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TK 1015
REFINERIA DE CARTAGENA
CARTAGENA - COLOMBIA
April 2009
Contract N:
Job Executed By:
Jaime Mrquez Vega
Ever Molina
Edilberto Suarez
Jorge Gutirrez
Report TK1015
NR166001-SC-97300-1040
Certified By:
Jaime Marquez Vega
API 653 Certified Inspector,
Certification N 26576
Page 1 of 78
Approved by:
Fernando Tovar
SGS Project Manager
TABLE OF CONTENT
1.
1.1.
1.2.
1.3.
1.4.
EXECUTIVE SUMMARY
General Details
Summary of Findings
Visual Inspection Photos
Visual Inspection Check List
2.
2.1.
2.2.
2.3.
2.3.1.
2.3.2.
2.3.3.
2.3.4.
2.4.
2.5.
FOUNDATION
Tank Settlement Requirements
Calculation of maximum Permissible out of Planar Deflection
Tank Settlement
Profile Finding
Illustration
Settlement Calculations
Settlement Graphic
Conclusions
Recommendations
3.
3.1.
3.1.1.
3.1.2.
3.1.3.
3.1.4.
BOTTOM
Bottom Projection Plate
Standard and Code References
Ultrasonic Thickness Measurement Finding of Projection Plates
Conclusions
Recommendations
4.
4.1.
4.1.1.
4.1.2.
4.1.3.
4.1.4.
4.1.5.
4.1.6.
4.2.
4.2.1.
4.2.2.
4.2.3.
4.2.4.
4.3.
4.3.1.
4.3.2.
4.3.3.
4.3.4.
SHELL
Shell Plate
Minimum Thickness Calculation for Tank Shell
Minimum Thickness Calculation for Riveted Tank Shell
Minimum Shell Thickness
Finding And Calculation For Tank Shell Plate
Conclusions
Recommendations
Shell Nozzle, Manhole and Reinforcement pad
Standard and Code References
Findings of Shell Nozzle, Manhole and Reinforcement Pad
Conclusions
Recommendations
Plumbness
Acceptance Criteria
Method of Inspection
Plumbness Findings
Plumbness Illustrations by axis
Report TK1015
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4.3.5.
4.3.6.
4.4.
4.4.1.
4.4.2.
4.4.3.
4.4.4.
4.4.5.
4.4.6.
Conclusions
Recommendations
Tank Roundness
Acceptance Criteria
Method of Inspection
Tank Roundness Findings
Tank Roundness Illustrations by axis
Conclusions
Recommendations
5.
5.1.
5.1.1.
5.1.2.
5.1.3.
5.1.4.
5.2.
5.2.1.
5.2.2.
5.2.3.
5.2.4.
ROOF
Roof Plate
Standard and Code Reference
Ultrasonic Thickness Finding of Roof Plate
Conclusion
Recommendations
Roof Nozzle
Standard and Code Reference
Ultrasonic Thickness Findings of Roof Nozzle and Reinforcement
Conclusions
Recommendations
6.
6.1.
6.2.
6.3.
6.4.
CATHODIC PROTECTION
Standard and Code References
Cathodic Readings
Tank Grounding
Recommendations
Report TK1015
Page 3 of 78
1.
EXECUTIVE SUMMARY
*First course
*Second course
*Third course
*Fourth course
*Fifth course
*Sixth course
*Seventh course
*ROOF:
*BOTTOM PROJECTION:
NOZZLES:
JOINTS TYPE
SHELL:
First course
Second course
Third course
Fourth course
Fifth course
Sixth course
Seventh course
Between courses
SHELL ROOF:
Report TK1015
1015
REFICAR
AREA 1000, REFINERIA DE CARTAGENA
Unknown
CRUDE OIL
Anodes of sacrifice
Information not available
Water (Assumed for hydrotest)
117
117.309
368 6.45
48
40 4.25
NA
NA
75,000
Page 4 of 78
Actual thickness:
0,622
Actual thickness:
0,518
Actual thickness:
0,498
Actual thickness:
0,439
Actual thickness:
0,305
Actual thickness:
0,273
Actual thickness:
0,276
Actual thickness:
0,190
Actual thickness:
0,417
see nozzles UT measures
Inches
Inches
Inches
Inches
Inches
Inches
Inches
Inches
Inches
ROOF:
SHELL BOTTOM:
BOTTOM PROJECTION:
APPURTENANCES:
GEOMETRY:
FOUNDATION:
BOTTOM PROJECTION:
SHELL:
ROOF:
ACCESS:
TANK:
ROOF:
COATINGS:
BOTTOM PROJECTION:
SHELL:
ROOF:
OTHERS:
Total Number of anodes installed:
Date Anodes installed:
RIVETS DATA:
Geometry:
Diameter:
Projection:
Pitch between vertical rivet:
Cone Type
1.575 (First and Second Course) bottom of cone
0.709 (First and Second Course)
3 for first and second row, 7 for third row, 14 for fourth row (on first course),
3.25 for first and second row, 6.5 for third row, 13 for fourth row ( on second
course)
Pitch between Horizontal. Rivet:
3
First course Four vertical rows (72 for first and second row) + (18 for third row)+ (8 for fourth
row) =Total 98
Second course Four vertical rows (90) + two vertical rows on each side (24) Total 114
Third course Four vertical rows Total 74
Fourth course Three vertical rows Total 62 (verified)
Fifth course Three vertical rows Total 74
Sixth course Two vertical rows Total 74
Seventh course Two vertical rows Total 74
Between courses Lapped Joint Riveted, one line of riveted
Note: Each vertical butt riveted joint denoted from 10 to 12 rivets seal welded around
of it. The strap to bottom projection plate is welded and 7 inches on vertical strap
sides .
