 0.955 0.955 Vessel Shell Course 4 Propane 0.959 0.955 0.969 0.973 0.955 Vessel Shell Course 5 Propane 0.933 0.935 0.940 0.933 0.933 Vessel Shell Course 6 Propane 0.972 0.970 0.968 0.964 0.964 Vessel Shell Course 7 Propane 0.958 0.959 0.966 0.966 0.958 Vessel Shell Course 8 Propane 0.962 0.966 0.959 0.955 0.955 Vessel Shell Course 9 Propane 0.954 0.955 0.955 0.958 0.954 Vessel Shell Course 10 Propane 0.956 0.956 0.957 0.952 0.952 Vessel Shell Course 11 Propane 0.951 0.952 0.957 0.952 0.951 East Head Crown Radius Propane 0.533 0.532 0.533 0.532 0.532 Report No.: 11033.033.1 Page 19
APPENDIX C Inspection Drawings 1) Vessel Layout Drawing Report No.: 11033.033.1 Page 20
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APPENDIX D Inspection Checklist 1) Pressure Vessel Inspection Checklist Report No.: 11033.033.1 Page 22
API-510 PRESSURE VESSEL INSPECTION CHECKLIST Inspector: Jeff Walling Cert No.: 2782 Company: ACME Energy Vessel: 0480 Report No.: 11033.033.1 Date: 5/26/2011 1 FOUNDATION 1.1 Steel Members a. b. c. d. a. X b. X c. X Visually inspect for pitting and corrosion. Check fnd bolts secure with minimum thrd engagement. Check for coating failures Check attachment welds for cracking and corrosion. 1.3 Concrete Foundation Supports Inspect for broken concrete, spalling and cracks. Inspect for erosion under foundation. Check for settlement around perimeter of tank. 1.2 Containment a. b. c. d. e. 1.4 Wooden Saddle Support a. b. c. Inspect the area for buildup of trash, vegetation and obstructions. Inspect sump drain operation. Check that runoff rainwater drains away from the tank. Describe type of construction - Earthen, Concrete, Asphalt, Grave Inspect condition of containment. Check for degradaded members (split, broken, dry rotted et.). Inspect for errosion and vegetation tank fnd. Check for settlement around perimeter of tank. 2 SHELLS 2.1 External Visual Inspection a. X b. c. X d. X e. X f. g. X a. b. c. d. e. f. g. h. a. X b. X c. X d. X e. f. g. X Visually inspect shell surface for paint failures, pitting, corrosion, denting, out-of-round and part deformation. Check for broken, unused insulation rod supports causing corrosion nodes. Visually inspect weld joints for cracking, pitting, corrosion and signs of leaking (product residue). Perform dye penetrant or magnetic particle tests if leaks or cracks are suspected. Check for proper grounding 2.2 Internal Visual Inspection 3 SHELL APPURTENANCES 3.1 Manways and Nozzles Clean angles and other components that form catch basins and check for degradation and corrosion.. Inspect nozzle penetration surfaces and welds for corrosion, cracking and deformation. Check atmospheric conditions, fill out and post safe entry permit form. Appropriate and wear required PPE for safe entry. Inspect shell surfaces for coating failures, pitting and corrosion. Inspect baffle plate surfaces weld attachments for cracking, pitting, or corrosion. Check bolts are secure with minimum thread engagement. Inspect agitator shaft and blade surfaces for cracking, pitting, corrosion. Check bolts are secure and have minimum thread engagement. Inspect heating coils surfaces and weld attachments, for cracking, pitting, corrosion. Check bolts are secure with minimum thread engagemen Inspect pressure containing weld joints for cracking, pitting, and corrosion. Perform dye penetrant or magnetic particle tests if cracks are suspected. Inspect for cracks or signs of leakage on weld joints at nozzles, manways, and reinforcing plates. Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection. Inspect for flange leaks and leaks around bolting. Check flange bolts are secure and have minimum thread engagement. Inspect sealing of insulation around manways and nozzles. Check for inadequate manway flange and cover thickness on mixer manways. Check exposed flange and cover faces. 3.2 Relief Devices a. b. Inspect for flange leaks and leaks around bolting. Check flange bolts are secure and have minimum thread engagement. c. Record inlet and outlet sizes sizes. Inlet: d. Check that relief system outlet discharges to safe location (outside of building). e. Record certification date No Tag attached f. Record pressure setting g. Record type and ID Outlet: 3.3 Shell-Mounted Sample Station a. b. c. Inspect sample lines for function of valves and plugging of lines, including drain or return-to-tank line. Check circulation pump for leaks and operating problems. Test bracing and supports of sample system and equipment. Page 1 of 3 Page 23
