Specialist tank & pipe inspection services

Specialist tank & pipe inspection services

January 2009 by Alan Ashton

An introduction to a comprehensive storage tank and

pipe work inspection service for the Middle East region

using technology driven equipment

A unique service using Silverwing MFL and UT expertise as both a

supplier of equipment and

provider of specialist corrosion inspection services

forStorage tanks and associated pipe work

Silverwing patented equipments are in use within 58 different countries

In a wide variety of climatic conditions - from the hottest

…to the coldest

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

The Cost Of Corrosion

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

A leaking Storage Can Damage:

Storage Tanks and Corrosion

• The Environment

• Public Health

• Plant Profit Margins

• Atmospheric

• Vapour Phase

• Interface

• Product side

• Under insulation or coating

• Under floor( soil side)

Corrosion sources

Occurs on external surfaces due to exposure to air and pollutants

Atmospheric Corrosion

Occurs in the vapour space of tanks above the level of liquid.

Caused by moisture condensing on the inner surfaces due to temperature

changes

Vapour Space Corrosion

Occurs at the interface between the liquidproduct and gas in the vapour space

Usually only a problem if liquid levels remain the same over long periods of time

Interface Corrosion

Formed as a result of the liquid stored in the tank

Product Side Corrosion

Corrosion Under Insulation

Caused by water trapped under insulation or coating

Under floor Corrosion

• Occurs at under (soil) side of tank floors

• Usually associated with moisture contact.

• Sub soil characteristics

• Impossible to detect visually

• Pitting

• Conical

• Pipe

• Lake

• Crevice

• Galvanic

• Biological

• Preferential

• Stray( interference) current

Classification of Corrosion types

Classification of Corrosion typesUnderside of floor cut-outs showing Under

floor corrosion

Example Lake & Pit type corrosion

Enlarged view lake type

Classification of Corrosion typesUnderside of floor cut-outs showing

Under floor corrosion

Example Biological corrosion

Silverwing offers a comprehensive

tank and pipe inspection service

utilising our highly experienced

service team covering both in service

and out of service inspection.

WHAT DO WE DO ?

• 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

IN SERVICE INSPECTION


Acoustic Emission - Signal

• 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


• 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


• 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

Sensors Data-acquisition unit

Acoustic Emission - Instrumentation


Examples of acoustic emission report on Storage tank floor plates


Spectral range

Thermography Theory


What is detected by the camera?

- object temperature

- background temperature

- emission factor

T

T

s

b

camera

Tb

Ts


Thermography Theory

• Thermography Comparisons


Tem

perature °CDistance [Metres]

0.62.64.66.68.610.612.614.616.618.620.6

0 5 10 15 20 25

Temperature profile along side wall

>20.6°C

<0.7°C

5.0

10.0

15.0

20.0

• Thermography sensitivity


Out of service MFL floor scanning using the latest generation

FloormapVS2i mapping system and

HandScan unit for inaccessible areas

OUT OF SERVICE INSPECTION

Computerized MFL tank floor inspection

Corrosion detection and sizing with advanced reporting

software

FloormapVS2i

FloormapVS2i


The new FloormapVS2i

is the most operator friendly, comprehensive tank floor inspection system in the

world.

FloormapVS2i


FloormapVS Mark 2

Unique User Benefits of the Floormap VS2i

• 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


FloormapVS Mark 2

• 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.



FloormapVS Mark 2

• 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



FloormapVS Mark 2

• 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.



FloormapVS Mark 2

• 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.



FloormapVS Mark 2

• 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.



FloormapVS Mark 2

• Real time as well as quicker data acquisition 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.



FloormapVS Mark 2

• 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.



FloormapVS Mark 2

• Full finger print reporting by data addition to support trend management and including:

MFL HandScan resultsDigital photosVisual commentsManual pit gauge and UT reports commentsAuto UT C scan reports , if performed by SilverwingVacuum box reports, if performed by SilverwingMPI inspection report. if performed by Silverwing

• USB port for data transfer to facilitate 24 hour working if required.



FloormapVS Mark 2

•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.

Unique User Benefits of the Floormap VS 2i


All new data acquisition and analysis software has been developed for the

FloormapVS2i on-board computer.

FloormapVS2i


The New FloormapVS2i contains significant improvements in terms

of defect positioning, defect sizing andease of use.

FloormapVS2i


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.

FloormapVS2i


The ruggedized on-board SM 1000 data acquisition computer uses touch screen technology for ease of use within the hostile storage tank environment

FloormapVS2i


Latest generation rare earth magnets achieve

localised magnetic saturation of the

mild steel tank floor plates

FloormapVS2i


FloormapVS2i

Magnetic saturation comparisons

FM 2000 - 1.40 TelsaFVMVS2i - 1.90 Telsa

An increase in 35%


FloormapVS2i

• Improved top surface detection such that defects not identified

by UT


FloormapVS2i


Our custom designed data acquisition software not only captures all the MFL signals but analyses and displays the location and severity of

the corrosion in real time

FloormapVS2i


The off-line reporting software automatically produces a CAD drawing of the tank floor with the discontinuities being positioned to within 30mm accuracy.