EXISTING NOZZLES AND APPURTENANCES:
Elevation
Item
LOCATION
Diameter
Axis (plate)
from the
Course
Description
bottom
1
Shell
10
10
14
1
Product line
2
Shell
16
20
22
1
Product line
3
Shell
6
25
7.5
1
Product line
Report TK1015
Page 5 of 78
4
5
6
7
8
9
10
Shell
Shell
Shell
Shell
Shell
Shell
Shell
20
20
2
1
2
20
8
105
200
275
275
272
280
90, 210,
330
11
Shell
110
12
Shell
270
13
Shell
270
14
Shell
15
16
17
18
19
Roof
Roof
Roof
Roof
Roof
24
8
6
10
10
359
353
255
270
92
6.5
22
20
47
29
28
8 from
seventh
course top
1 from
seventh
course top
12 from
sixth to
seventh
course
50 from
seventh
course top
7 course top
- 1 course
bottom
715
715
708
74
74
20
21
Roof
Roof
24
1
0
359
0
715
Item
1
2
3
4
5
6
7
8
9
10
12
13
14
15
Report TK1015
Course
1
1
1
1
1
1
1
1
1
2
7
7
7
7
Page 6 of 78
1
1
1
1
1
1
7
Manhole
Product line
Low low level indicator
Low level indicator
Manhole
Foam chambers
7 and 1
R12/S1
R13/S1
R21/S3
R12/S5
R10/S5
Manhole
Sample hatch
Level indicator, and stair
Pressure and vacuum valve
Pressure and vacuum valve
R11/S1, S2
R12/S1
Dimensions
59x21.5
68.5x62.5
68.5x62
64x53
95.5X51.5
77x59
63X 56 ,
94 X 50
75 X 58
137 X 32
30 X 12
35 X 12
10 X 12
45 X 25, y
and
Manhole
Swing winch over the manhole
cover
Thickness *
0,618
0,606
0,610
0,608
6,27
0,617
0,583
0,604
0,616
0,501
unknown
unknown
unknown
unknown
Remarks
16
17
18
19
Shell
Shell
Shell
Shell
175 -205
260
290 -320
330
7
7
7
7
30 X 12
400 X 50
30 X 12
420 X 50
12 X 12
unknown
unknown
unknown
unknown
*
The actual thickness UT measures are the AVERAGE
Note The insert plates dimensions are on the horizontal then vertical order, the weld spaces were taken from the
horizontal and vertical riveted joints axis to horizontal and vertical centerline butt welded joints of insert plates
1.2 Summary of Findings with Recommendations
Item
1.2.1
1.2.2
1.2.3
1.2.4
Location
Access and dike
Foundation
Shell
Report TK1015
Finding
a) The dike is not well defined. It is
not possible to determine the
geometry of the dike.
b) The area around the tank has too
much vegetation.
c) The area where the tank is placed
has not drain, the rain water stand
on. Due to this, the area where the
tank is placed show cracks in the
soil. On plates 8 and 9 first course
the concrete ring is under the dike
level
Recommendations
Clean the area, check the design and re-built
the dike.
Page 7 of 78
Item
Location
First course plate 2
Report TK1015
Finding
painted
c) The 16 nozzle denoted two bolts
no properly installed, deformed
flanges, the reinforcement plate
do not have wipe hole for
pneumatic test, the reinforcement
to shell weld denoted undercut on
top side, the reinforcement plate
to bottom projection plate weld
space is , and it is near to
vertical insert weld (59 by 21.5)
(marked over the plate, numbered
by 2 and 3).
d) Denoted burrs welds, (marked
over the plate, numbered by 2)
e) The 6 nozzle denoted six bolts
no properly installed.
(marked
over the plate, numbered by 4).
f) Denoted burrs welds, (marked
over the plate, numbered by 5)
g) The bottom projection plate
denoted corrosion and paint
failure (marked over the plate,
numbered by 6)
h) The plate 5 denoted laminations
near to horizontal lapped rivet
joint, (marked over the plate,
numbered by 7)
i) The horizontal lap riveted joint
denoted leakage (marked over the
plate, numbered by 8).
j) The vertical welded joints of the
insert plate on second course are
in line with the vertical welded
joints on first course (marked over
the plate, numbered by 9).
k) The bottom projection plate
denoted corrosion and paint
failure (marked over the plate,
numbered by 10)
l) The bottom projection plate to
concrete ring gap is 1 (plates 6
and 7) (marked over the plate,
numbered by 11
m) The horizontal lap riveted joint
denoted leakage (marked over the
plate, numbered by 12).
n) The vertical butt riveted joint
denoted leakage (plate 8
over
the
plate,
9)marked
Page 8 of 78
Recommendations
The bolts or fasteners shall extend completely
through their nuts. The reinforcement do not
meet the API 650 figure 5-6, requirements for
C and A values.
The insert plate do not meet the API 653 fig 91 requirements for R Value. Repair the
undercut
Item
Location
Finding
numbered by 13).
o) Denoted burrs welds, (marked
over the plate, numbered by 14)
p) The shell to bottom weld joint
denoted corrosion and paint
failure (marked over the plate,
numbered by 15).
q) Denoted burrs welds, (marked
over the plate, numbered by 16)
r) The 20 manhole denoted two
bolts no properly installed (marked
over the plate, numbered by 17).
s) Denoted burrs welds, (marked
over the plate, numbered by 18)
t) Denoted burrs welds, (marked
over the plate, numbered by 19).
u) Denoted a 4 width welded patch
plate around the 77 by 59 insert
plate, the patch plate corners are
in straight angle (no rounded) and
the patch plate to shell weld
denoted undercut, (marked over
the plate, numbered by 20). The
patch plate thickness is
v) The grounding cable denoted good
connection.
w) Denoted burrs welds, (marked
over the plate, numbered by 21).
x) The vertical butt riveted joint
denoted Leakage, plates 13 and
14, (marked over the plate,
numbered 22).
y) The shell to bottom weld joint
denoted corrosion and paint
failure (marked over the plate,
numbered by 23).
z) The vertical butt riveted joint
denoted Leakage, plates 13 and
14, (marked over the plate,
numbered 24).
aa) Denoted burrs welds, (marked
over the plate, numbered by 25).
bb)The 20 nozzle denoted 11 bolts
no
properly
installed,
the
reinforcement plate
denoted
thinning, the thinning is painted,
Report TK1015
Page 9 of 78
Recommendations
Remove by grinding to base metal level,
eliminate the raised and sharp edges and test
by penetrant testing .
Clean and recoat
No recommendations
Remove by grinding to base metal level,
eliminate the raised and sharp edges and test
by penetrant testing.
