Vessel 1A NII June 30 th 2016
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1 Vessel 1A NII June 30 th 2016 RMS Vessel Inspection Silverwing UK Ltd. Asset Inspection Report Location Inspection Type Job Number #90122 Procedure Number #102 Swansea Plant AUT Vessel External Equipment Used RMS300 Inspected By Authorised By Silverwing UK Ltd John Smith David Smith John Smith
2 Contents Scope of Work and Survey Goals... 4 Rapid motion scanner (RMS) Introduction... 7 Suary... 9 Layout Vessel 1A External Material Thickness Layout Vessel 1A External Surface Layout Vessel 1A External Amplitude Layout Vessel 1A External Material Thickness with Coating Area Large area of Laminations Material Thickness Area Large area of Laminations Surface Area Large area of Laminations Amplitude Area Large area of Laminations Material Thickness with Coating Area 350 x 830 area of Laminations Material Thickness Area 350 x 830 area of Laminations Surface Area 350 x 830 area of Laminations Amplitude Area 350 x 830 area of Laminations Material Thickness with Coating Area 310 x 260 area of Laminations Material Thickness Area 310 x 260 area of Laminations Surface Area 310 x 260 area of Laminations Amplitude Area 310 x 260 area of Laminations Material Thickness with Coating Area 32 x 12 defect Material Thickness Area 32 x 12 defect Surface Area 32 x 12 defect Amplitude Area 32 x 12 defect Material Thickness with Coating Area 56 x 16 & 64 x 8 areas with 50% wall thickness remaining Material Thickness Area 56 x 16 & 64 x 8 areas with 50% wall thickness remaining Surface Area 56 x 16 & 64 x 8 areas with 50% wall thickness remaining Amplitude Area 56 x 16 & 64 x 8 areas with 50% wall thickness remaining Material Thickness with Coating Area 56 x 12 area with 50-60% remaining wall thickness Material Thickness Area 56 x 12 area with 50-60% remaining wall thickness Surface Area 56 x 12 area with 50-60% remaining wall thickness Amplitude Area 56 x 12 area with 50-60% remaining wall thickness Material Thickness with Coating Area Coating breakdown area 1 Surface Scan Scan 1-1 Material Thickness Scan Scan 1-2 Material Thickness Scan Scan 1-3 Material Thickness Scan Scan 2-1 Material Thickness Scan Scan 2-2 Material Thickness Scan Scan 3-1 Material Thickness Page 2 of 61
3 Scan Scan 3-2 Material Thickness Scan Scan 4-1 Material Thickness Scan Scan 4-2 Material Thickness Scan Scan 5-1 Material Thickness Scan Scan 6-3 Material Thickness Scan Scan 11-2 Material Thickness Scan Scan 13-1 Material Thickness Scan Scan 14-1 Material Thickness Photographs Page 3 of 61
4 Scope of Work and Survey Goals Bulk Fuel Installation ~ Swansea Plant Required scope of work: Carry out an external survey of the shell plates using RMS300 system. The inspection will consist of an ultrasonic thickness survey of all vertical shell plates where access permits. Carry out a visual inspection of all accessible external welds. Carry out visual / ultrasonic survey of the external nozzles and manways. Carry out an ultrasonic corrosion survey of external shell to nozzle interfaces. Coent on the condition of external fixed pipework, saddle supports and other relevant tank features. Survey Goals: The attached report documents the findings of the examination performed on June 28 th ~30 th 2016 The Report provides an evaluation using data collected during the survey. Data was collected to provide information on the tanks present and continued usage. I. To detect and size remaining material at the Lower and Upper tanks. II. To detect size and map areas of internal / external originating corrosion. III. To consider characteristic, severity and corrosion rates of external pitting as far as is practicable. IV. To record ultrasonic thickness measurements of all shell plates in order to obtain their nominal thickness. V. To conduct an ultrasonic corrosion scan at the iediate shell plate area surrounding all Nozzles, as far as is practicable. VI. General visual inspection to note external nozzle, saddle support etc. condition. Survey Method: The RMS shell survey was conducted at a resolution of 10 x 2 () classified as corrosion detection. Any areas of significant interest were additionally scanned at a resolution of 2 x 2 () classified as corrosion mapping. Page 4 of 61
