SUMMARY OF TPI IN

S No

Location

Observation

Roof Plate/Roof
Nozzle

(1)Isolated pits of dimensions 3.6mm

and 2.6 mm.
(2)Coating
Damage and corrosion on lap welds
(3)Water
Pooling on deck
(4)
Instrument Nozzle was attached roof
manhole cover

Roof Hand Rail

(1)Flat bar connection on the roof

hand rail was found with holes and
damged (2)Deep pitting on flat bar
and on angle.(3) Rod connection to the
hand rail found corroded and damaged

Stair Way

(1)Holes and corrosion found on Stair

way Stringer
(2)Dmaged stair way top
platform connection

CURB ANGLE

(1)Localized Pit observed on Curb

Angle

Shell plate/ Shell

Nozzle

(1)UT Gauging was done on shell

plates and shell nozzles and observed
no considerable metal loss

5a

Shell plate/ Shell

Nozzle
(DPT)

Pin holes and porosities were observed

on RF pad joints of below mentioned
nozzles
( N1,N2,N3,N4,N5)

5b

Shell plate/ Shell

Nozzle
(MPI)

Pin holes and porosities were observed

on the external T weld joints during
MPI ( locations mentioned In MPI
reports)

5c

Shell plate/ Shell

Deformation observed 5th & 6th north
Nozzle
east side , 4th& 5th Course south west
(Visual Inspection)
.

5d

5e

5f

5g

Shell plate/ Shell

Nozzle
(Visual Inspection)

Localized pits observed on 7 th and 5

th shell course (photo 30 to 33)

Shell plate/ Shell

Nozzle
(Visual Inspection)

Coating Damage on 4th shell course

( photo 34)

Shell plate/ Shell

Nozzle
(Visual Inspection)

Pitting observed on manhole and

outlet neck bottom side (photo 35 to
36)

Shell plate/ Shell

Pitting observed on the bottom and
Nozzle
below the manhole of 1st shell course(
(Visual Inspection)
photo 37 to 38)

5h

5i

Shell plate/ Shell

Nozzle
(Visual Inspection)

Foam pourer nozzles were observed

without RF pads and pitting has been
observed on the shell around the
bracket attachment of the nozzle.
(photo 39 to 40)

Shell plate/ Shell

Nozzle
(Visual Inspection)

It was observed that one of the

manhole ( N3) was converted into an
outlet by attaching a nozzle on the
manhole cover

Bottom Plate

MFL scanning done on bottom plates

and severe soil side and bottom side
corrossion/holes/pitting were
observed.Significant indication (40%
and above)observed on all plates.
(Ref,section 9)

6a

Bottom Plate

Vacuum Box Test (ref.section 10)

6b

Bottom Plate

MPI (ref.section 10)

6c

Bottom Plate

Visual Inspection

6d

Bottom Plate

Bottom Sump

UT Scanning was carrie out on sketch

plate outer edge, sketch plate 400 mm
from shell,160x160 mm T joints and
10 mm both side of vertical and
horizontal weld joints, MFL identified
locations,Patch plates and below water
draw off pipes.

UT Scanning and Visual Insapection

Done. Holes and Pitting were
observed. Metal loss observed during
UT inspection

Internal Drain
Water Line

UT Gauging and Visual Inspection

done.Original wall thickness is not
available.Severe pitting found on drain
pipe. No pipe supports provided for
drain pipe.

WIND GIRDER

UT Gauging was carried out and no

considerable metal loss
observed.Holes found during visual
inspection

10

RING WALL
FOUNDATION

Crack observed on foundation

INSPECTION SUMMARY OF F
S No

Location

Observation

Foam Pourer

UT gauging and visual inspection done

on foam pourer.Metal loss was not
observed during UT gauging.
Corrossion pitting observed on nozzle
brackets, pourer flange B.Foam pourer
nozzle was observed withgout RF
pads.

Foam Riser A

UT Gauging and Visual Inspection done

on Riser A.No considerable metal loss
found on riser A.Corrossion found on
flange.(photo. 90 to 92)No material
interface between U bolt Supports
and pipes. Coating Damage and
corrossion observed.