Repair by seal weld
Item
Location
Finding
(marked over the plate, numbered
by 26)
cc) Denoted burrs welds, (marked
over the plate, numbered by 27).
dd)The shell to bottom weld joint
denoted 1/16 on depth corrosion
and paint failure (marked over the
plate, numbered by 28).
ee) The vertical butt riveted joint
denoted Leakage, plates 15 and
16, (marked over the plate,
numbered 29).
ff) The 2 nozzle denoted one bolt no
properly installed and failure paint,
(marked over the plate, numbered
by 30)
gg) A 1/16 on depth thinning near to
shell to bottom weld joint (side
shell)
on 19 and 20 plates,
(marked over the plate, numbered
31).
hh) The 20 manhole cover denoted
one bolt no properly installed,
(marked over the plate, numbered
by 32). The manhole is installed on
63 by 55 insert plate, the
horizontal butt welding insert
plate to horizontal lapped riveted
joint space is 7
ii) Denoted burrs welds, (marked
over the plate, numbered 33).
jj) Denoted a 94 by 50 insert plate,
the horizontal butt welding insert
plate to horizontal lapped riveted
joint space is 12 , the vertical
butt welded joint (right side) to
radial butt welded joint of annular
ring space is , (marked over the
plate, numbered 34).
kk) Denoted burrs welds, (marked
over the plate, numbered 35).
ll) Denoted a 4 width welded patch
plate around the 78 by 55 insert
plate, the patch plate corners are
in straight angle (no rounded) and
the horizontal lapped joint of
patch plate to horizontal lapped
riveted joint space is 4, (marked
over the plate, numbered by 36).
The patch plate thickness is
Report TK1015
Page 10 of 78
Recommendations
Item
Location
Report TK1015
Finding
mm)
The bottom projection plate
denoted corrosion and paint
failure (marked over the plate,
numbered by 37).
nn)The cables for cathodic protection
and grounding denoted no
connected, (marked over the plate,
numbered 38).
oo)Denoted burrs welds, (marked
over the plate, numbered by 39).
pp)The foam piping support denoted
with no proper plumbness, and
the pipe is not properly supported
(marked over the plate, numbered
by 40).
qq)Buckling: 130 150 Buckled in
seventh course,
rr) Insert Plates 15
a 30by 12
patch plate seventh course, 7080 axis a 137 by 32 insert plate
on second course and on seventh
course a 35 by 12insert plate,
92 axis 10 by 12 patch plate
on seventh course, 130- 135 axis
a 45 by 25 insert plate on
seventh course and 10 by 12
patch plate on seventh course,
175- 205 axis a 400 X 50
insert plate on seventh, 260 axis
30 by 12 patch plate on seventh
course, 300 axis a 420 X 50
insert plate on seventh course
from 290 to 320, 330 axis 12
by 12 patch plate on seventh
course,
ss) Burrs welds: 10 axis burrs welds
on third course, 160, 350 axis
burrs welds on second and five
course.
tt)
Leakage: 140 axis vertical
butt riveted joint second course,
280 axis vertical butt riveted joint
second course, 290 axis vertical
lapped riveted joint third course.
uu)Nozzles: 110 axis a 2 riveted
thread nozzle on seventh course
vv) Thinning: 50 axis A 10 BY 10
thinning on seventh course, 65
axis A 12 BY 12 thinning on five
course, 300 axis near to horizontal
lapped riveted joint five to sixth
and sixth to seventh course
Page 11 of 78
Recommendations
Clean and recoat.
Item
1.2.5
Location
Roof
359 and 0 (roof center)
353
Accessories
1.2.7
Report TK1015
Finding
denoted thinning with severe
corrosion and paint failure,
ww)
Others: 270 axis the high
high level indicator stair denoted
corrosion and paint failure,
a) The (two) manholes cover bolts
denoted severe corrosion and
paint failure, the manhole
denoted reinforcement
b) The sample hatch cover is in
carbon steel and do not have
gasket for spark prevent when it
operate, denoted holes and do not
have chain, the sample hatch
nozzle denoted reinforcement.
c) The roof denoted absence of
handrail, only denoted handrail
near to stairway (and it is corroded
and denoted paint failure).
d) The roof denoted sagging on all
plates.
e) The top angle denoted severe
corrosion on 80% of all perimeter
f) The (two)
10 nozzles
for
pressure and vacuum valves
denoted severe corrosion and
paint failure on bolts and flanges
g) The roof denoted 7 holes (from
to 2 in diameter)
h) The roof denoted 21 patch plates
Page 12 of 78
Recommendations
Recoat.
Item
Report TK1015
Location
Finding
denoted no properly installed
f) The stair to shell grounding cable is
absent.
g) The stair to shell support pad
denoted corrosion and paint
failure.
h) The stairway safety chain is
absent.
Page 13 of 78
Recommendations
through their nuts. Recoat
Install the cable.
Change the support stair
1.3
Vegetation on dike
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270 axis the high high level indicator stair denoted corrosion
and paint failure seventh course
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1.3
C.1.1
c.
d.
FOUNDATION
Measure foundation levelness and bottom elevations (see Appendix B for extent of
measurements).
Concrete Ring
Inspect for broken concrete, spalling, and cracks, particularly under backup bars used in
welding butt-welded annular rings under the shell.
Inspect drain openings in ring, back of water draw basins and top surface of ring for
indications of bottom leakage.
Inspect for cavities under foundation and vegetation against bottom of tank.
Check that runoff rainwater from the shell drains away from tank.
e.
C.1.1.1
a.
b.
COMPLETED
C.1.1.2
a.
b.
C.1.1.3
C.1.1.4
C.1.1.5
a.
Report TK1015
Asphalt
Check for settling of tank into asphalt base which would direct runoff rain water under the
tank instead of away from it.
Look for areas where leaching of oil has left rock filler exposed, which indicates
hydrocarbon leakage.
Oiled Dirt or Sand
Check for settlement into the base which would direct runoff rain water under the tank
rather than away from it.
Rock
Presence of crushed rock under the steel bottom usually results in severe underside
corrosion. Make a note to do additional bottom plate examination (ultrasonic, hammer
testing, or turning of coupons) when the tank is out of service.
Site Drainage
Check site for drainage away from the tank and associated piping and manifolds.
Page 34 of 78
COMMENTS
See the settlement results. The tank has a tilt
with angle 1.36 0.79
The concrete ring denoted totally underground.
There are not any type of drain in the concrete ring.
