Tank and Pressure Vessel Maintenance

Ch 4 Tank & Pressure Vessel Maintenance
Chapter 4
Tank & Pressure Vessel
Maintenance
Kuliah MS4102 Perawatan Mesin 1
4.1. General
 Vertical, aboveground atmospheric-pressure storage tanks are
commonly used in processing facilities.
 For more than a century, storage tanks have been in use
within the petrochemical industry, fulfilling their intended
purpose: to store products.
 By definition, an atmospheric tank has a design pressure (DP)
less than 2.5 psig.
 Most ASTs are
constructed out of
welded steel plates.
Older tanks have riveted
or bolted seams and
newer tanks are welded.

• Fuel storage tanks must be vented so fumes can escape

(breathing), reducing the potential for ruptures and collapses.
• ASTs should have cathodic protection, such as sacrificial
anodes, to reduce corrosion.
• To reduce the chances for corrosion, tanks should be placed
on a pad, foundation or supports rather than directly on the
ground.
• Tanks must have overfill protection, i.e. direct vision gauges,
high liquid level alarms, flow restrictions or high liquid level
shut off devices
shut-off devices.
• Tanks should be labeled as to contents, size, last internal
inspection, safe gauge height and year built.
Some Incidents
Filling of a vertical tank
The top of tank
blew off because
the relief valve
could not displace
the air fast
enough for the
volume of water
that was being
pumped
p p in.

The plastic sheet

on top of the tank
Emptying of a vertical tank
The collapse of this tank happened while it was being emptied.

A plastic sheet protecting the roof was trapped in the vent;
hence a vacuum was caused. Kuliah MS4102 Perawatan Mesin 5
The accident happened

during the filling of a
Sphere collapse 2000 m3 LPG sphere.
Its legs collapsed.
One person was killed
and one seriously
injured
Severe corrosion of the

legs under the concrete
fire p
protection was the
main cause.
The corrosion occurred
due to water ingress
between the concrete
and the steel legs.
Hydro-test of
The root cause of the incident is not
a new vertical vessel fully known. But, there was some
thought that hydro testing with "very
cold" water was a contributing factor.
cold
Fortunately no injuries occurred.
Wall Thickness
Tank versus Pressure Vessel

• Tank, storage tank, atmospheric tank
• Pressure vessel, tank, column, drum
Gbr. 4.1 Tank Gbr. 4.2 Pressure Vessel

Tank Pressure Vessel

• Atmospheric pressure • Having significant internal
((less then 15 p
psig).
g) pressure or external
p
pressure.
• Fluid:
liquid with a certain SG. • Fluid:
either gas, liquid, or both
• Main load:
(mix).
hydrostatic pressure,
dead weight, live load. • Main load:
static
t ti pressure, dead
d d
weight, live load.
Tank Capacity
– Nominal capacity: capacity as printed on the tank wall.
– Geometry capacity: the volume of vertical cylindrical section.
– Storage
g capacity:
p y the volume from the tank bottom to the
maximum design level.
– Net working capacity: the volume between HLL and LLL or
HHLL and LLLL
Gbr. 4.3
Tank capacity

Tank Components:
– Shell
– Roof
– Rafter
– Column
– Top Angle
– Bottom Plate
– Welding Joint
– Nozzles & Manhole
– Anchor Bolts
– Venting
– Gauging
– Ladder
Shell
Column & Rafter
Shell
Top Angle

Cone roof with internal floating roof Dome roof with internal floating roof
Self-supporting cone roof Self-supporting dome roof
Supported cone roof Hanging roof

Codes & Standards

 API Std 650: “Welded Tanks for Oil Storage”.
Covers: vertical, cylindrical, aboveground, field-welded steel
t k for
tanks f oilil storage
t with
ith maximum
i operating
ti ttemperatures
t nott
0
greater than 250 F and pressures in the vapor space less than
2.5 psig.
 API Std 620: “Design and Construction of Large, Welded, Low-

Pressure Storage Tanks”.
Covers: the design and construction of large
large, welded
welded, low
low-
pressure carbon steel above ground vertical storage tanks
(including flat-bottom tanks) with maximum operating
temperatures not greater than 2500F and pressures in the
vapor space less than 15 psig.
Codes & Standards