FloormapVS2i


Individual dis-continuities view

FloormapVS2i


Maximum dis-continuity per track

FloormapVS2i


Appurtenances and notes can be added

FloormapVS2i


Plate view showing discontinuities

FloormapVS2i


Link digital images to plate

FloormapVS2i


Add patch plates and automatically generate of full bill of material

FloormapVS2i


Tank Plate statistics of dis-continuities

FloormapVS2i


FloormapVS2i

Summary of plate discontinuities


Easy to use, customizable report configuration

FloormapVS2i


Produce a hard copy of the report

FloormapVS2i


Handscan

MFL HandScan unit

To ensure that the tank floor inspection can be optimised in the areas where the Floormap unit cannot access Silverwing always utilises the Hand scan unit in lieu of spot thickness checking


Remote access UTcorrosion surveys on tank walls using the Scorpion B scan UT remote access crawler, or ScanmapVS or the RMS C-scan imaging system for inspection of large surface areas and vessels

AUTO UT CRAWLER units

IN & OUT OF SERVICE INSPECTION

Vacuum Box

The vacuum box leak detection system is used for effective weld integrity evaluation and results can be added to the FloormapVS reporting software

Tank floor weld Leak testing by 20in Hg vacuum box technique


Laser alignment

• To ensure that we are able to provides a complete tank inspection services to the client Silverwing also provide a laser alignment service using Sokia 530 unit to cover• Vertical( plumbness) alignment• Circumferential concentricity• Tank settlement


Labour hire & training

• API 653 tank

recertification

• Training &

familiarisation

• courses Hire of specialist API

and UT engineers

Consultancy

Consultancy

- Typical Tank Inspection Strategy

We are convinced that our experienced engineers coupled with highly accurate, advanced equipment and software makes the Silverwing Tank Inspection

service unbeatable value for money in the gaol to minimise the risk form unforeseen environmental

catastrophes

In addition we also offer to supply:

• Silverwing Middle East also supplies tank floor and tank wall inspection equipment and vacuum box testing systems for direct purchase

• Calibration and recertification of Silverwing equipment to meet ISO 9000

• Silverwing ME offers a full after sales service

• Training and familiarisation courses for all current

• Silverwing equipment

Pipescan

PipeScan is an easy to use, cost effective, portable, magnetic flux leakage inspection system for the detection of random internal as well as PIT type corrosion in non insulated pipe work systems

MFL Manual PipeScan


Pipescan

Fixed, Adjustable and Circumferential scan heads

MFL Manual PipeScan


Both in service and out of service surveys can be carried out since MFL is not

affected by product flowing through the pipe

MFL Manual PipeScan


Corrosion is easily detected above predetermined levels normally requested by the Client or plant operator and is automatically displayed as both a visual and audible alarm

Pipescan


MFL Manual PipeScan

Electronic Module

Pipescan Electronic module1 On/off switch2 Battery state indicator3 Alarm threshold control4 Visual warning indicators5 Audible alarm6 Audible alarm/ Remote earphone switch7 Plate thickness selector switch8 Sensor cable input sockets9 Remote earphone socket

MFL Manual PipeScan

MFL PipeScan is both a user friendly as well as cost effective system for determining the plant integrity when combined with A-scan or B –Scan or C scan

Ultrasonic monitoring of corrosion techniques

MFL Manual PipeScan

• Magnetic flux leakage measurements via18 hall effect sensors

• Pipe sizes Nominal bore 48 mm to 2400 mm diameter with wall thicknesses up to 19 mm including bonded coating of up to

6 mm.

• Manually operated, typically at speeds of 0.5m/second.

TECHNICAL CHARACTERISTICS

MFL Manual PipeScan

• Battery charge life normally 10 hours continuous working

• Restricted space limit of 120 mm

• Operating weight including 12v battery of electronic module -18 kg

MFL Manual PipeScan


Sensitivity may be adjusted to suit a particular operator criteria

• Pitting 30% for pipe systems 6 mm wall thickness



MFL Manual PipeScan


TECHNICAL CHARACTERISTICS – PS 100B

PS100B SCANNING HEAD

SpecificationsType Fixed LongitudinalPipe Diameter 48mm-54mmSensor Gap 2mm (4 shims)

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS-PS 100F

PS100F Scanning Head


MFL Manual PipeScan

TECHNICAL CHARACTERISTICS- PS 100C

PS100C SCANNING HEAD


MFL Manual PipeScan

TECHNICAL CHARACTERISTICS - PS 500

PS500 SCANNING HEAD

SpecificationsType Adjustable LongitudinalPipe Diameter 100mm-200mmSensor Gap 1mm (2 shims)

MFL Manual PipeScan


PS200 SCANNING HEAD


MFL Manual PipeScan

TECHNICAL CHARACTERISTICS – PS 1200

PS1200 SCANNING HEAD


MFL Manual PipeScan


PS300 SCANNING HEAD

SpecificationsType Fixed CircumferentialPipe Diameter 300mm - 2400mmSensor Gap 1mm (2 shims)

MFL Manual PipeScan

TECHNICAL CHARACTERISTICS - PS 400 PS400 SCANNING HEAD

SpecificationsType Fixed CircumferentialPipe Diameter 150mm-300mmSensor Gap 1mm (2 shims)

MFL Manual PipeScan

• Overhead pipe work corridors

• Offshore flow lines and jetty lines

TYPICAL APPLICATIONS

MFL Manual PipeScan

• Pipe line corridors

• Crossed pipe work

MFL Manual PipeScan


• Transfer pipe work systems

MFL Manual PipeScan


Long range ultrasonic screening of Pipe work using the latest generation

G3 system from Guided Ultrasonic Limited

Alternative Pipe Scanning or Screening

Why not plan a visit to our stand at the StocExpo 09 Exhibition in Hyatt Regency on 20th and 21st January 2009 where you will be able to see the equipment operational

THE FUTURE

THANK YOU FOR LISTENING, ANY QUESTIONS???ww.silverwingme.com

Specialist tank & pipe inspection services

Documents

Transcript of Specialist tank & pipe inspection services