Denoted vegetation near to concrete ring
The tank has not any system to runoff the rainwater.
Per API 653 formulas the maximum calculated settlement
is 1.544, settlement obtained is 0.79, and settlement
actual is 2.48. Per API 653 the settlement is in tolerance.
The tank denoted underground concrete ring.
C.1.2
C.1.2.1
a.
b.
SHELLS
External Visual Inspection
Visually inspect for paint failures, pitting, and corrosion.
Clean off the bottom angle area and inspect for corrosion and thinning on plate and weld.
c.
a.
C.1.2.2
C.1.2.3
b.
c.
d.
e.
C.1.2.4
a.
Report TK1015
Locate leaks by sketch or photo (location will be lost when shell is abrasive cleaned for
painting).
Inspect rivets for corrosion loss and wear.
Inspect vertical seams to see if they have been full fillet lap-welded to increase joint
efficiency.
If no record exists of vertical riveted seams, dimension and sketch (or photograph) the
riveted pattern: number of rows, riveted size, pitch length, and note whether the joint is
butt-riveted or lap-riveted.
Wind Girder (Floating Roof Tanks)
Inspect wind girder and handrail for corrosion damage (paint failure, pitting, corrosion
Page 35 of 78
COMPLETED
COMMENTS
Denoted stand water evidences
NA
NA
Report TK1015
product buildup), especially where it occurs at tack-welded junction, and for broken welds.
Check support welds to shell for pitting, especially on shell plates.
Note whether supports have reinforcing pads welded to shell.
SHELL APPURTENANCES
Manways and Nozzles
Inspect for cracks or signs of leakage on weld joint at nozzles, manways, and reinforcing
plates.
Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection.
Inspect for flange leaks and leaks around bolting.
Inspect sealing of insulation around manways and nozzles.
Check for inadequate manway flange and cover thickness on mixer manways.
Tank Piping Manifolds
Inspect manifold piping, flanges, and valves for leaks.
Inspect fire fighting system components.
Check for anchored piping which would be hazardous to the tank shell or bottom
connections during earth movement.
Check for adequate thermal pressure relief of piping to the tank.
Check operation of regulators for tanks with purge gas systems.
Check sample connections for leaks and for proper valve operation.
Check for damage and test the accuracy of temperature indicators.
Check welds on shell-mounted davit clips above valves 6 in. and larger.
Autogauge System
Inspect autogauge tape guide and lower sheave housing (floating swings) for leaks.
Inspect autogauge head for damage.
Bump the checker on autogauge head for proper movement of tape.
Identify size and construction material of autogauge tape guide (floating roof tanks).
Ask operator if tape tends to hang up during tank roof movement (floating roof tanks).
Compare actual product level to the reading on the autogauge (maximum variation is 2
in.).
Page 36 of 78
COMPLETED
COMMENTS
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
C.1.3.8
C.1.3.9
C.1.3.10
a.
Report TK1015
On floating roof tanks, when the roof is in the lowest position, check that no more than
two ft of tape are exposed at the end of the tape guide.
Inspect condition of board and legibility of board-type autogauges.
Test freedom of movement of marker and float.
Shell-Mounted Sample Station
Inspect sample lines for function of valves and plugging of lines, including drain or returnto-tank line.
Check circulation pump for leaks and operating problems.
Test bracing and supports for sample lines and equipment.
Heater (Shell Manway Mounted)
Inspect condensate drain for presence of oil indicating leakage.
Mixer
Inspect for proper mounting flange and support.
Inspect for leakage.
Inspect condition of power lines and connections to mixer.
Swing Lines: Winch Operation
Nonfloating. Raise, then lower the swing line with the winch, and check for cable tightness
to confirm that swing line lowered properly.
Floating. With tank half full or more, lower the swing line, then let out cable and check if
swing has pulled cable tight, indicating that the winch is operating properly.
Indicator. Check that the indicator moves in the proper direction: Floating swing line
indicators show a lower level as cable is wound up on the winch. Non-floating swing line
indicators show the opposite.
Swing Lines: External Guide System
Check for leaks at threaded and flanged joints.
Swing Lines: Identify Ballast Varying Need
Check for significant difference in stock specific gravity.
Swing Lines: Cable Material and Condition
For non stainless steel cable, check for corrosion over entire length.
Page 37 of 78
COMPLETED
COMMENTS
NA
NA
NA
NA
The tank has not heater
NA
NA
NA
NA
NA
The cable is OK
C.1.4
C.1.4.1
C.1.4.2
C.1.4.3
C.1.4.4
C.1.4.5
C.1.4.6
a.
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COMPLETED
COMMENTS
The cable is OK
There is not leakage
OK
NA
NA
The roof has not insulation.
NA
b.
c.
d.
e.
f.
g.
h.
i.
j.
C.1.5
C.1.5.1
a.
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COMPLETED
COMMENTS
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
Report TK1015
On tanks governed by Air Quality Monitoring District rules, check for the condition of seal
inside hatch cover.
Check for corrosion and plugging on thief and gauge hatch cover.
Where sample hatch is used to reel gauge stock level, check for marker and tab stating
hold-off distance.
Check for reinforcing pad where sample hatch pipe penetrates the roof deck.
On floating roof sample hatch and recoil systems, inspect operation of recoil reel and
condition of rope.
Test operation of system.
On ultra clean stocks such as JP4, check for presence and condition of protective coating or
liner inside sample hatch (preventing rust from pipe getting into sample).
Gauge Well
Inspect visible portion of the gauge well for thinning, size of slots, and cover condition.
Check for a hold-off distance marker and tab with hold-off distance (legible).
On floating roofs, inspect condition of roof guide for gauge well, particularly the condition
of the rollers for grooving.
If accessible, check the distance from the gauge well pipe to the tank shell at different
levels.
If tank has a gauge well washer, check valve for leakage and for presence of a bull plug or
blind flange.
Fixed Roof Scaffold Support
Inspect scaffold support for corrosion, wear, and structural soundness.
Autogauge: Inspection Hatch and Guides (Fixed Roof)
Check the hatch for corrosion and missing bolts.
Look for corrosion on the tape guides and float guides wire anchors.
Autogauge: Float Well Cover
Inspect for corrosion.
Check tape cable for wear or fraying caused by rubbing on the cover.