 API Std 653 “Tank Inspection, Repair, Alteration, &
Reconstruction”
 API RP 575 “Recommended Practice for Inspection of
Atmospheric and Low Pressure Storage Tanks”
 API RP 576 “Inspection of Pressure Relieving Devices”
 API RP 579 “Fitness for Services”

Codes & Standards

• API Specification 12D : "Field Welded Tanks for Storage of
Production Liquids“.
Covers: vertical, cylindrical, aboveground, welded steel tanks in
nominal capacities of 500-10,000 bbl in standard sizes for
production service.
• API Specification 12F, "Shop Welded Tanks for Storage of

Production Liquids“.
Covers vertical, cylindrical, aboveground, shop-welded steel
tanks in nominal capacities of 90-500 bbl in standard sizes for
production service.
4.2. Operation and Maintenance
During operation, the following activities are required.
 Storing
 Transfer: filling or emptying
 Leak detection
 Spill prevention
 Inspection
 Minor repair
 Certification
 Painting and coating
 Cleaning
 Overhaul and/or repair

Transfer Procedure
• Transfer procedure:
Fungsi utama operasional fasilitas penyimpan cairan
adalah memindahkan (transfer) cairan dari perpipaan ke
tangki, dari satu tanki ke tangki lain atau dari tangki ke
kendaraan/kapal.
• Things to be considered
– Spill/overfill
– Overpressure
– Collapse
– Cavitation
– Safety
Transfer Procedure
 Sebelum transfer:
• Cek level bahan bakar pada tangki pengirim dan penerima
• Periksa perpipaan terhadap kebocoran.
• Cek posisi valve, tetap berkomunikasi dengan operator masing-
masing ujung tarnsfer.
 Selama transfer:
• Mulai transfer pada laju rendah.
• Pastikan ada orang/teknisi yang MENJAGA saat transfer.
transfer
• Tetap berkomnunikasi antar operator selama transfer.
• Cek level tangki penerima secara teratur.
• Kurangi laju ketika level bahan bakar mendekati batas atas.
• Beritahu operator pengirim bahan bakar ketika transfer hampir
selesai.
Transfer Procedure
 Saat transfer selesai:
• Tutup katup-katup yang sesuai pada manifold dan tangki.
• Lakukan komnunikasi/meeting dengan antar operator pengirim
dan penerima.
• Endapkan tangki selama 6 - 24 jam dan cek water level pada
bawah tangki.
Spill Prevention
Pencegahan kebocoran sangat penting untuk:
• Menurunkan potensi masalah kesehatan,
• Menurunkan resiko lingkungan,
• Mencegah kerugian finansial, akibat kehilangan produksi, denda,
biaya pembersihan dll.
Ref. : Aboveground Storage Tank Operator Handbook, Second

Edition, Alaska Department of Environmental Conservation
Spill Prevention
 Penyebab Kebocoran
 Kesalahan operator
• Tangki terlalu penuh.
• Valve terbuka.
• Prosedur transfer yang buruk.
• Tidak adanya product monitoring.
• Tidak adanya usaha untuk mengenali masalah.
• Pemeliharaan y yang
g buruk.
 Desain dan pembangunan instalasi yang buruk
• Kurangnya pengamanan.
• Fasilitas berlokasi di daerah rawan banjir/bencana.
• Buruknya drainase atap tangki ke peralatan lain di bawahnya.
Spill Prevention
 Penyebab Kebocoran (cont’d.)
 Masalah di Storage Tank
• Rancangan dan pembangunan yang buruk.
• Buruknya fondasi.
• Bawah tangki, terkorosi, bocor dll.
• Venting yang buruk.
 Masalah pada Perpipaan
• I t l i perpipaan
Instalasi i pada
d jalur
j l ramai.
i
• Adanya atau banyaknya sambungan ulir, bukan las.
• Kurang efektifnya tumpuan pipa.
• Valve terkorosi atau tidak dalam kondisi yang baik.