5 Any significant external pitting could be analysed by the RMS system (due to the increase in the delay line / water path). Shell Plate areas not accessed by the RMS system were systematically monitored by A Scan Flaw detector to identify internal corrosion loss, if any. All Nozzles and Manways were visually and ultrasonically (where conditions allowed) examined. The following equipment was utilized during the inspection; Silverwing RMS 300 system. (Serial Nos ) Pit Gauge. (Serial Nos. PG999) Silverwing UK Ltd provided the following personnel: John Smith ~ EEMUA 159 (10UK/02TA/360) Assessor. API 653 (583) Assessor. PCN level II (3175) Technician. David Smith ~ PCN level II (3110) Technician. Report authorised by; J Smith Dated Page 5 of 61
6 Equipment Item Description Serial No. Software Version RMS RMS 3.1 Unit Probes Serial No Frequency Diameter MHz Focal length = 50 Probe diameter = 8 Laptop Model Serial No Software Version ASUS F RMS 3.1 Page 6 of 61
7 Rapid motion scanner (RMS) Introduction The Rapid motion Scanner (RMS) is a high speed remote access ultrasonic corrosion mapping system which can inspect ferrous materials and pipe work. The RMS2 system is a crawler and control system which outputs encoder pulses and ultrasonic signals. In order to generate a C-scan map the use of a third party data capture system, capable of transmitting / receiving ultrasonic signals and processing the encoder information is required. The system can operate at a high capture speed and is capable of interpreting ultrasonic signals at speeds of 730 per second when set a resolution of 2 or greater. The minimum resolution the system can inspect is 0.5. Colour palette Figure 1 The C-Scan image of this scan shown in figure 1 indicates a change in wall thickness as a variation in colour. The relationship between material thickness and colour is shown by the colour palette shown alongside the C-Scan. This palette has a thickness range of 0 to 9 as indicated by the numbers down the right hand side of the colour palette. Figure 2 We can see in the C-scan image in Figure 1. This is a way of showing us or mapping out corrosion areas within a material, providing us with an overall thickness of the material (Dark blue Area). As this area is giving us our thickest part of the material, we can then say this will be our nominal thickness area(s). This will be safe to assume that there is no material loss in these areas. The A-scan image in Figure 2 shows us 4 Signals on the screen. The first signal to the far left is the top surface (Where the signal firsts meets the Plate material). The signal has had to travel through a water column (Starting from the initial pulse at point 0. This method of ultrasonics is used with many iersion techniques and irrigated Page 7 of 61
8 systems such as the RMS system. The second signal is called the 1 st back wall echo (BWE). This is where the pulse has now travelled through the material from the first signal and refracted back to the probe. This now gives us our first thickness reading. (See gate 1 in light blue). Finally the third signal is called our 2 nd back wall echo (BWE). This is just a repeat signal of gate 1 (See Figure 1). The point between gate 1 and gate 2 is giving us our actual material thickness (not including the coating) see gate 2 in yellow, this is now our True Thickness of the material (Echo to Echo). The following report generated in CMAP shows 4 different CScan views: Material Thickness with Coating (calculated from gates 1 st back wall echo Reference), Material Thickness (calculated from gates 2 nd back wall echo 1 st back wall echo), Amplitude (calculated from the highest amplitude signal within the amplitude gate), Surface profile (calculated from the top surface marker to the Reference gate). Page 8 of 61