Sample Hatch (Internal Floating Roof)
Page 40 of 78
COMPLETED
COMMENTS
Denoted absence of seal or gasket
OK
There is not reel gauge.
The sample hatch has reinforcing pad
NA
NA
NA
NA
NA
NA
NA
NA
C.1.5.9
C.1.5.10
C.1.5.11
C.1.5.12
a.
b.
C.1.5.13
a.
b.
c.
C.1.6
C.2.12
Report TK1015
Page 41 of 78
COMPLETED
NA
NA
NA
COMMENTS
NA
NA
NA
NA
NA
NA
C.2.12.4
a.
b.
Report TK1015
Handrails
Identify and report type (steel pipe, galvanized pipe, square tube, angle) and size of
handrails.
Inspect for pitting and holes, paint failure.
Inspect attachment welds.
Identify cold joints and sharp edges. Inspect the handrails and midrails.
Inspect safety drop bar (or safety chain) for corrosion, functioning, and length.
Inspect the handrail between the rolling ladder and the gauging platform for a hazardous
opening when the floating roof is at its lowest level.
Platform Frame
Inspect frame for corrosion and paint failure.
Inspect the attachment of frame to supports and supports to tank for corrosion and weld
failure.
Check reinforcing pads where supports are attached to shell or roof.
Inspect the surface that deck plate or grating rests on, for thinning and holes.
Check that flat-surface-to-flat-surface junctures are seal-welded.
Deck Plate and Grating
Inspect deck plate for corrosion-caused thinning or holes (not drain holes) and paint
failure.
Inspect plate-to-frame weld for rust scale buildup.
Inspect grating for corrosion-caused thinning of bars and failure of welds.
Check grating tie down clips. Where grating has been retrofitted to replace plate, measure
the rise of the step below and above the grating surface and compare with other risers on
the stairway.
Stairway Stringers
Inspect spiral stairway stringers for corrosion, paint failure, and weld failure. Inspect
attachment of stairway treads to stringer.
Inspect stairway supports to shell welds and reinforcing pads.
Page 42 of 78
COMPLETED
COMMENTS
Handrail is 2x 2 x 3/16 carbon steel angle.
Denoted paint failure
A crack denoted on stair handrail to roof handrail weld
The handrail and midrail denoted corrosion and paint
failure.
Denoted safety chain absent
NA
NA
COMPLETED
C.2.12.5
a.
b.
c.
d.
e.
f.
g.
h.
i.
j.
k.
l.
m.
Rolling Ladder
Inspect rolling ladder stringers for corrosion.
Identify and inspect ladder fixed rungs (square bar, round bar, angles) for weld attachment
to stringers and corrosion, particularly where angle rungs are welded to stringers.
Check for wear and corrosion where rolling ladder attaches to gauging platform.
Inspect pivot bar for wear and secureness.
Inspect operation of self-leveling stairway treads.
Inspect for corrosion and wear on moving parts.
Inspect rolling ladder wheels for freedom of movement, flat spots, and wear on axle.
Inspect alignment of rolling ladder with roof rack.
Inspect top surface of rolling ladder track for wear by wheels to assure at least 18 in. of
unworn track (track long enough).
Inspect rolling ladder track welds for corrosion.
Inspect track supports on roof for reinforcing pads seal-welded to deck plate.
Check by dimensioning, the maximum angle of the rolling ladder when the roof is on low
legs.
Max. angle ____________ .
If rolling ladder track extends to within 5 ft of the edge of the roof on the far side, check
for a handrail on the top of the shell on that side.
Notes:
the access to the roof shall be carefully, the roof structure shall be checked internally.
Report TK1015
Page 43 of 78
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
NA
COMMENTS
severe corrosion
The middle stairway support denoted thinning and
partially underground, the stairway
rest over the
concrete block
FOUNDATION
2.1
Settlement of a tank is the result of either one, or a combination of the following three settlement components.
a.
Uniform settlement. This component often can be predicted in advance, with sufficient accuracy from soil tests.
It may vary in magnitude, depending on the soil characteristics. Uniform settlement of a tank does not induce stresses
in the tank structure. However, piping, tank nozzles, and attachments must be given adequate consideration to prevent
problems caused by such settlement.
b.
Rigid body tilting of a tank (planar tilt). This component rotates the tank in a tilted plane. The tilt will cause an increase
in the liquid level and, therefore, an increase in the hoop stress in the tank shell. Also, excessive tilting can cause
binding of peripheral seals in a floating roof and inhibit roof travel. This type of settlement could affect tank nozzles that
have piping attached to them. Figure B-3 shows that the settled location of the tank shell, after rigid body tilt, can be
represented by either a cosine or sine wave with respect to its original position in a horizontal plane.
c.
Out-of-plane settlement (differential settlement). Due to the fact that a tank is a rather flexible structure, chances are
great that the tank shell will settle in a nonplanar configuration, inducing additional stresses in the tank shell.
The out-of-plane settlements at the bottom edge lead to a lack of circularity at the top of the tank, and in the case of a
floating roof tank, the extent of the induced ovality may impede the proper functioning of the floating roof in such a
way that re-leveling is required. Also, such settlements may cause flat spots to develop in the tank shell. This type of
settlement could affect tank nozzles that have piping attached to them.
d.
2.2
While uniform settlement and rigid body tilt of a tank may cause problems as described above, the out-of-plane
settlement is the important component to determine and evaluate in order to ensure the structural integrity of the
shell and bottom. Based on this principle, a common approach is to determine the magnitudes of the uniform and rigid
body tilt component (if any) for each data point on the tank periphery. Once this is carried out, the plane of rigid tilt is
then important as a datum from which to measure the magnitudes of the out-of-plane settlements.
To determine the maximum out-of-plane deflection for shell settlement, the following formula can be used to calculate the
maximum permissible out-of plane deflection as per API 653, Appendix B.3.2.