API-510 PRESSURE VESSEL INSPECTION CHECKLIST Inspector: Jeff Walling Cert No.: 2782 Company: ACME Energy Vessel: 0480 Report No.: 11033.033.1 Date: 5/26/2011 3.4 Heater (Steam Coils) a. Inspect condensate drain for presence of oil, indicating leakage. 3.5 Mixer/Agitator a. b. c. Inspect for proper mounting flange and support. Inspect for leakage. Inspect condition of power lines and connections to mixer. 3.6 Deck Plate and Grating a. X b. X c. d. Inspect deck plate for corrosion-caused thinning or holes (not drain holes) and paint failure. Inspect plate-to-frame weld for rust scale buildup. Inspect grating for corrosion-caused thinning of bars and failure of welds. Check grating tie down clips. Where grating has been retrofitted to replace plate, measure the rise of the step below and above the grating surface and with other risers on the stairway. 3.7 Stairway Stringers/Rungs/Treads a. b. c. Inspect stairway stringers, rungs and treads for corrosion, paint failure and weld failure. Inspect stairway supports to shell welds and reinforcing pads. Inspect steel support attachment to concrete base for corrosion. 4 VESSEL JACKET 4.1 Jacket Shell a. b. c. d. e. f. g. h. Identify type of jacket (half pipe, cylindrical, dimpled and spot welded, etc.) Measure and record pitch distances. Visually inspect shell surface for paint failures, pitting, corrosion, denting, out-of-round and part deformation. Clean angle support rings and inspect for corrosion and thinning on plate, annular space and welds. Inspect the shell-to-foundation seal or barrier. Check for broken, unused insulation rod supports causing corrosion nodes. Visually inspect for weld joints for cracking, pitting, corrosion and signs of leaking (product residue). Perform dye penetrant or magnetic particle test if leaks or cracks are suspected. 5 INSULATION 5.1 Visual Inspection a. b. c. Check for holes, missing portions, deterioration due to corrosion or abuse. Check for sufficient sealing, especially around vessel appurtenances. Check for wetness 6 PRESSURE /TEMPERATURE INDICATORS 6.1 Physical and Operating Conditions a. X b. X c. X d. X Check that indicators are securely attached and operating properly. Check that indicators are in accessible locations and readable. Check that indicators have current calibration date. Check for any damage, and corrosion build up. 7 ASME/NAME PLATE DATA 7.1 Physical Condition a. X b. X Check that ASME plate is securely attached Check that ASME plate is in accessible location and readable. Page 2 of 3 Page 24
API-510 PRESSURE VESSEL INSPECTION CHECKLIST Inspector: Jeff Walling Cert No.: 2782 Company: ACME Energy Vessel: 0480 Report No.: 11033.033.1 Date: 5/26/2011 7.2 Record Following ASME Data a. X Board Number None b. X Serial Number T-57340 c. X Radiography Examination 250 @ 125F d. X MAWP e. X MDMT f. X Nominal Shell Thickness g. X Nominal Head Thickness h. X Nominal Height i. X Head Material j. X Shell Material k. l. X Jacket Material Manufacturer Trinity Steel Co., Inc m. X Year Built 1966 8 VESSEL LAYOUT DRAWINGS 8.1 Record Following Data a. X b. X c. X d. X e. X f. X Notes: Head and skirt lengths and type. Shell lines of support (Head Tang, Braces, Jckt Closures) Foundation support member dimensions and orientation. Inside/Outside diameter. Vessel part nominal thicknesses. Nozzle layouts, sizes and uses. 9 UT THICKNESS READINGS 9.1 Measure and Record Vessel Part Thicknesses a. X Heads - (4) locations, (1) in each quadrant. b. X Shell - (4) locations, (1) in each quadrant for each course. c. d. Jacket - As required (at least (4) locations). Nozzles - (4) locations, (1) in each quadrant for 2 inches and greater, (1) for < 2" Page 3 of 3 Page 25