9 Suary Item Name Area: Vessel 1A External/Large area of Laminations Area: Vessel 1A External/350 x 830 area of Laminations Area: Vessel 1A External/310 x 260 area of Laminations Area: Vessel 1A External/32 x 12 defect Area: Vessel 1A External/56 x 16 & 64 x 8 areas with 50% wall thickness remaining Area: Vessel 1A External/56 x 12 area with 50-60% remaining wall thickness Area: Vessel 1A External/Coating breakdown area 1 External/Scan 1-1 External/Scan 1-2 External/Scan 1-3 External/Scan 1-4 External/Scan 2-1 External/Scan 2-2 Measurements / Notes Material Thickness Surface Amplitude 1.57 % 100 % % Material Thickness with Coating Material Thickness Surface Amplitude 1.57 % 100 % % Material Thickness with Coating Material Thickness Surface Amplitude 1.57 % 100 % % Material Thickness with Coating Material Thickness Surface Amplitude 1.57 % 100 % % Material Thickness with Coating Material Thickness Surface Amplitude 1.57 % 100 % % Material Thickness with Coating Material Thickness Surface Amplitude 2.35 % 100 % % Material Thickness with Coating Surface Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Page 9 of 61
10 Item Name External/Scan 2-3 External/Scan 3-1 External/Scan 3-2 External/Scan 3-3 External/Scan 4-1 External/Scan 4-2 External/Scan 4-3 External/Scan 5-1 External/Scan 5-2 External/Scan 5-3 External/Scan 5-4 External/Scan 6-1 External/Scan 6-2 External/Scan 6-3 External/Scan 7-1 External/Scan 7-2 External/Scan 8-1 External/Scan 8-2 External/Scan 9-1 External/Scan 9-2 External/Scan 10-1 External/Scan 10-2 External/Scan 11-1 External/Scan 11-2 External/Scan 12-1 External/Scan 13-1 Measurements / Notes Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Material Thickness Page 10 of 61
11 Item Name External/Scan 13-2 External/Scan 14-1 Measurements / Notes Material Thickness Material Thickness Page 11 of 61
12 Layout Vessel 1A External Material Thickness The layout above indicates the full area covered by the inspection, The C-Scan data is colourised to indicate wall thickness. The relationship between material thickness and colour is shown by the colour palette shown alongside the C-Scan. Areas of concern are identified by rectangular boxes in the layout and these are addressed individually in the report identifying minimum, maximum and average thicknesses for the Area and any notes from the Inspector. Where appropriate A-Scan, B-Scan and Profile views are also included to provide further details. Page 12 of 61
13 Layout Vessel 1A External Surface The layout above indicates the full area covered by the inspection, The C-Scan data is colourised to indicate wall thickness. The relationship between material thickness and colour is shown by the colour palette shown alongside the C-Scan. Areas of concern are identified by rectangular boxes in the layout and these are addressed individually in the report identifying minimum, maximum and average thicknesses for the Area and any notes from the Inspector. Where appropriate A-Scan, B-Scan and Profile views are also included to provide further details. Page 13 of 61
14 Layout Vessel 1A External Amplitude % The layout above indicates the full area covered by the inspection, The C-Scan data is colourised to indicate wall thickness. The relationship between material thickness and colour is shown by the colour palette shown alongside the C-Scan. Areas of concern are identified by rectangular boxes in the layout and these are addressed individually in the report identifying minimum, maximum and average thicknesses for the Area and any notes from the Inspector. Where appropriate A-Scan, B-Scan and Profile views are also included to provide further details. Page 14 of 61