{S}
Where:
L2 * Y *11
2*E *H
2.3
Tank Settlement
2.3.1
Report TK1015
Profile Find
Page 44 of 78
SETTLEMENT PROFILE
TANK 1015
Point
Height (inch)
1
0.000
2
2.480
3
2.126
4
2.165
5
1.496
6
1.063
7
0.709
8
0.787
9
0.551
10
0.276
2.3.2
Report TK1015
11
0.551
12
-0.315
Illustration
Page 45 of 78
SKETC 3D
Report TK1015
Page 46 of 78
2.3.3
Smax
Tilt
Rigid
Phase
Settlement calculations
Report TK1015
Page 47 of 78
2.3.4
2.4
Settlement Graphic
Conclusions
The survey found the tank is within API 653 requirements. API 653; maximum deflection permitted for this tank is calculated to
be 1,541 and the deflection calculated from measurement is 0.79.
The tank has a rigid body tilting settlement (planar tilt).
2.5
Recommendations
To make a study of soil in order to have clear type of soil and it characteristics
Report TK1015
Page 48 of 78
BOTTOM
3.1
A total of 2 points were taken at each axis marked for the settlement along the entire circumference of the Bottom projection
plate. A point was taken near the toe of the weld and the other was taken at the edge of the projection.
3.1.1
Standard API 653, Clause 4.4.7.7: The thickness of the projection of the bottom plate beyond the shell as measured at the toe
of the outside bottom-to-shell fillet weld shall not be less than 0.1 in. The projection of the bottom plate beyond the outside
toe of the shell-to-bottom weld shell shall be at least 3/8 in..
3.1.2
Point
Average
Axis
0
Edge
0.439
0.451
0.451
0.447
Near toe
0.444
0.448
0.461
0.451
Axis
Point
Average
90
Bottom Projection plate
Edge
0.466
0.452
0.452
0.457
Near toe
0.445
0.474
0.475
0.465
Axis
Point
Average
180
Bottom Projection plate
Edge
0.450
0.428
0.448
0.442
Near toe
0.451
0.461
0.433
0.448
Axis
Point
Average
270
Bottom Projection plate
Edge
0.470
0.468
0.469
0.469
Near toe
0.469
0.467
0.468
0.468
Point
Axis
Point
Average
170
Bottom Projection plate
Report TK1015
Edge
0.363
0.398
0.370
0.377
Near toe
0.389
0.387
0.382
0.386
Page 49 of 78
Point
Axis
Point
Average
210
Bottom Projection plate
3.1.3
Edge
0.331
0.311
0.255
0.299
Near toe
0.307
0.289
0.297
0.298
Conclusions
Bottom Projection Plates is 2 on width, this is within API 653 Tolerance. The thickness average for bottom projection plate is
0,416.
Maximum Interval Inspection as Per API 653 is 20 Years for known corrosion rates.
Recommended to do next interval inspection before or within 20 years.
3.1.4
Recommendations
4.
SHELL
4.1
Shell Plate
4.1.1
According with Standard API 653, Section 4.3.3.1, the minimum acceptable shell plate thickness for tanks with diameters equal
to or less than 200 ft shall be calculated as follows:
a. When determining the minimum acceptable thickness for an entire shell course, tmin is calculated as follows:
tmin =
Where:
2.6(H - 1) * D * G
S* E
tmin
the minimum acceptable thickness, in in. for each course as calculated from the above formula; however,
tmin shall not be less than 0.1 in. for any tank course,
height from the bottom of the shell course under consideration to the maximum liquid level when
evaluating an entire shell course, in ft; or
height from the bottom of the length L (see 4.3.2.1) from the lowest point of the bottom of L of the locally
thinned area to the maximum liquid level, in ft; or
height from the lowest point within any location of interest to the maximum liquid level, in ft,
maximum allowable stress in lbf/in.2; use the smaller of 0.80Y or 0.429T for bottom and second course; use
the smaller of 0.88Y or 0.472T for all other courses.
Report TK1015
Page 50 of 78
Allowable shell stresses are shown Table 4-1 for materials listed in the current and previous editions of API
Std 12C and Std 650.
Y
specified minimum yield strength of the plate; use 30,000 lbf/in.2 if not known.
the smaller of the specified minimum tensile strength of the plate or 80,000 lbf/in.2; use 55,000 lbf/in.2 if
not known,
original joint efficiency for the tank. Use Table 4-2 if original E is unknown. E = 1.0 when evaluating the
retirement thickness in a corroded plate, when away from welds or joints by at least the greater of 1 in. or
twice the plate thickness.
4.1.2
According with Standard API 653, Para. 4.3.4.1: The minimum acceptable thickness for riveted tank shells shall be calculated
using the formula of 4.3.3.1 except that the following allowable stress criteria and joint efficiencies shall be used:
S
21,000 lbf/in2
See Standard API 653, Table 4-3 for joint efficiencies for locations within 6 in. of riveted.
Report TK1015
Page 51 of 78
On API 653 standard, Para. 4.3.4.3: For tanks with riveted joints, consideration shall be given to whether, and to what extent,
corrosion affects such joints. If calculations show that excess thickness exists, this excess may be taken as corrosion allowance.
Non-liquid loads (see 4.3.3.5) shall also be considered in the analysis of riveted tanks.
