ICAR MTS Vibration Testing Hydraulic Power Unit

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Mechanical Integrity Report for the ICAR MTS Vibration Testing Hydraulic Power Unit at 208 North Palmetto Boulevard Clemson, South Carolina 29631 Inspection: 8 October 2012 Prepared by: George E.

1 Mechanical Integrity Report for the ICAR MTS Vibration Testing Hydraulic Power Unit at 208 North Palmetto Boulevard Clemson, South Carolina Inspection: 8 October 2012 Prepared by: George E. Matthews, E.I.T. Senior Consultant Reviewed by: Jeremy M. Orr, P.E., C.W.I. Principal Engineer - Manager Purchase Order Number: CU ATS Job Number: Professional Engineers and Scientists Design Consulting Testing and Inspection Members in AAFS, ACS, ANSI, ASM, ASME, ASNT, ASQ, ASTM, AWS, BOMA, FSCT, IAAI, IWCA, NACE, NCSL, NFPA, SAFS, TAPPI GEORGIA SOCIETY OF PROFESSIONAL ENGINEERS, NATIONAL SOCIETY OF PROFESSIONAL ENGINEERS In the state of North Carolina, Engineering Services will be provided by ATS Engineering, PLLC or a properly licensed subcontractor In the state of New York, Engineering Services will be provided by Neville W. Sachs, P.E., PLLC or a properly licensed subcontractor Page 1 of 9

2 Table of Contents Table of Contents General Information, Background, Equipment Orientation and Access Page 3 Present Condition and Analysis Page 4 Action Items Page 6 Future Inspections, Personnel Qualifications and Reference Industry Codes and Standards Page 7 Photographs Page 8 Appendix A: NDE Report Appendix B: Calculations Summary Page 2 of 9

3 General Information, Background, Equipment Orientation and Access Design Pressure Unknown Design Temperature Unknown Operating Pressure Atmospheric Operating Temperature Ambient Contents Hydraulic Oil Specific Gravity 1.0 Shell Length x Width x Height x 1-2 x Manufacturer MTS Systems Corp. Year Constructed 1998 Serial Number UL Number Unknown Material Unknown Carbon Steel Previous Inspection None Drawing(s) None Jesse Showalter (VT) NDE Performed by Peter Dudley/Joey Laprade (UTT) Overall View Background This report contains the results of the inspection, analysis and action items regarding the MTS Vibrations Testing Hydraulic Power Unit. The inspection included an external visual inspection and applicable NDE to the accessible portions of the tank. Equipment Orientation The zero references as discussed in this report were as follows: The tank was oriented according to the primary direction each shell faced (refer to the rollout in Appendix A). All nozzles and manways were individually oriented with 0 at the top of the individual nozzle and manway necks (towards the top of the tank) and progressed to 360 in a counterclockwise direction. Equipment Access No scaffolding was constructed for the inspection. The tank was accessible from the ground. Page 3 of 9

4 External Present Condition Present Condition and Analysis No visible deterioration or damage was observed throughout. No normal or emergency venting was located. No grounding cable was located. Analysis The tank was analyzed as STI SP001 Category 3 for the operating parameters as provided by the client. The tank lacked proper emergency venting requirements per UL 142. The required normal vent size is NPT 1¼. The required emergency vent size is NPT 2. A summary of the ultrasonic thickness measurements is located in the Summary of Measurements table that immediately follows. The completed NDE Report is located in Appendix A. The calculations summary is located in Appendix B. Calculated minimum required thicknesses are exclusive of any corrosion allowance. Page 4 of 9

5 Summary of Measurements Present Condition and Analysis Component Top Plate North Shell East Shell West Shell South Shell Floor Previous Average Measured Minimum Measured Minimum Required Corrosion Rate (inches/year) Remaining Life (years) Assumed, per STI SP Corrosion rates and remaining life calculations cannot be performed until a second set of UT measurements is acquired. Legend > 10% Above Minimum Required Within 10% of Minimum Required At Minimum Required or Below Page 5 of 9