15 Layout Vessel 1A External Material Thickness with Coating The layout above indicates the full area covered by the inspection, The C-Scan data is colourised to indicate wall thickness. The relationship between material thickness and colour is shown by the colour palette shown alongside the C-Scan. Areas of concern are identified by rectangular boxes in the layout and these are addressed individually in the report identifying minimum, maximum and average thicknesses for the Area and any notes from the Inspector. Where appropriate A-Scan, B-Scan and Profile views are also included to provide further details. Page 15 of 61
16 Area Large area of Laminations Material Thickness Position: (376, 4704) Size: (946, 1034) Minimum: 3.63 Maximum: Average: Area of Laminations found 150 above the bottom weld Page 16 of 61
17 AScan Marker 5: Sample AScan taken from the large area of laminations Measurements 1st BWE - Reference gate = Amplitude gate = 100 % Second Back Wall - 1st BWE = Top Surface - Reference gate = 0.19 BScan BScan over cluster of Laminations BScan BScan over 44 x 16 size defect Page 17 of 61
18 Profile Profile over 44 x 16 size defect found within area Page 18 of 61
19 Area Large area of Laminations Surface Position: (376, 4704) Size: (946, 1034) Minimum: 0.01 Maximum: 2.98 Average: 0.57 Page 19 of 61
20 Area Large area of Laminations Amplitude Position: (376, 4704) Size: (946, 1034) Minimum: 1.57 % Maximum: 100 % Average: % % Page 20 of 61
21 Area Large area of Laminations Material Thickness with Coating Position: (376, 4704) Size: (946, 1034) Minimum: 9.88 Maximum: Average: 24.6 The possible presence of significant laminations in the pipe material was assessed by viewing the AScan and detecting ultrasonic reflections other than normal back wall echo. Evidence of laminations was detected. As a result the section examined failed the requirements of the API 510 code related to vessel inspections. Page 21 of 61
22 Area 350 x 830 area of Laminations Material Thickness Position: (3696, 5426) Size: (354, 834) Minimum: Maximum: Average: Page 22 of 61
23 Area 350 x 830 area of Laminations Surface Position: (3696, 5426) Size: (354, 834) Minimum: 0.06 Maximum: 8.52 Average: 1.55 Page 23 of 61
24 Area 350 x 830 area of Laminations Amplitude Position: (3696, 5426) Size: (354, 834) Minimum: 1.57 % Maximum: 100 % Average: % % Page 24 of 61
25 Area 350 x 830 area of Laminations Material Thickness with Coating Position: (3696, 5426) Size: (354, 834) Minimum: Maximum: Average: Page 25 of 61
26 Area 310 x 260 area of Laminations Material Thickness Position: ( , 1610) Size: (307.15, ) Minimum: Maximum: Average: Page 26 of 61
27 AScan Marker 1: Sample AScan taken from 310 x 260 area of Laminations Measurements 1st BWE - Reference gate = Amplitude gate = 100 % Second Back Wall - 1st BWE = Top Surface - Reference gate = 1.61 Page 27 of 61
28 Area 310 x 260 area of Laminations Surface Position: ( , 1610) Size: (307.15, ) Minimum: 0.06 Maximum: 8.22 Average: 1.35 Page 28 of 61
29 Area 310 x 260 area of Laminations Amplitude Position: ( , 1610) Size: (307.15, ) Minimum: 1.57 % Maximum: 100 % Average: % % Page 29 of 61
30 Area 310 x 260 area of Laminations Material Thickness with Coating Position: ( , 1610) Size: (307.15, ) Minimum: Maximum: Average: Page 30 of 61
31 Area 32 x 12 defect Material Thickness Position: (90, 6090) Size: (1130, 580) Minimum: 4.34 Maximum: Average: Page 31 of 61
32 AScan Marker 2 : Sample AScan taken from Area 32 x 12 defect Measurements 1st BWE - Reference gate = Amplitude gate = 100 % Second Back Wall - 1st BWE = Top Surface - Reference gate = 0.1 BScan Profile Page 32 of 61
33 Area 32 x 12 defect Surface Position: (90, 6090) Size: (1130, 580) Minimum: 0.01 Maximum: 7.87 Average: 0.38 Page 33 of 61