4.1.3
The minimum shell thickness shall be according with next information extracted from Standard API 650:
4.1.4
Calculations are based on Section 4.3.3.1 of Standard API 653, no corrosion allowance was considered
GENERAL DETAIL OF TANK SHELL PLATE
>70
Crude oil
Water
117.287
40.322
UNKNOWN
5,282 (First Course)
21.000
2
ALLOWABLE PRODUCT STRESS (lbf/in ):
21.000
21.000
2
ALLOWABLE HYDROSTATIC STRESS (lbf/in ):
21.000
JOINT EFFICIENCY, E:
Table 4-3
NUMBER OF STATION POINT:
12
YEARS IN SERVICE: (Assumed)
PRODUCT:
SG (for Hydrotest):
DIAMETER (ft):
HEIGHT (ft):
MATERIAL:
PLATE WIDHT (ft):
Report TK1015
Page 52 of 78
Average
Axis
0
First Course
Down
0.632
0.634
0.634
0.633
Middle
0.630
0.635
0.635
0.633
Top
0.630
0.630
0.631
0.630
Axis
Point
Average
90
First Course
Down
0.620
0.622
0.620
0.621
Middle
0.626
0.627
0.626
0.626
Top
0.620
0.618
0.617
0.618
Axis
Point
Average
180
First Course
Down
0.621
0.619
0.618
0.619
Middle
0.619
0.622
0.622
0.621
Top
0.611
0.609
0.610
0.610
Axis
Point
Average
270
First Course
Report TK1015
Down
0.616
0.621
0.619
0.619
Middle
0.629
0.630
0.630
0.630
Top
0.608
0.606
0.609
0.608
Page 53 of 78
TK 1015
SHELL READINGS INCHES (Manual or Crawler) 2 TO 7 COURSE
Point
Average
Axis
5
Second Course
Third Course
Fourth Course
Fifth Course
Sixth Course
Seventh Course
Report TK1015
Down
0.519
0.520
0.520
0.520
Middle
0.513
0.520
0.519
0.517
Top
0.519
0.519
0.511
0.516
Down
0.500
0.498
0.501
0.500
Middle
0.490
0.499
0.500
0.496
Top
0.492
0.502
0.497
0.497
Down
0.427
0.436
0.432
0.432
Middle
0.444
0.439
0.438
0.440
Top
0.440
0.443
0.448
0.444
Down
0.294
0.292
0.308
0.298
Middle
0.322
0.321
0.318
0.320
Top
0.297
0.297
0.296
0.297
Down
0.265
0.270
0.270
0.269
Middle
0.271
0.282
0.282
0.278
Top
0.272
0.271
0.271
0.272
Down
0.276
0.278
0.276
0.277
Middle
0.279
0.276
0.275
0.277
Top
0.267
0.286
0.274
0.276
Page 54 of 78
TK 1015
OTHER INDICATIONS SHELL READINGS (INCHES)
Item
Description
Dimensions
Location
Point
Average
INSERT PLATE
59" X 21,5"
COURSE 1 SHEET
2
DOWN
0.624
0.626
0.624
0.625
TOP
0.614
0.609
0.609
0.611
COURSE 1 SHEET
6
DOWN
0.601
0.607
0.602
0.603
TOP
0.606
0.611
0.611
0.609
COURSE 1 SHEET
7
DOWN
0.608
0.600
0.599
0.602
TOP
0.615
0.621
0.619
0.618
COURSE 1 SHEET
9
DOWN
0.596
0.603
0.594
0.598
TOP
0.618
0.620
0.619
0.619
COURSE 1 SHEET
10
DOWN
0.622
0.627
0.623
0.624
TOP
0.630
0.630
0.629
0.630
DOWN
0.617
0.620
0.630
0.622
TOP
0.612
0.608
0.611
0.610
PAD
0.616
0.618
0.620
0.618
COURSE 1 SHEET
19
DOWN
0.550
0.571
0.512
0.545
TOP
0.621
0.622
0.620
0.621
COURSE 1 SHEET
20
DOWN
0.582
0.600
0.587
0.590
TOP
0.617
0.619
0.617
0.618
COURSE 1 SHEET
21
DOWN
0.617
0.619
0.622
0.619
TOP
0.613
0.612
0.613
0.612
COURSE 2 SHEET
6
DOWN
0.504
0.507
0.507
0.506
TOP
0.495
0.499
0.494
0.496
10
Report TK1015
INSERT PLATE
INSERT PLATE
INSERT PLATE
INSERT PLATE
INSERT PLATE
INSERT PLATE
INSERT PLATE
INSERT PLATE
INSERT PLATE
68,5" X 62"
68,5" X 62"
64" X 53"
95,5" X 51,5"
77" X 59"
63" X 56"
94" X 50"
75" X 58"
137" X 32"
COURSE 1 SHEET
11
Page 55 of 78
CorrosionRate =
Re mainingLife =
TANK COURSE
Original
Thickness
(inch)
(Unknown, same value obtained
for tmin per API 653 was
assumed)
0
0.762
0.660
0.537
0.456
0.337
0.254
0.115
0.630
90
0.617
180
0.609
270
0.606
0.511
0.490
0.427
0.292
0.265
0.267
0.622
0.518
0.498
0.439
0.305
0.273
0.276
Year
0.002
0.0007
0.0002
0.0003
0.0006
5
0.762
5
0.660
5
0.537
5
0.456
5
0.337
5
0.254
5
0.115
33.139
27.739
26.693
22.142
15.669
12.271
12.414
Minimum Thickness
Measured (Inch)
Corrosion Rate
(inch/Year)
per
Report TK1015
Page 56 of 78
See the next sketch for Ultrasonic Thickness Measurements locations on Shell Plates
Report TK1015
Page 57 of 78
4.1.5
Conclusions
Shell thicknesses are not within stipulated requirements of API 653 because the minimum required thickness is bigger than
actual thickness.
It is not possible determine the interval of inspection and remaining life because the actual thicknesses are out of tolerance
according to standard API 653.
4.1.6
Recommendations
Change the design criteria according with these results of thickness data or improve the efficient joint. The maximum height
shall be changed.
Report TK1015
Page 59 of 78
4.2
4.2.1
Report TK1015
Page 60 of 78
Report TK1015
Page 61 of 78
4.2.2
4.2.3
Conclusions
All nozzles (except manholes and a 2 nozzle on 265 and 270) do not comply to API 650 Requirements. For this case this
standard employs the principles of API Standard 650, (API 653, Clause 1.1.3).
4.2.4
Recommendations
According to the standard and code for the acceptance criteria, the nozzles shall be changed except (except manholes and a 2
nozzle on 265 and 270), because the thicknesses are below the values allowed by the API 650 standard.
4.3
Plumbness
4.3.1
Acceptance Criteria
Standard API 653, Clause 10.5.2.1: The maximum out-of-plumbness of the top of the shell relative to the bottom of the shell
shall not exceed 1/100 of the total tank height, with a maximum of 5 in. The 1/100 criteria, with a maximum of 5 in., shall also
apply to fixed roof columns. For tanks with internal floating roofs, apply the criteria of this section or API Std 650, Appendix H,
whichever is more stringent.
Report TK1015
Page 62 of 78
Standard API 653, Clause 10.5.2.2: The out-of-plumbness in one shell course shall not exceed the values specified for mill
tolerances in ASTM A 6 or A 20, whichever is applicable.
4.3.2
Method of Inspection
Optical measurement offsets were carried out using a topography equipment Sokkia, Model 630 RK. The tank was surveyed
with product (in service).
The total number of stations to be carried out was taken in the same axis established for settlement.
