honda hydraulic power unit - clemson...

APPLIED TECHNICAL SERVICES, INC.

Corporate Office: Marietta, GA • Branch Offices: Birmingham, AL • Mobile, AL • Jacksonville, FL • Augusta, GA • Savannah, GA • Louisville, KY • Baton Rouge, LA Shreveport, LA • Wilson, NC • Charleston, SC • Columbia, SC • Greenville, SC • Chattanooga, TN • Memphis, TN • Arlington, VA • Chesapeake, VA • Rockville, VA

1049 Triad Court, Marietta, Georgia, 30062 • (770) 423-1400 Fax (770) 514-3299 • www.atslab.com

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

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ATS450, 4/18/12 Proprietary Document

Mechanical Integrity Report for the

ICAR – Honda Hydraulic Power Unit

at

208 North Palmetto Boulevard

Clemson, South Carolina 29631

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: CU00134445 ATS Job Number: 187436




Table of Contents

of 9 ATS450, 4/18/12 Proprietary Document

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




General Information, Background, Equipment Orientation and Access


Design Pressure Unknown Design Temperature Unknown Operating Pressure Atmospheric Operating Temperature Ambient Contents Diesel Specific Gravity 0.83 Shell Length x Width x Height 4’-11” x 2’-6” x 1’-7”

Manufacturer Pneumatic and Distributors Inc.

Year Constructed Unknown Serial Number 96 8300 UL Number Unknown Material Unknown Carbon Steel Previous Inspection None Drawing(s) None

NDE Performed by Jesse Showalter (VT) Stan Sullivan (UTT)

Background This report contains the results of the inspection, analysis and action items regarding the ICAR Honda 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 roll-

out 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.

Overall View




Present Condition and Analysis


External Present Condition Minor dirt and debris buildup was observed on the top plate. Minor staining was observed on the shell. Minor coating failure was observed on the East and West shell nozzle covers. Minor general surface corrosion was observed on the support system at areas of coating failure. No normal vent or emergency vent was located at the time of inspection. 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 normal and emergency venting requirements per UL 142. The required normal vent size is NPS 1¼. The required emergency vent size is NPS 2. A summary of the ultrasonic thickness measurements is located in the Summary of Thickness 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.




Present Condition and Analysis


Summary of Thickness Measurements

0.239 0.383 0.382 0.2810.250 0.258 0.257 0.1870.135 0.139 0.139 0.1010.250 0.255 0.255 0.1870.135 0.138 0.136 0.1010.135 0.136 0.136 0.101

North Shell

Minimum Measured Thickness (inches)

ComponentPrevious

Thickness (inches)

Average Measured Thickness (inches)

Top Plate

Legend> 10% Above Minimum Required

Assumed, per STI SP001 7.2.4

East ShellSouth Shell

Bottom PlateWest Shell

Corrosion Rate

(inches/year)

Remaining Life

(years)

Minimum Required Thickness (inches)

At Minimum Required or BelowWithin 10% of Minimum Required

Corrosion rates and remaining life calculations cannot be performed until a second set of UT measurements is acquired.




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 NPS 1¼ normal vent should be installed on the tank, per UL 142. 1

2 A NPS 2 emergency vent should be installed on the tank, per UL 142. 1

3 The carbon steel components should be cleaned and coated to prevent further deterioration. 3

4 Proper grounding should be verified or installed. 3

Legend

Priority 1 High likelihood and consequence of failure. Critical Code or Standard deficiency. May not be fit for continued service without repair.

Priority 2 Medium likelihood and consequence of failure.

Priority 3 Low likelihood and consequence of failure. Non-critical Code or Standard deficiency. Industry best practice or preventative maintenance. Housekeeping items.



1049 Triad Court, Marietta, Georgia, 30062 • (770) 423-1400 Fax (770) 514-3299 • www.atslab.com 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 # 27219 API 653 # 27205 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

Peter Dudley ATS certified Level II UTT, MT, PT per SNT-TC-1A Joey Laprade ATS certified Level II UTT, MT, PT per SNT-TC-1A Reference Industry Codes and Standards 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




Photographs


Photo 1: Overall view of the tank.

Photo 2: View of the top plate.




Photographs


Photo 3: View of minor general surface corrosion at areas of

coating failure.

Photo 4: View of nozzles on top plate.

Top Plate Minor dirt/debris was observed. Otherwise, no visible deterioration or damage was observed.

Shell Minor staining was observed. Otherwise, no visible deterioation or damage was observed.

Bottom Plate No visible deterioration or damage was observed.

Nozzle / Manway / Repad No visible deterioration or damage was observed.

Corporate Office: Marietta, GA • Branch Offices: Birmingham, AL • Mobile, AL • Jacksonville, FL • Augusta, GA • Savannah, GA • Louisville, KY • Baton Rouge, LA

Nameplate Information


Coating Minor coating failure was observed on the East/West wall nozzle covers.

Condition / Comments

Ser. No.: 96 8300

APPLIED TECHNICAL SERVICES, INC.Shreveport, LA • Wilson, NC • Charleston, SC • Columbia, SC • Greenville, SC • Chattanooga, TN • Memphis, TN • Arlington, VA • Chesapeake, VA • Rockville, VA

Component

Appendix A: NDE Report

External Visual Inspection:

ATS460, 4/18/12 Honda Hydraulic Power Unit.xls

Notes:

Interstitial Space Not applicable.

