Quick solution for leakage at shell of condensate tank 2

[Yahya Omar]

by Visual Inspection, leakage from 5th course of shell has been observed
what is the fast solution online without shutdown as a short term?
What about UPS (Unique polymer system) copy attached ?

 

[Tmoose]

Have you been closer to the leak than the picture?
What is the design operating pressure?
What is the ACTUAL operating pressure ?
Is the level of condensate expected to reach that level in proper operation?

I'd want to confirm (*) the leakage is not the symptom of a larger problem.

* = be DAMNED sure

 

When was the last API 653 In-service inspection?
When was the last API 653 Out-of-service inspection?

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

[Yahya Omar]

The design operating pressure is 5 bar, and the actual one is ranging from 0.5 to 2 bar
Yes the cond level expected to reach in proper operation

 

[Yahya Omar]

Last in service inspection in current year.

Last out service API 653 inspection at 2011

 

[Ron]

That's a straight line....indicative of a vertical shell weld that might be failing. I'm with Tmoose....get a closer look and look for bigger problem than a leak.

 

[IFRs]

My concern would not be that this leaks but that if the vertical seam is compromised you have a potential disaster on your hands. I'd immediately lower the level in the tank to below that entire vert and then get up close and personal with NDE to see what's going on.

 

[Dhurjati Sen]

Dear Yahya Omar,

What is the service? Seems gasoline from the attached document. Is it a floating roof tank?

I understand the problem from the management's point of view, in service inspection in current year could not detect any thickness loss as the location is not beside the stairs and the next M&I could be another 4 to 6 years away.

Surely you have lowered the level below the 5th course.

You have to operate the tank at that level and go for shell partial replacement at the earliest if it is a fixed roof tank.

As a temporary measure, you can go ahead with the proposed action (unique polymer system).

If its a floating roof tank, then you have lot of options to choose from.

Regards.





DHURJATI SEN

 

First thing I would do is check the condition and capacity of the berm.

"Everyone is entitled to their own opinions, but they are not entitled to their own facts."

 

[MJCronin]

It was a "fast solution" by a welder and a corrupt inspector that caused this problem .....

Do you really want another "fast solution" from a bunch of internet strangers ....?

Hope that you quickly drain the tank to a level below the crack....

Come back to us with more detailed photos when the tank (and your plantsite) is made safe.

Has the original tank fabricator been called back to the plant site ? What did he say ????

MJCronin
Sr. Process Engineer

 

[Yahya Omar]

Capacity: 16940 M3
Service: Gasoline
Type: floating tank
Diameter: 3200 mm
Dimensions: 220000 mm
Design Temp: 60C

But the repair is done (Cold repair by belzona)
Find the following tank after repairing:

 

[Dhurjati Sen]

Dear Yahya Omar,

You did the right thing. How many years after is the next turn-around? Do not extend that, rather take the tank for scheduled M&I earlier, if possible.

Line up contractor, procure plates and get ready for partial replacement of course 5.

Do not forget to do the standard inspections at that time like MFL / LFET of bottom plates, etc.

Also do not waive hydro-test although you could do it as per API 653.

Regards.

DHURJATI SEN

https://www.nace.org/people/dhurjatisen

 

[viper3982]

I bet Phil Swift could slap some Flex Seal on that...it's a 'fast solution'.

As both MJCronin and IFRs said:
First priority: make it safe (immediate action)

If you have done this; you don't need a 'fast solution'.

MJCronin is right..
The "Fast" solution is to CORRECTLY REPAIR THE VESSEL.
If you buy off on any thing else; you will find out the very hard way that it was not as fast of a solution as you were hoping.

*especially when in the future that liability-train comes rolling in

 

[IFRs]

Let's see - you have a million asset that putting a 2 dollar band-aid on risks a public disaster. That's worse than putting bald tires on a Jaguar or filling your fighter jet with fuel through a cheap filter. I understand that taking a tank out of service costs money and goodwill but really??? Just do the right thing.