Each tank will be strapped with calibrated steel strapping tape for the outside circumference at the first course of each tank.
The outside circumference will be then divided by 30 for the total number of stations required.
4.3.3
Plumbness Findings
Report TK1015
Page 63 of 78
Maximum
Deviation
Vertically
(inch)
Deviation of
top of the
shell (inches)
Acceptable
Limit API 653
(1/100 TANK
HEIGHT)
inches
Acceptable
Limit API 650
(1/200 TANK
HEIGHT) inches
API 653
Station 1 (0)
-2.929
-2.677
4.842
2.421
ACCEPTABLE
REJECTED
Station 2 (30)
-2.452
-2.066
4.842
2.421
ACCEPTABLE
ACCEPTABLE
Station 3 (60)
-3.094
-2.854
4.842
2.421
ACCEPTABLE
REJECTED
4.842
2.421
ACCEPTABLE
REJECTED
4.842
2.421
ACCEPTABLE
ACCEPTABLE
4.842
2.421
ACCEPTABLE
REJECTED
4.842
2.421
ACCEPTABLE
REJECTED
4.842
2.421
ACCEPTABLE
ACCEPTABLE
Criteria
API 650
Axis
Station 4 (90)
Station 5 (120)
Station 6 (150)
Station 7 (180)
Station 8 (210)
-4.212
-2.007
-3.106
-2.625
-2.889
-4.212
-2.007
-3.106
-2.515
-2.350
Station 9 (240)
-4.196
-3.614
4.842
2.421
ACCEPTABLE
REJECTED
Station 10 (270)
-4.480
-4.480
4.842
2.421
ACCEPTABLE
REJECTED
Station 11 (300)
-2.889
-2.862
4.842
2.421
ACCEPTABLE
REJECTED
ACCEPTABLE
ACCEPTABLE
Station 12 (330)
4.3.4
Report TK1015
-2.441
-1.917
4.842
Page 64 of 78
2.421
4.3.5
Conclusions
4.3.6
Recommendations
The axis 0 , 60, 90 ,150, 180, 240, 270 , 300 require to be repair in order to meet the API 650 requirements for
plumbness. Evaluate if the new purpose service require floating roof
4.4
Tank Roundness
4.4.1
Acceptance Criteria
Standard API 653, Clause 10.5.3: Radii measured at 1 ft above the shell-to-bottom weld shall not exceed the tolerances shown
in Table 10-2.
Radius tolerances measured higher than one foot above the shell-to-bottom weld shall not exceed three times the tolerances
given in Table 10-2.
4.4.2
Method of Inspection
Optical measurement offsets were carried out using a topography equipment Sokkia, Model 630 RK. The tank was surveyed
with product (in service).
The total number of stations to be carried out was taken in the same axis established for settlement.
Each tank will be strapped with calibrated steel strapping tape for the outside circumference at the first course of each tank.
The outside circumference will be then divided by 30 for the total number of stations required.
4.4.3
The roundness values were taken on same axis where plumbness measured recorded in 4.3.4
4.4.4
Report TK1015
Page 66 of 78
Report TK1015
Page 67 of 78
Report TK1015
Page 68 of 78
Report TK1015
Page 69 of 78
Report TK1015
Page 70 of 78
The roundness at the middle of the seventh course of the tank is showed in next illustration.
Report TK1015
Page 71 of 78
Report TK1015
Page 72 of 78
4.4.5
Conclusions
The 1, 2, 5, and 7 roundness measures axis at 1 ft high do not meet the API 653 Table 10-2 requirements
The 3 roundness measures axis at middle high (20.243 ft)do not meet the API 653 Table 10-2 requirements
The 1, 2, 3, 4, 5, 6, 7, 8, 9 and 10 roundness measures axis at top high (37.510 ft)do not meet the API 653 Table 10-2
requirements
4.4.6
Recommendations
This result should be taken account if the installation of floating roof is considered in the future.
5.
ROOF
5.1.
5.1.1.
Roof Plate
Standard and Code Reference
5.1.2.
TK 1015
ROOF READINGS (INCHES)
Point
Average
Axis
0
Report TK1015
Center
0.184
0.188
0.189
0.187
0.192
0.191
0.179
0.187
0.209
0.206
0.205
0.206
0.166
0.194
0.181
0.180
0.219
0.220
0.222
0.220
0.186
0.160
0.170
0.172
0.179
0.182
0.176
0.179
Page 73 of 78
Axis
Point
Average
90
Center
0.184
0.188
0.189
0.187
0.175
0.184
0.175
0.178
0.181
0.188
0.193
0.187
0.201
0.200
0.197
0.199
0.195
0.197
0.202
0.198
0.180
0.187
0.172
0.180
0.179
0.180
0.181
0.180
Axis
Point
Average
180
Center
0.184
0.188
0.189
0.187
0.214
0.211
0.219
0.215
0.216
0.216
0.212
0.214
0.195
0.197
0.202
0.198
0.215
0.209
0.209
0.211
0.205
0.193
0.194
0.197
0.175
0.179
0.172
0.175
Axis
Point
Average
270
5.1.3.
Center
0.184
0.188
0.189
0.187
0.187
0.185
0.185
0.186
0.189
0.187
0.186
0.188
0.192
0.186
0.189
0.189
0.183
0.188
0.186
0.186
0.185
0.183
0.183
0.184
0.180
0.184
0.188
0.184
Conclusions
The present average thickness in the roof is 0,190; roof plates comply with the requirements of API 653.
5.1.4.
Recommendations
Change The roof because it denoted sagging on all plates, 7 holes, 21 patch plates and the top angle denoted severe corrosion
and paint failure.
Report TK1015
Page 74 of 78
5.2
Roof Nozzles
Ultrasonic Thickness measurement taken on four places around nozzle and reinforcement pad.
5.2.1.
5.2.2.
Report TK1015
Page 75 of 78
5.2.3.
Conclusions
The N1 , N3 8 and 10 nozzles reinforcement thickness attached to the roof are not conform to the requirements of API 650,
figure 5.19.
5.2.4.
Recommendations
CATHODIC PROTECTION
6.1
6.2
Report TK1015
Cathodic Readings
Page 77 of 78
6.4 Recommendations
Perform the activities according with Standard API 653, Clause 6.3.4:
Report TK1015
Page 78 of 78