Specialist tank & pipe inspection services

1. Specialist tank & pipe inspection services January 2009 by Alan Ashton

2. An introduction to a comprehensive storage tank and pipe work inspection service for the Middle East regionusing technology driven equipment

3. A unique service using Silverwing MFL and UT expertise as both a supplier of equipment and provider of specialist corrosion inspection services for Storage tanks and associated pipe work

4. Silverwing patented equipments are in use within 58 different countries

5. In a wide variety of climatic conditions - from the hottest

6. …to the coldest

7. The Cost Of Corrosion The American Petroleum Institute calculated that between 1990 and 1996 the annual average remediation and spill costs for 14 petroleum companies was 1.171 BILLION US DOLLARS

8. Therefore the API survey shows that the indirect cost of CORROSION for these 14 petroleum companies between 1990 and 1996 was……..1.171 BILLION US DOLLARS per year The Cost Of Corrosion

9. Storage Tanks and Corrosion A leaking Storage Can Damage: • The Environment • PublicHealth • Plant Profit Margins

10. Corrosion sources • Atmospheric • Vapour Phase • Interface • Product side • Under insulation or coating • Under floor( soil side)

11. Occurs on external surfaces due to exposure to air and pollutants Atmospheric Corrosion

12. Vapour Space Corrosion Occurs in the vapour space of tanks above the level of liquid. Caused by moisture condensing on the inner surfaces due totemperature changes

13. Occurs at the interface between the liquidproduct and gas in the vapour space Interface Corrosion Usually only a problem if liquid levels remain the same over long periods of time

14. Formed as a result of the liquid stored in the tank Product Side Corrosion

15. Corrosion Under Insulation Caused by water trapped under insulation or coating

16. Under floor Corrosion • Occurs at under (soil) side of tank floors • Usually associated with moisture contact. • Sub soil characteristics • Impossible to detect visually

18. Classification of Corrosion types • Pitting • Conical • Pipe • Lake • Crevice • Galvanic • Biological • Preferential • Stray( interference) current

19. Example Lake & Pit type corrosion Classification of Corrosion types Underside of floor cut-outs showing Under floor corrosion Enlarged view lake type

20. Example Biological corrosion Classification of Corrosion types Underside of floor cut-outs showing Under floor corrosion

21. WHAT DO WE DO ? Silverwing offers a comprehensive tank and pipe inspection service utilising our highly experienced service team covering both in service and out of service inspection.

22. IN SERVICE INSPECTION • In service Acoustic Emission screening to identify potential defects and prioritise the order in which tanks should be taken out of service for a detailed Maintenance inspection • Thermography • API 653 surveys • Tank shell and roof corrosion measurement • Laser alignment

23. IN SERVICE INSPECTION Acoustic Emission - Signal

24. IN SERVICE INSPECTION • Technique based on detection of high frequency vibrations (AE signals) • Signals detected by AE sensors (50 kHz -1MHz) • High speed data-acquisition unit collects data

25. IN SERVICE INSPECTION • Data-analysis for characterising • Corrosion / cracks / leaks • Extremely sensitive technique:0.5 mm pencil point break detectable at 70 m from sensor Acoustic Emission – Basic theory

26. IN SERVICE INSPECTION • Sensors are placed on tank wall • Approx. 1 metre above bottom • No. of sensors controlled by tank diameter normally one or two rows Acoustic Emission – Basic theory

27. IN SERVICE INSPECTION Acoustic Emission - Instrumentation Sensors Data-acquisition unit

28. IN SERVICE INSPECTION Examples of acoustic emission report on Storage tank floor plates

29. IN SERVICE INSPECTION Thermography Theory Spectral range

30. e T b T s camera IN SERVICE INSPECTION Thermography Theory What is detected by the camera? T - object temperature s T - backgroundtemperature b e - emission factor

31. IN SERVICE INSPECTION • Thermography Comparisons

32. 20.6 18.6 16.6 14.6 12.6 10.6 8.6 Temperature °C 6.6 4.6 2.6 0 5 10 15 20 25 0.6 Distance [Metres] IN SERVICE INSPECTION • Thermography sensitivity Temperature profile along side wall

33. OUT OF SERVICE INSPECTION Out of service MFL floor scanning using the latest generation FloormapVS2i mapping system and HandScan unit for inaccessible areas

34. FloormapVS2i OUT OF SERVICE INSPECTION Computerized MFL tank floor inspection Corrosion detection and sizing with advanced reporting software FloormapVS2i

35. FloormapVS2i OUT OF SERVICE INSPECTION The new FloormapVS2i is the most operator friendly, comprehensive tank floor inspection system in the world.

