Leakage issues in "1908 Riveted Tank " 6

[Shafx]

Hello Seniors!

We are repairing a riveted tank which is constructed in 1908. After integrity assessment report generated the scope of work.We have replaced
*All the bottom plates.
*All the roof plates.
*1st shell course.
*300mm width of patch plate on the top shell through out circumference below the curb angle.
Now during hydrotest we encountered several rivets weeping and horizontal lap joints(fillet weld) leakage.We performed seal pass on some rivets and on 2 of the horizontal lap joint through out the circumference.
Now after again refilling some of the rivets started weeping.
Now my client did not want to construct it from zero level(that we suggested before the integrity report).What are the options i have?
Only idea i have is that Patch plates on all the rivet joints from inside and after that painting with some polyurethane mixture on all the patches.
Tank Data Sheet and some leakage photos has been attached.
Thanks in advance.

 

[IFRs]

I think your only options are seal weld (heat will affect the adjacent rivets), blast and paint inside and outside (blasting may remove the rivet heads), cutout and replace. All are expensive but maintenance money may be easier to get than capital money.

Lap welding a plate to hide the rivets is not a great idea from a number of perspectives.

 

[HTURKAK]

Tha tank was constructed in 1908..that is, 112 years old. I am at the age that could be grandfather of a teenage child..my grandfather was also a child in 1908.

You have replaced roof, bottom and 1st course ..That is, you have replaced almost 70 % of the tank. I will suggest , replace the remaining shell and get a new tank.

Other options,
-the use of repair patches as per API 653,
-seal weld of leaky joints from interior surface,???
- The use of FRP lining for the shell ( make sure that FRP type is suitable for the intended content ).

 

[LittleInch]

Internally line / coat the inside surface?

Rubber, fibreglass or similar could work.



Remember - More details = better answers
Also: If you get a response it's polite to respond to it.

 

[Dhurjati Sen]

You should have gone for a new tank and not rivetted but welded as per API 650.

You should have posted it at the start of the project. Then suggestion would have been not to take up this project as the client is neither sensible nor sane.

Only option for you is to pack up and leave.

Do you read Dilbert? He would have suggested to sub-contract the job to somebody else.


DHURJATI SEN
Kolkata, India

 

[NOLAscience]

Dhurjati Sen is correct, but I would not sub-contract the job to someone else as I would then still have to at least keep up on the progress and my name would be associated with the project and I certainly don't want that.

 

[MJCronin]

Some good information on riveted storage tank repair here:

https://www.researchgate.net/public..._IN_RIVETED_STEEL_TANK_WITH_5000_m_3_CAPACITY

http://www.tankindustry.com/Websites/tankindustry/images/TechnicalPapers/Maintaining_Aged_Tanks.pdf

https://www.ast-forum.com/ast_forum_tree.asp?master=12312

https://www.eng-tips.com/viewthread.cfm?qid=37965

https://www.eng-tips.com/viewthread.cfm?qid=352847

Please respect those engineers that contribute to this Forum !!!

Please keep us involved when you decide upon your final solution and please help educate others by posting pictures of your rivetted joint problems ...

This is not a one way street ...... Help your fellow engineers !!

Best Regards

MJC




MJCronin
Sr. Process Engineer

 

[MJCronin]

There may always be several attractive "final solutions" for older rivetted tanks !!!

https://sports.yahoo.com/rusty-storage-tank-converted-most-171721210.html

MJCronin
Sr. Process Engineer

 

[Shafx]

Thanks to all.

Specially Mr.MJcronin for sharing reading material.
Now the contractor is negotiating with client on inside tank"Rivets patch work methodology" and client is insisting that by removing roof from top side of top shell course(cutting of inside column too) and lifting of roof with allied internal structure.Estimation of roof weight with internal structure will be around 25Mton.

Lets see what will be decided.

 

[MJCronin]

Did you get a cost estimate for a brand new tank ???

MJCronin
Sr. Process Engineer

 

[HTURKAK]

You have replaced , All the bottom plates, 1st shell course, All the roof plates.

I could not see the reason for ; removing new replaced roof ..

 

[MJCronin]

When the client gets deeply involved in the design decisions, such as which bolts to replace, which rivets are defective and how the tank must be reconstructed from various bits and pieces, there is only one possible outcome....

This Guy had lots of replacement parts ...and a lot of problems with bolts and rivets

MJCronin
Sr. Process Engineer