Internal Visual Inspection:

Component Condition / Comments

Grounding Cable None located at the time of inspection.

No relief device was located.

Relief / Vent(s) - Interstitial Space Not applicable.

Weld Seam No visible deterioration or damage was observed.

Support System Minor general surface corrosion was observed at areas of coating failure.

Relief / Vent(s) - Main Tank

Anchor Bolt / Saddle / Lug No visible deterioration or damage was observed.



APPLIED TECHNICAL SERVICES, INC.Shreveport, LA • Wilson, NC • Charleston, SC • Columbia, SC • Greenville, SC • Chattanooga, TN • Memphis, TN • Arlington, VA • Chesapeake, VA • Rockville, VA



Top:Plan View: (AS SEEN FROM ABOVE)

Rollout / Nozzle Locations (NOT TO SCALE):

Bottom:


West Wall: East Wall:

North Wall: South Wall:


Top:

Notes:A> 10% Above Minimum Required

Within 10% of Minimum Required

Legend

5 0.281

1 0.281

3

At Minimum Required or Below

0.281

0.281

0.382

0.384

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.

0.383


UTT Inspection Location (A)

4



Ultrasonic Thickness Measurements:

East to West Minimum Measured Thickness (inches)


Shreveport, LA • Wilson, NC • Charleston, SC • Columbia, SC • Greenville, SC • Chattanooga, TN • Memphis, TN • Arlington, VA • Chesapeake, VA • Rockville, VA


0.384

0.384

2 0.281

ATS460, 4/18/12 Honda Hydraulic Power Unit.xlsATS460, 4/18/12 Honda Hydraulic Power Unit.xls

Bottom:

Notes:A



Legend

Ultrasonic Thickness Measurements:








> 10% Above Minimum Required


0.1362 0.101

5 0.101

4 0.101 0.136

0.136

0.101 0.136

0.101 0.136

East to West Minimum Measured Thickness (inches)

3

1

ATS460, 4/18/12 Honda Hydraulic Power Unit.xlsATS460, 4/18/12 Honda Hydraulic Power Unit.xls




Shell Ultrasonic Thickness Measurements:



0.1360.138

0.2550.255

0.2550.255

0.1390.137

3 0.1390.139

0.258

0.25512

North Minimum Measured Thickness (inches)

0.13940.1010.101

5 0.139

0.257

0.1390.101

0.1010.101

0.258

0.259


West Minimum Measured Thickness (inches)

East Minimum Measured Thickness (inches)

South Minimum Measured Thickness (inches)

2



5 0.1874 0.1873 0.187

0.187


Notes:A



Legend

> 10% Above Minimum Required

0.1380.2571 0.187



Notes:A Threaded

B Bolted cover

Corporate Office: Marietta, GA • Branch Offices: Birmingham, AL • Mobile, AL • Jacksonville, FL • Augusta, GA • Savannah, GA • Louisville, KY • Baton Rouge, LA APPLIED TECHNICAL SERVICES, INC.



Appendix A: NDE ReportNozzles / Manways / Reinforcement Ultrasonic Thickness Measurements:


N14 18N/A Unknown

N16 0.5N15 18 B B

UnknownN/A UnknownN/A UnknownN/A Unknown

N3 0.5

N6

N/AN8 0.5

NPS

Nozzle Thickness (inches) Reinforcement Pad

Internal Projection (inches)

0° Scan 180° Width (inches)

Unknown

Thickness (inches)

N1 0.75 A A A None N/A

Nozzle

N/A Unknown

UnknownN2 0.75 A A A None N/A

2 A A A NoneA A A None

UnknownN5 0.5 A A A None N/A UnknownN4

A A A None N/A

N/A

UnknownN7 0.5 A A A None N/A Unknown

0.5

A A A None N/A UnknownN9 1.25 A A A None

N10 2 A A A NoneN11 1.25 A A A None

1.25 A A A None1.25 A A A None

N/A UnknownN12

B B B None N/A UnknownN13

B NoneA A A None N/A Unknown

N17 0.5 A A A None N/A Unknown


Rectangular Construction

Actual Capacity = U.S. gallons= in.= in.

Where:L = Length of the Tank (ft.) =W =Width of the Tank (ft.) =D = Depth of the Tank (ft.) =

Actual Capacity = U.S. gallons

Min. Design ThicknessSTI Min. Required Thickness

0.093

Per STI SP001 10.0, 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 0.135" (10 gauge) and 0.250" based on measuring an uncorroded area per STI SP001 7.2.4. The minimum required thickness was calculated as 75% of that value.

146

UL 142: MINIMUM THICKNESS (s.g. less than or equal to 1.0)

APPLIED TECHNICAL SERVICES, INCORPORATEDCorporate Headquarters • 1049 Triad Court, Marietta, Georgia 30062 • 770.423.1400 • Fax 770.514.3299 • www.atslab.com

APPENDIX B: CALCULATIONS SUMMARY

4.922.501.58

UL 142: VENTING

146

(per UL 142 Section 17)0.101 / 0.187 (per UL 142 Section 25)

Wetted Surface Area (rectangular) = ft2

Normal Venting

Minimum Opening = 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 = NPS (per Table 8.1)

The pipe size applies to lengths of not more than 12 in.

Emergency vents are not prohibited from use for normal venting.

1 1/4

23

2

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