Spill Prevention
 Penyebab Kebocoran (cont’d.)
 Masalah pada Perpipaan (cont’d.)
• Pipa tidak tertumpu, melainkan langsung di atas tanah.
• Pipa kontak dengan tanah yang asam  mudah terkorosi.
• Tidak ada pipa fleksibel.
• Pipa tidak diinspeksi secara reguler/rutin.
 Pada Secondary Containment
• Tidak terdapat penampung tumpahan, tidak baik atau tidak
memadai.
• Terdapat kebocoran pada saluran, terutama liner nya.
• Adanya air pada saluran.
Spill Prevention
 Tindakan Pencegahan
 NOTES: “Tidak ada kebocoran yang terlalu kecil untuk tidak
di b iki”
diperbaiki”.
 Karyawan harus dilatih dengan prosedur operasi yang benar
dan tindakan pencegahan kebocoran, kesiapan dan respon.
 Tidak diperbolehkan ada minuman beralkohol/obat terlarang.
 Selalu up-to-date terhadap data-data produk dan peralatan.
 Buat jadwal pemeliharaan yang teratur.
teratur
 Lakukan inspeksi standar secara rutin sekaligus tindakan
perbaikan jika diperlukan.
 Rancanglah fasilitas dengan baik dan sesuai standar.
 Bangga dan bertanggungjawablah terhadap fasilitas.
Tank Basic Inspection

 Soundness
 Visible leaks? must be stopped & repair
 Stains on the ground around the tank?
 Seams & weld.
 Corrosion protection
 Any sign of rust/corrosion?
 If using sacrificial anode: make sure there is sufficient metal
left
left.
 If using ICCP: make sure the proper amount of electricity is
flowing.
Tank Basic Inspection

 Tank signs: tank #, product, capacity, flammable (?)
 Vents: clear, no debris plugging them.
 Paint: Check for peeling, blistering or chipping.
 Foundation:
– If using beams, is there crack or deformation?
– Concrete: crack, settlement
 Gauges & overfill devices:
– working?
ki ?
– test overfill alarms
– Test shut-off devices

Tank Cleaning
– Tank cleaning is a vital area of tank maintenance,
especially if your aim is to maximize your tank's
overall lifetime.
f
– But cleaning a tank takes it out of operation - and this
costs money.
– Proper and sufficient maintenance is necessary to
minimize the effects of degradation mechanisms,
such as corrosion and settlement.
– If parts of the tank are degraded beyond a defined
limit, extensive repairs are required to keep the tank
or a specific tank component fit-for-purpose.
Facility Maintenance
 Good housekeeping  clean and proprer.
 Safety: fire extinguishers and other safety equipment must
be in good working
orking condition
condition.
 Security: fence, lock, lighting.
 Tank paint
 Storage Tank:  Facility piping:
 Vent  Valves & corrosion protection
 Overfill device  Change
g filters
 Gauges  Hydrostatically tests
 Corrosion protection  Rewrap or repaint pipes
 Water drains

4.3. Typical Damages of AST
C
Corrosion
i off anchors
h
Settlement of the tank

Sinking in foundation
Lifting of tank and plants under bottom

Cavity under the steel bottom
Corrosion of shell inside the tank
Corrosion of roof plates
Corrosion under heat insulation

Corrosion of bottom plates
Plants on spiral stairway

Local deformations of the shell
Deviation of shell into inside

Surface damages, lap joints and

reinforcement of welds Lap vertical joint in the shell
Holding of a water on the floating roof

4.4. Maintenance & Repair (API 653)
• API 653 provides minimum requirement for

maintaining integrity of welded or riveted
riveted, non-
non
referigerated, atmospheric pressure, aboveground
storage tank after they have been placed in service.
• This standard covers steel storage tanks built to API
Standard 650 and its predecessor API 12C.
• It covers: maintenance,
i t i
inspection,
ti repair,
i alteration,
lt ti
relocation and reconstruction of tanks.
Maintenance & Repair (API 653)
Suitability for Service:

Roof, Shell, Bottom p
plate, Foundation
Inspection:
Frequency, external inspection, internal
inspection, bottom thickness, Records
Tank Repair & Alteration:

Removal & Replacement of shell plate; Repair of
defects in shells; defective welds, tank bottoms,
roof, hot taps
Documentation:
Marking, record keeping, certification


 General Evaluation of Suitability for Service
 Internal corrosion due to product or water bottoms
 External corrosion due to environment
 Stress level versus allowable stress
 Properties of the stored product
 Metal design temperature
 External roof live load, wind and seismic loadings
 Tank foundation,
foundation soil & settlements
 Chemical analysis & mechanical properties of material
 Distortions
 Operating conditions, e.g. filling/emptying rates & frequency

 Tank Roof Evaluation
 Roof support systems (rafters, girders, columns & bases)
shall
h ll b
be iinspectedd against
i corrosion
i and dddamage especially
i ll
center column.
 For floating roof, check for crack, puncture, or pitting
corrosion.