Foam Riser B

UT Gauging and Visual Inspection done

on Riser B.No considerable metal loss
found on riser A.Corrossion found on
flange.(photo. 94 to 97)No material
interface between U bolt Supports
and pipes. Coating Damage and
corrossion observed.

Foam Riser B

UT Gauging and Visual Inspection done

on Riser C.No considerable metal loss
found on riser Holes observed on riser
C.(photo. 101 to 103 )No material
interface between U bolt Supports
and pipes. Coating Damage and
corrossion observed.

2" FW Riser for

Roof

UT Gauging done at random locations

and no considerable metal loss
observed. Pitting observed on one
support ( photo 105).U bolt support
Missing.(photo 106) No non material
interface between U bolt and piping.

2" FW Sprinkler
Ring

UT Gauging done at random locations

and no considerable metal loss
observed.No non material interface
between U bolt and piping.

3" FW Riser to

UT Gauging done at random locations

and no considerable metal loss
observed.No non material interface
between U bolt and piping.Coating
Damage Observed

6" Foam Supply

Ring

UT Gauging done at random locations

and no considerable metal loss
observed.No non material interface
between U bolt and piping.Coating
Damage Observed. Support Found
Damaged ( photo. 121)

Shell Brackets Dye

Penetrant Testing

Visual Condition of Shell Bracket

attachment weld was not acceptable
to perform dye penetrant inspection. It
was observed that support brackets
were directly welded to shell without
RF Pads.

OF TPI INSPECTION REPORT

Recommendation by TPI

API 653/API RP 575/API 650

Requirements

Structural integrity of roof plate and roof

Pits shall be repaired/replaced.
support system shall be verified. Roof plates
Surface Preparation and coating to
corroded to an average thickness of 0.09
avoid corrossion.
inc. ( 2.286 mm) in any 100 inch2 or roof
Water pooling need to be arrested to
plates with any holes through the roof plates
avoid local dishing
shall be repaired or replaced

Repair/Replace all corroded area

Stairways, Hand Rails and platforms shall be

visually inspected and evaluated as per
OSHA requirements as detailed in 29 CFR
2910

Repair/Replace all corroded area

Stairways, Hand Rails and platforms shall be

visually inspected and evaluated as per
OSHA requirements as detailed in 29 CFR
2910

As the pits are localized and without

any considerable depth, no
immediate action required

--------------

No immediate Action Required

(1)Actual shell thickness Measurements as

per clause 4.3.2
(2)Minimum shell thickness
meaurement as per clause 4.3.3 Compare
these Values

For tank penetrations,extend of

Rectify the defects and reinspect the reinforcement,weld spacing and thickness of
same
components shall be reviewed for structural
adequacy and compliance with API 650.

For tank penetrations,extend of

Rectify the defects and reinspect the reinforcement,weld spacing and thickness of
same
components shall be reviewed for structural
adequacy and compliance with API 650.

Banding values are within acceptable

limit.No immediate Recommendation

With a vertical sweep board 36 inch

long,Banding value shall be within 1"

No immediate Action Required

(1)No pit depth results in the remaining

shell thickness being less than one half the
minimum accpetable shell thickness
exlusive of corrossion allowance
(2)The sum of their
dimensions along any vertical line doe not
exceed 2 in. an 8 in.length.

Through surface preparation followed

by protective coating application

--------------

Through surface preparation followed

by protective coating application

--------------

No immediate Action Required

(1)No pit depth results in the remaining

shell thickness being less than one half the
minimum accpetable shell thickness
exlusive of corrossion allowance
(2)The sum of their
dimensions along any vertical line doe not
exceed 2 in. an 8 in.length.

It recommended to rectify the same by

placing a RF pad around the nozzle.

--------------

No recommendation

--------------

Due to severe corrossion on bottom

plate associated with through holes
and product side pitting in almost all
over the floor plates, it is
recommended to replace the entire
bottom plate.