APPENDIX E Manufacturers Data Sheets 1) U1 Mfg Data Sheet Report No.: 11033.033.1 Page 26
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APPENDIX F Inspection Photographs Report No.: 11033.033.1 Page 28
ACME ENERGY TANK 0480 REPORT 11033.033 - INSPECTION PHOTOGRAPHS Overall view of Tank 0480 Dataplate Page 29
ACME ENERGY TANK 0480 REPORT 11033.033 - INSPECTION PHOTOGRAPHS ASME Name Plate Concrete saddle with rubber liner Page 30
ACME ENERGY TANK 0480 REPORT 11033.033 - INSPECTION PHOTOGRAPHS Corrosion between manway flanges Relief vents Page 31
ACME ENERGY TANK 0480 REPORT 11033.033 - INSPECTION PHOTOGRAPHS Walkway Temperature and pressure gauges Page 32
APPENDIX G NDE Records 1) UT Calibration Record 2) NDE Technician Certification 3) API Inspector Certification Report No.: 11033.033.1 Page 33
ULTRASONIC EXAMINATION REPORT CLIENT: ACME Energy CLIENT PO #: 164 REPORT NO.: 11033.033.1, 2, & 3 EIT JOB #: 11033.033.900 EQUIP ID: Tanks 480, 483, 484, 29319 SERVICE: Propane JOB DESCR.: Horizontal AST thickness readings. EXAM DATE: 5/26/2011 PROCEDURE #: EIT-UTT-01 SPECIFICATION: API-510 MATERIAL: CS TEST PARAMETERS UT UNIT Unit: Dakota MVX S/N: 77143 Cal Date: 05/26/2011 PROBE SPECIFICATIONS Long Frq 5 mhz Size:.5 Type: HD S/N F7 SW Frq: mhz Size: Type: S/N SW Frq: mhz Size: Type: S/N SW Frq: mhz Size: Type: S/N MFG: Ultra Grade Gel-40 COUPLANT Surface Cond: Coated CALIBRATION STANDARD Type: 4 lvl step wedge, 4340 FE CS S/N: 052-5609 Calibration Reference Level (db) 0: 51 45: 60: 70: Other: 0: 45: 60: 70: Start Time: 0700 End Time: 10:30 Start Time: 3:30 End Time: 15:00 Results/Comments: Reference API-510 Report UT Level II Technician: Jeff Walling Page 34
EAGLE I. TECHNOLOGIES NAME: METHOD LEVEL DATE EXAMINER GENERAL SPECIFIC PRACTICAL COMPOSITE UTT II 4/9/2010 Joe Monroe 86% 100% 95% 94% 4/9/2015 PT II 9/3/2010 Wayne Bailey 93% 95% 91% 93% 9/3/2015 MT II 9/3/2010 Wayne Bailey 93% 95% 85% 91% 9/3/2015 MFE II 1/21/2011 Brian Rotto 90% 85% 89% 88% 1/21/2016 Jeffrey Walling NDT CERTIFICATION / QUALIFICATION RECORD Employee ID Number: 3965 NDT CERTIFICATIONS EXAM SCORES EXPIRATION DATE RESTRICTIONS thickness only None None None COMPANY NAME/ADDRESS CAPE Westech Inspection BP/GIANT MATIS PREVIOUS EMPLOYER NDT CERTIFICATIONS FROM TO NDT METHODS & HIGHEST LEVEL ATTAINED 6/2009 9/2013 1/19/2004 11/20/2009 9/1/1998 4/15/2003 9/16/1995 9/1/1998 Level II UTT/MT/PT/MFE Level II UT thickness limited Level II UTT/MT/PT/LT Level II UTT/MT/PT EYE EXAMINATION EDUCATION AND TRAINING DATE TYPE TESTED BY PASS / FAIL INSTRUCTOR ORG DATE LENGTH 10/22/2012 Far Amer. Best Pass David Spooner MATIS 12/16/1997 12 hours 10/22/2012 Near Amer. Best Pass David Spooner MATIS 12/16/1997 12 hours 10/22/2012 Color Contrast Amer. Best Pass Joe Monroe Eastern NDT 4/9/2010 24 hours SUBJECT Level II UTT Level II PT Level II UTT refer to employee eye exam cert (CAPE-FRM-101) Stan Meyer WCFS 8/25/2010 20 hours Level II MT Stan Meyer WCFS 8/27/2010 12 hours Level II PT Brian Rotto CAPE 1/21/2011 8 hours Level II MFE OTHER NOTABLE CERTIFICATIONS OR QUALIFICATIONS CERT EXP DATE CERT EXP DATE API 653 4/30/2014 PD DEP 1/10/2016 API 510 6/30/2014 NB Comm. 2014 TRAINEE / LEVEL I NDT HOURS (IF APPLICABLE) API 570 6/30/2014 VA-B&PV Com 2013 METHOD EMPLOYER HOURS TOTAL DATE STI 9/18/2017 MET.AS 2012 Jeff Walling NDE PROGRAM MANAGER - ASNT CERT No. 10/22/2012 SIGNATURE DATE EIT Certification Record Form: CAPE-FRM-102 This NDT Qualification record is in accordance with EIT-WP-01 and SNT-TC-1A (2006). All historical information supplied for this document is true and accurate to the best of my knowledge. Page 35
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