34 Area 32 x 12 defect Amplitude Position: (90, 6090) Size: (1130, 580) Minimum: 1.57 % Maximum: 100 % Average: % % Page 34 of 61
35 Area 32 x 12 defect Material Thickness with Coating Position: (90, 6090) Size: (1130, 580) Minimum: Maximum: Average: Page 35 of 61
36 Area 56 x 16 & 64 x 8 areas with 50% wall thickness remaining Material Thickness Position: (1748, 5780) Size: (474, 282) Minimum: Maximum: Average: Page 36 of 61
37 AScan Marker 4 Measurements 1st BWE - Reference gate = Amplitude gate = 100 % Second Back Wall - 1st BWE = Top Surface - Reference gate = 1.31 BScan Page 37 of 61
38 Area 56 x 16 & 64 x 8 areas with 50% wall thickness remaining Surface Position: (1748, 5780) Size: (474, 282) Minimum: 0.36 Maximum: 2.74 Average: 1.17 Page 38 of 61
39 Area 56 x 16 & 64 x 8 areas with 50% wall thickness remaining Amplitude Position: (1748, 5780) Size: (474, 282) Minimum: 1.57 % Maximum: 100 % Average: % % Page 39 of 61
40 Area 56 x 16 & 64 x 8 areas with 50% wall thickness remaining Material Thickness with Coating Position: (1748, 5780) Size: (474, 282) Minimum: Maximum: Average: Page 40 of 61
41 Area 56 x 12 area with 50-60% remaining wall thickness Material Thickness Position: (2590, 1570) Size: (300, 450) Minimum: Maximum: Average: Page 41 of 61
42 AScan Marker 3 Measurements 1st BWE - Reference gate = 11.9 Amplitude gate = % Second Back Wall - 1st BWE = Top Surface - Reference gate = 2.38 BScan Profile Page 42 of 61
43 Area 56 x 12 area with 50-60% remaining wall thickness Surface Position: (2590, 1570) Size: (300, 450) Minimum: 0.06 Maximum: 8.22 Average: 1.77 Page 43 of 61
44 Area 56 x 12 area with 50-60% remaining wall thickness Amplitude Position: (2590, 1570) Size: (300, 450) Minimum: 2.35 % Maximum: 100 % Average: % % Page 44 of 61
45 Area 56 x 12 area with 50-60% remaining wall thickness Material Thickness with Coating Position: (2590, 1570) Size: (300, 450) Minimum: Maximum: Average: Page 45 of 61
46 Area Coating breakdown area 1 Surface Position: (440, ) Size: (1070, 1890) Minimum: 0.06 Maximum: 7.63 Average: 0.89 Captioned photograph shows area of coating break down below the bottom weld Page 46 of 61
47 Scan Scan 1-1 Material Thickness Position: (240, ) Size: (300, 1600) Minimum: Maximum: Average: Page 47 of 61
48 Scan Scan 1-2 Material Thickness Position: (240, ) Size: (300, 2000) Minimum: Maximum: Average: Page 48 of 61
49 Scan Scan 1-3 Material Thickness Position: (240, ) Size: (300, 2000) Minimum: Maximum: Average: Page 49 of 61
50 Scan Scan 2-1 Material Thickness Position: (540, ) Size: (300, 2000) Minimum: Maximum: Average: Page 50 of 61
51 Scan Scan 2-2 Material Thickness Position: (540, ) Size: (300, 2000) Minimum: Maximum: Average: Page 51 of 61
52 Scan Scan 3-1 Material Thickness Position: (840, ) Size: (300, 2000) Minimum: Maximum: Average: Page 52 of 61
53 Scan Scan 3-2 Material Thickness Position: (840, ) Size: (300, 2000) Minimum: Maximum: Average: Page 53 of 61
54 Scan Scan 4-1 Material Thickness Position: (1140, ) Size: (300, 2000) Minimum: Maximum: Average: 24.9 Page 54 of 61
55 Scan Scan 4-2 Material Thickness Position: (1140, ) Size: (300, 2000) Minimum: 3.63 Maximum: Average: Page 55 of 61
56 Scan Scan 5-1 Material Thickness Position: (1400, ) Size: (300, 2000) Minimum: Maximum: Average: Page 56 of 61
57 Scan Scan 6-3 Material Thickness Position: (1610, ) Size: (300, 1200) Minimum: Maximum: Average: Page 57 of 61
58 Scan Scan 11-2 Material Thickness Position: (3040, ) Size: (300, 450) Minimum: Maximum: Average: Page 58 of 61
59 Scan Scan 13-1 Material Thickness Position: (3600, ) Size: (300, 5000) Minimum: Maximum: Average: Page 59 of 61
60 Scan Scan 14-1 Material Thickness Position: (3900, ) Size: (300, 5000) Minimum: Maximum: Average: Page 60 of 61
61 Photographs Page 61 of 61
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