6 Action Items Action Items The following are the prioritized action items based on the observations and findings at the time of the inspection: No. Item Priority 1 A NPT 1¼ emergency vent should be installed, per UL A NPT 2 emergency vent should be installed, per UL Proper grounding should be verified or installed. 3 Priority 1 Priority 2 Priority 3 Legend High likelihood and consequence of failure. Critical Code or Standard deficiency. May not be fit for continued service without repair. Medium likelihood and consequence of failure. Low likelihood and consequence of failure. Non-critical Code or Standard deficiency. Industry best practice or preventative maintenance. Housekeeping items. Page 6 of 9

7 Future Inspections, Personnel Qualifications and Reference Industry Codes and Standards Future Inspections Per STI SP001 Table 5.5 for Category 3 tanks, the tank should be externally re-inspected and leak tested within 10 years. The tank should be periodically inspected by a competent person, per the guidelines in STI SP001 Section 6. According to the Clemson University Spill Prevention Control and Countermeasure (SPCC) Plan, the tank should be re-inspected within 10 years. Personnel Qualifications Jeremy M. Orr SC PE # API 653 # STI # AC11307 GA, AL, ME, FL, LA, TX, SC, CA registered Professional Engineer; Mechanical Engineer with 13 years experience in inspection, evaluation, repair and design in various industries; AWS CWI, API 653 / 510 / 570 / 580 / 571/ 577 certified; STI certified inspector; NACE coating inspector level I certified; ASNT certified level II VT; SPRAT level I certified rope access technician; ATS certified Level II UTT, MT, PT, VT per SNT-TC- 1A; active member of TAPPI, AWS, NACE International, ASME George E. Matthews GA Registered Engineer-in-Training, Mechanical Engineer with 3 years experience in inspection, evaluation, repair and design in various industries Jesse B. Showalter GA Registered Engineer-in-Training, Mechanical Engineer with 3 years experience in inspection, evaluation, repair and design in various industries Stan Sullivan Reference Industry Codes and Standards ATS certified Level II UTT, MT, PT per SNT-TC-1A Clemson University, Spill Prevention Control and Countermeasure Plan STI SP001, Standard for the Inspection of Aboveground Storage Tanks UL 142, Steel Aboveground Tanks for Flammable and Combustible Liquids Page 7 of 9

8 Photographs Photo 1: Overall view of the tank. Photo 2: View of the nameplate. Page 8 of 9

9 Photographs Photo 3: View of the electrical box wall. Page 9 of 9

10 Appendix A: NDE Report External Visual Inspection: Component Condition / Comments Nameplate Information Model No.: / Serial No.: / Manufacture Date: 10/98 Top Plate No visible deterioration or damage was observed. Shell Bottom Plate Coating No visible deterioration or damage was observed. No visible deterioration or damage was observed. No visible deterioration or damage was observed. Nozzle / Manway / Repad No visible deterioration or damage was observed. Relief / Vent(s) - Main Tank None located at the time of inspection. Relief / Vent(s) - Interstitial Space Not applicable. Weld Seam Support System Anchor Bolt / Saddle / Lug Grounding Cable No visible deterioration or damage was observed. Mobile platform, no visible deterioration or damage was observed. Not applicable. None located at the time of inspection. Internal Visual Inspection: Component Condition / Comments Interstitial Space Not applicable. Notes: ATS460, 4/18/12 MTS Vibration Test Hydraulic Power Unit.xls

11 Appendix A: NDE Report Rollout / Nozzle Locations (NOT TO SCALE): Plan View: (AS SEEN FROM ABOVE) Electrical box: Pump side wall: Bolted cover: Notes: No other nozzles were located on the shell and floor. ATS460, 4/18/12 MTS Vibration Test Hydraulic Power Unit.xls