(1)Minimum thickness calculation for

No leaks observed. Corrossion on weld bottom plate shall be as per API 653 Clause
4.4.5.
joints.
(2)Unless astress analysis
is performed, the minimum bottom plate
thickness in the critical zone of the tank
bottom defined shall be smller of one-half
the original bottom plate thickness or 50%
No relevent indication
of the lower shell course but not less than
0.1. Isolated pitting will not apparently
affect the strength of the plate.
(3)The thickness of
the projection of the bottom plate beyond
(1)Holes Observed on bottom plates
the shell as measured at the toe of the
(2)Product side pits observed over the
outside bottom to shell fillet weld shall not
entire bottom plate (3)Gap and
be less than 0.1 inch.Projection of the
damage observed on outer edge
bottom plate beyond the outside toe of the
sealent (4)Previous repair patches are
shell-to -bottom weld shall be atleast 3/8"
not as per API 653
(4)Patch
dimensions shall be as per API 9.10.1.1.

be less than 0.1 inch.Projection of the

bottom plate beyond the outside toe of the
shell-to -bottom weld shall be atleast 3/8"
(4)Patch
dimensions shall be as per API 9.10.1.1.
Due to severe corrossion on bottom
plate associated with through holes
and product side pitting in almost all
over the floor plates, it is
recommended to replace the entire
bottom plate

Recommended to replace the sump

due to holes,pitting and metal
loss.Original thickness is also
unknown.

Installation of new sump shall confirm to API

650 Section 5 , Para 5.8.7, Table 5-16a and
5-16 b and fig 21

Drain pipe thickness shall be minimum pipe

Replace the drain pipe due to severe
thickness required for shedule 40 piping
pitting on it.
(As per API 650)

No immediate Action Required

Minimum acceptable thickness for wind

girders shall be as per API 650

Repair the crack to avoid water

ingression which may corrode iron
structure

MMARY OF FIRE AND FOAM WATER LINE

TPI Recommendations

Adnoc Feedback/R

No immediate Action Required.

Replace corroded areas.

RF pad shall be single rolled sheet and it can not be palc

nozzle.Two piece of RF pads are not in common and shall n
for existing nozzle and can continue the existing situation
( As per API 650, for Nozzle Size Below 2", RF

Replace corroded flange. Non metallic

interface shall be added in between U
bolt nd pipe material.Through surface
preparation followed by protective
coating.

Remove the flange connection and inspect the extend of

( Neoprine sleeves)in between U bolt and pipe material
follwed by

Replace corroded flange. Non metallic

interface shall be added in between U
bolt nd pipe material.Through surface
preparation followed by protective
coating.

Remove the flange connection and inspect the exten

interface( Neoprine sleeves) in between u bolt and pip
preparation follw

Replace locations where holes obsrved

Non metallic interface shall be added
in between U bolt nd pipe
material.Through surface preparation
followed by protective coating.

Replace the locations where holes observed. Calculate re

non metallic interface( Neoprine sleeves) in between
proper surface preparati

Pitted support shall be replaced.

Missing U bold need to be replaced.
Insert nonmetallic interface material
between U bold and piping.Surface
preparation and coating

Remove corrosion on support by smooth grinding follwed

material( Neoprine sleeves) in between U bolt and pip

Insert non metallic material in

between U bolt and piping

Insert non metallic material( Neoprine sleeves) in be

fowwloed b

Insert non metallic material in

between U bolt and piping. Through
surface preparatiuon followed by
Protective coating Application

Insert non metallic material( Neoprine sleeves) in be

fowwloed b

Insert non metallic material in

between U bolt and piping. Through
surface preparatiuon followed by
Protective coating Application. Replace
the damaged support

Insert non metallic material( Neoprine sleeves) in be

fowwloed by pinting. Strengt

Rectify it

Irregular weld profile and weld defetcs shall be removed by

RF pads without cutting existing

EPORT (SED II)

Adnoc Feedback/Recommendations

(1)Structural Integrity of roof support system is not verified/no

observations/no recommendations and also the inspection reports for
roof supports are missing.(only wind girders inspection report
available).(2) Up and downs are present due to previous repair on roof
plates. Isolated pitting and water pooling locations shall be protected
by through surface preparation follwed by the application protective
coating. (3) Roof appurtenances(Hatches, Breathers /vents etc.)
inspection reports are missing(4)Repair/replacement of roof
plates are not recommendable and its not a major concern
now.

It is recommandable to repair/replace the particular flat bars and angle

locations where deep pitting and holes found since the tank is out of
service and we are planning to go for a major repair ( bottom plate
replacement).However it is not a mandatory requirement for
tank calibration and recertification.