36. OUT OF SERVICE INSPECTION • Hall effect sensors are used to detect the flux leakage path to ensure that the MFL unit secures precise data rather than averaging data when using electro magnetic Unique User Benefits of the Floormap VS2i FloormapVS Mark 2

37. OUT OF SERVICE INSPECTION • Eliminate the variable scanning speed of manually operated equipment which can result in different amplitude signal strength for the same discontinuity depending on the speed by utilising a fixed speed DC motor as well as eliminate the requirements contained in Appendix G of API 653. Unique User Benefits of the Floormap VS2i FloormapVS Mark 2

38. OUT OF SERVICE INSPECTION • Permanent sintered neodymium iron boron magnets which: • Eliminate the need to have a 110 v supply for MFL scanning inside the tank • Eliminates any heavy duty power cables • Reduced time to complete inspection by as much as 25% • guarantee uniform strength across the magnet • are mechanically the strongest Unique User Benefits of the Floormap VS2i FloormapVS Mark 2

39. OUT OF SERVICE INSPECTION • Improved defect detection and sizing over previous designs being able to detect any discontinuity within 3 mm on an 8 m long plate. • Annular plate scanning capability on certain tank designs. Unique User Benefits of the Floormap VS2i FloormapVS Mark 2

40. OUT OF SERVICE INSPECTION • Automatic CAD drawing of tank floor which ensures that: • there is a patch plate design capability including bill of material schedule with total Material requirements - a MAJOR time and overhead saving for any organisation. Unique User Benefits of the Floormap VS2i FloormapVS Mark 2

41. OUT OF SERVICE INSPECTION • the operator and client has a very clear report on which areas where not automatically scanned due to being inaccessible • reduces shutdown cost by eliminating the need to deploy a third party inspector to witness the scanning. Unique User Benefits of the Floormap VS2i FloormapVS Mark 2

42. OUT OF SERVICE INSPECTION • Real time as well as quicker dataacquisition and analysis giving the MFL operator immediate access to plate and track data as well as the ability to repeat selected scans which may be suspect. Unique User Benefits of the Floormap VS2i FloormapVS Mark 2

43. OUT OF SERVICE INSPECTION • Combined defect profiling and amplitude analysis using a bespoke software programme to automatically cross check the data by using amplitude analysis to refine the data and ensure that the final reported data is easily identifiable as being either pipe, conical or lake type by the trained operator and more accurate than that secured by manual UT. Unique User Benefits of the Floormap VS2i FloormapVS Mark 2

44. OUT OF SERVICE INSPECTION Unique User Benefits of the Floormap VS2i • Full finger print reporting by data addition • to support trend management and including: • MFL HandScan results • Digital photos • Visual comments • Manual pit gauge and UT reports comments • Auto UT C scan reports , if performed by Silverwing • Vacuum box reports, if performed by Silverwing • MPI inspection report. if performed by Silverwing • USB port for data transfer to facilitate 24 hour working if required. FloormapVS Mark 2

45. OUT OF SERVICE INSPECTION Unique User Benefits of the Floormap VS 2i • Multiple license capability for read only version users such that the data maybe be shared and viewed at various local and worldwide locations within a terminal operator organisation. • Base line data acquisition comparison reports to assist with future asset life assessment by being able to superimpose previously collected FM data for the same tank and identify the change in the tank floor between the different inspection dates. • Multi Language capability. FloormapVS Mark 2

46. FloormapVS2i OUT OF SERVICE INSPECTION All new data acquisition and analysis software has been developed for the FloormapVS2i on-board computer.

47. FloormapVS2i OUT OF SERVICE INSPECTION The New FloormapVS2i contains significant improvements in terms of defect positioning, defect sizing and ease of use.

48. FloormapVS2i OUT OF SERVICE INSPECTION A new encoder system has been developed which is electronically calibrated to each individual scanner, giving accuracy to within 30mm on an 8 metre track length.

49. FloormapVS2i OUT OF SERVICE INSPECTION The ruggedized on-board SM 1000 data acquisition computer uses touch screen technology for ease of use within the hostile storage tank environment

50. FloormapVS2i OUT OF SERVICE INSPECTION Latest generation rare earth magnets achieve localised magnetic saturation of the mild steel tank floor plates