 Tank Shell Evaluation
 Shells corrosion occurs in form of uniform loss of metal over a
l
large area or iin llocalized
li d areas.
 Pitting may occur. It does not represent a significant threat
unless close to one another.
 Check shell integrity using mthod of evaluation againts
corrosion using procedure given by API 653
(Methods for determining the minimum shell thickness suitable
for continued operation are given in 4.3.2, 4.3.3, and 4.3.4.)

 The thinning due to corrosion shall also be evaluated against
other
h lloads,
d if applicable,
li bl e.g.
 Wind-induced buckling
 Seismic loading
 Operation at temperature over 200F
 External loading due to piping
 Vacuum-induced external p pressure
 Wind-induced overturning
 Loads due to settlements


 Distortions
 Example: Out-of-roundness, buckled areas, flat spots.
 Causes: foundation settlements, over- or under-pressure, high wind,
poor shell fabrication or repair
 Flaws/Cracks
 Shell weld
 Shell openings
 Shell stiffeners

 Tank Bottom Evaluation
 Main inspection: Leakage!
 Mitigation plan:
 Shorter inspection intervals
 Bottom lining
 Upgrading/repair
 Replacement


 Failure Causes:
 Internal pitting
 Corrosion of weld joints
 Weld joint cracking history
 Roof support loads
 Underside corrosion
 Inadequate
q drainage
g
 The lack of annular bottom plate
 Uneven settlement
 Inadequate pre-consolidation
 Inadequate support sumps

 Effectivity
of cathodic protection (API 651)
 Lining (API 652)
 Main inspection: Leakage!  leak detection system


 Bottom plate thickness measurement
 Calculation of “remaining thickness” for tank bottom at the
end of the in-service period (normally 10 years)
 If this remaining thickness is less than bottom renewal
thickness (as required in standard), then:
 Shorter inspection intervals
 Bottom lining
 Upgrading/repair
 Replacement

 Tank Foundation Evaluation
 Principal causes:
 Settlement
 Cracking and deterioration of concrete.
Initiated by calcining, attack by underground water, frost,
alkalies & acids.
 Concrete pads, ring walls, and piers, showing spalling,
cracks, or general deterioration, shall be repaired to
prevent water from entering the concrete structure and
corroding the reinforcing steel.
 Anchor bolts, check for:
 Distortion
 Excessive crack of concrete structure

Maintenance Management
 Inspection/maintenance periods
 In order to maximize its functionality and structural integrity,
a tankk must bbe iinspected
d andd maintained
i i d at predetermined
d i d
intervals to check the progress of unwanted degradation
mechanisms.
 When degradation of a specific tank component nears its
rejection limit, proper repairs need to be carried out.
 However, to prevent unwanted shut-down, routine
maintenance and inspection should also be carried out
during the in-service period of a tank.
 Formal visual external inspection at least every 5 years or
at the
h quarter corrosion-rate
i lif off the
life h shell
h ll ((whichever
hi h
less).
 Insulation may be remove for inspection of the exterior wall
or roof.
 Cathodic protection system requires periodic surveys
according to API RP 651.
 Tank electrical grounding shall be visually checked.

 Reference of code for inspection:
 EEMUA*) Publication No. 159, “User’s guide to the
inspection, maintenance and repair of above-ground
vertical steel storage tanks”, Volume 1 and 2, 3rd
edition, 2003
 API standard 653, “Tank inspection, repair, alteration
and reconstruction, 3rd edition, December 2001.
 API Recommended Practice 575, “Inspection of
atmospheric and low-pressure storage tanks, 1st edition,
November 1995.
*) EEMUA: Engineering Equipment and Materials Users’ Association
 Main Activities of Tank Maintenance
 Preparation, deals with arranging
adequate
d t contracts
t t withith NDT iinspection
ti
companies and contractors as well as
purchasing long-lead delivery items.
 Actual out-of-service period, where
various other tasks have to be
performed.
 Box-up, when the tank is connected to
the plant utilities, control room and
pipeline systems.
 In-service routine preventive
maintenance.
 Out-of-service Activities (EEMUA 159)
1. Records, incl. tank's original data, as-built documents, records of
inspection modification
inspection, modification, product change
change. After the maintenance
maintenance, a
description of all repairs, inspection reports and NDT reports must be
added to these files so they are properly updated
2. Cleaning, inc. cleaning and gas freeing activity
3. Inspection, inc. internal and external inspections to assess the actual
status of all tank components
 Out-of-service Activities (EEMUA 159)
4. Compliance, to assess whether the component is still fit-for-purpose
or whether it should be replaced
replaced.
5. Engineering, if the tank components need to be repaired or even
replaced, engineering tasks are needed to assess where, how and
when these repairs will be performed.
6. On-site Repair
7. Fit for purpose, when all

repairs have been executed,
the tank must be declared fit-
for-purpose by a responsible
staff member of the tank
owner before the tank is
allowed back in service.