It is recommandable to repair/replace the stair way stringers and

damaged stair way top platform connections where holes and
corrossion found since the tank is out of service and we are planning to
go for a major repair ( bottom plate replacement).However it is not a
mandatory requirement for tank calibration and
recertification.

TPI reccommondation is valid and we can follow the same.

(1) For shell course 1,2,3 & 4, the minimum thickness observed during
inspection is higher than that of acceptable/required thickness (2) For
Shell Course 6 & 7, observed thickness is higher than that of minimum
design thickness. No immediate action is required. However would
like to know the method/procedure used for calculating the Actual &
Minimum thickness for shell course

Rectify the defect by smooth grinding with pencil grinders and perform
DPT after rectification.

Rectify the defect by smooth grinding with pencil grinders and perform
MPI after rectification.

Maximum Distortion value observed is 24 mm, and the accpetable

limit is 25.5 mm. No immediate action is required.

No immediate action required.

Through surface preparation followed by protective coating application

Through surface preparation followed by protective coating application

Since pit depth is within acceptable limit, no immediate action is

required. Through surface preparation and protective coating
application is recommended

RF pad shall be a single rolled sheet and it can not be palced/ installed
around nozzle without cutting the existing nozzle.Two piece of RF pads
are not in common and shall not be a good engineering practice.
Stiffners are available for 6" existing nozzle and can continue the
existing situation after rectifying pitting by grinding followed by DPT.
( As per API 650, for Nozzle Size Below 2", RF pad is not
required , stiffners are sufficient)
This nozzle is connected to outlet line of the tank. Introducing new
nozzle to tank shell will be more time consuming and complex activity
and we can go ahead with the same existing situation. IDM suggested
NPSH study for these outlet lines
( SED1 and SED 2)
as Sharjah DPM team raised pump suction issues due to existing outlet
line size.

(1)Previous repair patches are not as per API 653.

(2)Significant indication (40% and
above)observed on all plates.
(3)Through holes found on bottom plates.
(4)Severe corrossion
on bottom plate associated with through holes and product
side pitting in almost all over the floor plates
Due to above reasons it is advisable to go for
complete bottom plate replacement however we need to
discuss wih Intertek regarding minimum thickness calculation
of bottom plates.We can finalize our decision on
replacement /repair of bottom plates after the meeting.

replacement /repair of bottom plates after the meeting.

Replace the sump also if we go for complete bottom plate replacement

of SED 2.

Do remaining life calculations for drain pipe(as per API 570) and
replace if actual thickness is less than that of minimum required
thickness.Provide new supports for drain pipes.

No immediate action required. Remove the hole by smooth grinding

and perform DPT

Repair concrete Ring wall to provide adequate bearing capacity and to

avoid water ingression

ATER LINES FOR SED 2

oc Feedback/Recommendations

et and it can not be palced/ installed around nozzle without cutting the existing
t in common and shall not be a good engineering practice. Stiffners are available
ue the existing situation after rectifying corrossion by grinding followed by DPT.
ozzle Size Below 2", RF pad is not required , stiffners are sufficient)

d inspect the extend of corrossion as per API 574. Insert non metallic interface
U bolt and pipe material to avoid crevice corrosion.Do proper surface preparation
follwed by painting

on and inspect the extend of corrossion as per API 574. Insert non metallic
between u bolt and pipe material to avoid crevice corrosion.Do proper surface
preparation follwed by painting

s observed. Calculate remaining life calculations of piping as per API 574. Insert
e sleeves) in between u bolt and pipe material to avoid crevice corrosion.Do
proper surface preparation follwed by painting

smooth grinding follwed by DPT. Replace the missing U bolt. Insert non metallic
between U bolt and piping. Through surface preparation fowwloed by pinting.

eoprine sleeves) in between U bolt and piping. Through surface preparation

fowwloed by pinting.

eoprine sleeves) in between U bolt and piping. Through surface preparation

fowwloed by pinting.

eoprine sleeves) in between U bolt and piping. Through surface preparation

loed by pinting. Strengthen the damaged support.

tcs shall be removed by smooth grinding follwoed by DPT.It is difficult to provide

without cutting existing supports.Continue use as it is.