12 Appendix A: NDE Report Ultrasonic Measurements: Top: UTT Inspection Location (A) Minimum Required North to South Minimum Measured Legend > 10% Above Minimum Required Within 10% of Minimum Required At Minimum Required or Below Notes: A Readings were taken across each shell starting at 2" from the left edge, evenly spaced across the shell, and ending 2" before the right edge. ATS460, 4/18/12 MTS Vibration Test Hydraulic Power Unit.xls

13 Appendix A: NDE Report Ultrasonic Measurements: Bottom: UTT Inspection Location (A) Minimum Required North to South Minimum Measured Legend > 10% Above Minimum Required Within 10% of Minimum Required At Minimum Required or Below Notes: A Readings were taken across each shell starting at 2" from the left edge, evenly spaced across the shell, and ending 2" before the right edge. ATS460, 4/18/12 MTS Vibration Test Hydraulic Power Unit.xls

14 Appendix A: NDE Report Shell Ultrasonic Measurements: UTT Inspection Location (A) Minimum Required North Minimum Measured West Minimum Measured East Minimum Measured South Minimum Measured Legend > 10% Above Minimum Required Within 10% of Minimum Required At Minimum Required or Below Notes: A Readings were taken across each shell starting at 2" from the left edge, evenly spaced across the shell, and ending 2" before the right edge. ATS460, 4/18/12 MTS Vibration Test Hydraulic Power Unit.xls

15 Appendix A: NDE Report Nozzles / Manways / Reinforcement Ultrasonic Measurements: Notes: A Threaded B No access Nozzle Reinforcement Pad Nozzle NPS 0 Scan 180 Width Internal Projection N1 1 A A A None N/A Unknown N2 0.5 A A A None N/A Unknown N3 Unknown B B B None N/A Unknown N A A A None N/A Unknown N5 2 A A A None N/A Unknown N A A A None N/A Unknown N7 1 A A A None N/A Unknown N8 0.5 A A A None N/A Unknown N9 0.5 A A A None N/A Unknown N A A A None N/A Unknown N A A A None N/A Unknown N12 2 A A A None N/A Unknown N A A A None N/A Unknown N14 Unknown B B B None N/A Unknown N A A A None N/A Unknown ATS460, 4/18/12 MTS Vibration Test Hydraulic Power Unit.xls

16 UL 142: MINIMUM THICKNESS (s.g. less than or equal to 1.0) Rectangular Construction APPLIED TECHNICAL SERVICES, INCORPORATED Corporate Headquarters 1049 Triad Court, Marietta, Georgia Fax APPENDIX B: CALCULATIONS SUMMARY Actual Capacity = 92 U.S. gallons Minimum Design = in. (per UL 142 Section 17) STI Min. Required = in. (per STI SP001 Section 10) Per STI SP , the minimum required thickness for Category 3 tanks is 75% of the original construction thickness. The original construction thickness for this tank was assumed to be 0.179" (7 gauge) based on measuring an uncorroded area per STI SP The minimum required thickness was calculated as 75% of that value. Where: L = Length of the Tank (ft.) = W =Width of the Tank (ft.) = D = Depth of the Tank (ft.) = UL 142: VENTING Actual Capacity = 92 U.S. gallons Wetted Surface Area (rectangular) = 28 ft 2 Normal Venting Minimum Opening = 1 1/4 NPS (per Table 8.2) A vent opening must be in addition to the fill, withdrawal and liquid level gauge openings. The normal vent must be at least as large as the filling or withdrawal connection, whichever is larger. Emergency Venting Rectangular Minimum Opening = 2 NPS (per Table 8.1) Emergency vents are not prohibited from use for normal venting. The pipe size applies to lengths of not more than 12 in. Page 1 of 1

Canadian Natural Resources Ltd. GENERAL PRESSURE VESSEL INFORMATION Job #

District: Karr Creek Facility: Sturgeon Lake Battery Vessel Name Equipment Number: Oil Treater Orientation: Horizontal Canadian Natural Resources Ltd. GENERAL PRESSURE VESSEL INFORMATION Job # 10.113812