 Total Life-cycle
 Total Life-cycle
 Care must be taken to the Indirect Costs, that includes:
 Non-availability of the tank during its out-of-service period
(during which time additional tank capacity may need to be
hired),
 Lost rental earnings for depots and terminals, and
 Additional cleaning costs of tanks used to temporarily store the
product removed from the out-of-service tank.
 Ways
W to do
d it:
i
 Reduce out-of-service time (non-availability cost)
 Reduce total maintenance and inspection costs
 Extend in-service time

References
 API Std 650
 API Std 653
 API RP 575
 Aboveground Storage Tank Operator Handbook, Second
Edition, Alaska Department of Environmental Conservation.
 A vision on tank maintenance costs, by Jan de Jong.
 http://www.astanks.com/EN/Intro_EN.html.

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What are the main components of a storage tank?

What are the main components of a storage tank?

What are the main activities involved in tank maintenance?

What are the main activities involved in tank maintenance?

Ch 4 Tank & Pressure Vessel Maintenance

Kuliah MS4102 Perawatan Mesin 1

Ch 4 Tank & Pressure Vessel Maintenance

Kuliah MS4102 Perawatan Mesin 2

• Fuel storage tanks must be vented so fumes can escape

Kuliah MS4102 Perawatan Mesin 3

Ch 4 Tank & Pressure Vessel Maintenance

Kuliah MS4102 Perawatan Mesin 4

The plastic sheet

Emptying of a vertical tank

The collapse of this tank happened while it was being emptied.

Ch 4 Tank & Pressure Vessel Maintenance

The accident happened

Severe corrosion of the

Kuliah MS4102 Perawatan Mesin 7

Ch 4 Tank & Pressure Vessel Maintenance

Tank versus Pressure Vessel

Gbr. 4.1 Tank Gbr. 4.2 Pressure Vessel

Tank Pressure Vessel

Kuliah MS4102 Perawatan Mesin 9

Ch 4 Tank & Pressure Vessel Maintenance

Kuliah MS4102 Perawatan Mesin 10

Kuliah MS4102 Perawatan Mesin 11

Ch 4 Tank & Pressure Vessel Maintenance

Column & Rafter

Kuliah MS4102 Perawatan Mesin 12

Self-supporting cone roof Self-supporting dome roof

Kuliah MS4102 Perawatan Mesin 13

Ch 4 Tank & Pressure Vessel Maintenance

Supported cone roof Hanging roof

Kuliah MS4102 Perawatan Mesin 14

Codes & Standards

 API Std 620: “Design and Construction of Large, Welded, Low-

Ch 4 Tank & Pressure Vessel Maintenance

Codes & Standards

Kuliah MS4102 Perawatan Mesin 16

Codes & Standards

• API Specification 12F, "Shop Welded Tanks for Storage of

Kuliah MS4102 Perawatan Mesin 17

Ch 4 Tank & Pressure Vessel Maintenance

Kuliah MS4102 Perawatan Mesin 18

Kuliah MS4102 Perawatan Mesin 19

Ch 4 Tank & Pressure Vessel Maintenance

Kuliah MS4102 Perawatan Mesin 21

Ch 4 Tank & Pressure Vessel Maintenance

Ref. : Aboveground Storage Tank Operator Handbook, Second

Ch 4 Tank & Pressure Vessel Maintenance

Kuliah MS4102 Perawatan Mesin 24

Ch 4 Tank & Pressure Vessel Maintenance

Tank Basic Inspection

Kuliah MS4102 Perawatan Mesin 27

Ch 4 Tank & Pressure Vessel Maintenance

Tank Basic Inspection

Kuliah MS4102 Perawatan Mesin 28

Ch 4 Tank & Pressure Vessel Maintenance