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NISTM June 27, 2013 Tank Conference
Anaheim, California PEMY Consulting
Philip Myers 925-302-6707
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Fixed Roof Tank Over Pressure Incident
• An unexpected high flow rate of nitrogen surged into the tank at the arrival of the first pipeline displacement pig, causing the frangible roof seam on the Tank to part. Damage occurred on the tank roof, sidewall and tank stairway landing.
2
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Lightning Strike Tank Seal Fire
• A tank rim-seal fire was started when a 160,000 barrel open floating roof tank in gasoline service was struck by lightning. At the time of the incident, the tank was approximately ¾ full and had been undisturbed for approximately 3 weeks. The tank roof seals consist of a primary mechanical shoe seal and a secondary metallic wiper seal, which were installed in late 2000 when the tank was in diesel service. In 2004 the tank was converted to gasoline service. The seals were originally installed to minimize the amount of rainwater getting into the tank.
3
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4
What went wrong
• The urethane that was used for the primary shoe seal fabric is compatible with diesel, but is not compatible with the oxygenate blended into gasoline. The fabric deteriorated after the tank was converted to gasoline service, which resulted in holes and tears in the fabric.
• No Management of Change was performed when the tank was switched to gasoline service, because the MOC process had not yet been implemented at this terminal location.
• The lightning shunts were not being inspected as part of preventative maintenance at this terminal, and some of them were discovered afterwards to not be in contact with the tank shell.
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Lightning Strike Tank Seal Fire
5
Lessons Learned
Compatibility of primary shoe seal fabrics with stored products is not widely recognized among the terminal workforce. To
maintain this learning, an item related to this incident, including Lessons Learned, has been added to the Terminal and
Operations Engineering SharePoint site.
This incident helps to reinforce the importance of the MOC process, which is now in place at this location.
Visual inspection of lightning shunts has been added to the monthly tank inspection checklist.
Example of lightning shunt not
contacting shell of tank
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Floating Roof Collapse and LOC
6
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7
What went wrong
• The tank was isolated three months prior to the spill incident, which included closing and locking the roof drain valve.
• Almost no inspection of the roof was being performed by terminal workers, despite frequent rainfall in the area. Excessive water accumulation on the roof caused the landing legs to collapse.
• The contract Entry Supervisor reported an excessive amount of water on the tank roof shortly after he ordered his worker out of the tank; however, no corrective actions were taken.
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Floating Roof Collapse and LOC
8
Lessons Learned
Always perform frequent inspections of EFR tanks, whether in-service or out-of-service, in
order to determine, among other things, liquid accumulation on the roof and to drain the
roof when necessary.
Always conduct inspection of EFR tanks following rain storms to help ensure that the roof
is drained of accumulated water arising from the rain fall.
Always conduct pre-job planning and risk assessment as the first step in the equipment
isolation process and in the preparation of the Isolation Checklist, and always ensure that
Terminal Management approves the isolation plan before implementing.
Senior and more experienced facility personnel must always take ownership for ensuring
that critical reviews are conducted on all plans that can affect the safety of the facility in
which they work, and always exercise Stop Work Authority where there is doubt regarding
the adequacy of such plans, irrespective of the perceived level of final authorization.
Always address abnormal conditions and take deliberate steps to respond to safety
concerns in order to ensure that risks created by the presence of a potential hazard
are assessed to help prevent possible losses.
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9
How Do You Assess Risks?
• Guesses, hunches,arm-waiving, or just keeping the blinders on are not uncommon, but there are better ways…
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10
What is Risk?
• Risk is the combination of:
– the likelihood of a failure (LOF) that causes a loss, and
– the consequence of that failure (COF)
• Risk = LOF x COF
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11
Risk Assessment and Management
• Risk can be assessed by determining:
– What can go wrong
– How likely is it to happen, and
– What would be the consequences
• Risk can then be managed by instituting strategies to reduce the risk
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12
Details of Consequence Analysis
• Above ground release scenario:
– Release volume: flow rate and duration.
– Flow rate: overfill rate or hole size.
– Also account for dike containment and distance to offsite receptors.
offsite dike / liner
surface water
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13
AST Consequence Analysis Overview of Leak Scenarios
surface water
1 2 3
6
ground water
offsite dike / liner
1
2
3
4
5
6
dike/liner
onsite, surficial soil
offsite, surficial soil
subsurface soil
groundwater
surface water
Cleanup Location
4
5
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14
Details of Consequence Analysis
• Below Ground Releases –first, estimate time
required to reach groundwater depth
–then, if release duration results in contact, estimate portion in water
ground water
dike / liner
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0
5
10
0
5000
100000
200
400
600
800
200
300
400
500
600
700
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19
The Decision Problem
• Which control technique should be selected for this AST: – Prevention?
– Detection?
– Protection?
Note: Remediation is not an acceptable control measure
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The Big Picture = Management Systems
• Local, State, and Federal Regulations and Rules
• Corporate Management Systems
• Industry and API standards
• Experts and Consultants
• State of the Art Ideas: risk assessment, fitness for service, risk based inspection, etc
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Features of a Management System
• MS is a business function of the overall organization.
• MS is a systematic and organized approach to solving safety and environmental problems.
• The purpose of a MS is to achieve and maintain the necessary level of safety and environmental in an organization.
• Implementation of a MS involves management organization, responsibility, and competence (‘human issues’).
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SMS Key Elements
• Key Element 1: Safety and Environmental Advocacy • Key Element 2: Safety and Environmental Information • Key Element 3: Hazard and Risk Assessment and Analysis • Key Element 4: Management of Change • Key Element 5: Procedures and Safe Work Practices • Key Element 6: Training • Key Element 7: Equipment Integrity and Industry Standards • Key Element 8: A Permit System • Key Element 9: Pre start up safety review • Key Element 10: Emergency response and control • Key Element 11: Near Miss and Incident investigation • Key Element 12: Auditing • Key Element 13: Documents and Data Information Management Systems
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More Information on Management Systems
• PEMY Consulting ([email protected]) • API RP 75 Development of a Safety and Environmental
Management Program for Offshore Operations and Facilities
• API RP 75L Guidance document for the Development of a Safety and Environmental Management System for Onshore Oil and Natural Gas Production Operation and Associated Activities
• API 770 A Manager’s Guide to Reducing Human Errors – Improving Performance in the Process Industries
• API 754 Process Safety Performance Indicators for the Refining and Petrochemical industries
• UK Health Safety Executive Web Site
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API Tools
• API 2610 – petroleum terminals
• API 340-PUB 340 summarizes 99 causes of liquid releases at AST facilities and presents 176 measures to prevent or control them.
• API 653 – tank inspection
• API 2611 – piping inspection for terminals
• etcera
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API 2610
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40
Types of Storage Tank Floating Roofs
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41
Container
Type
Atmospheric
Tank
Low Pressure
Tank
Pressure
Vessel
Shell:
Horizontal
Shell:
Vertical
Tank has:
Open Top
Tank has:
Fixed Cover
Shell:
Sphere
Shell:
Vertical
Shell:
Noded Spheroid
Shell:
Vertical
Shell:
Sphere
Shell:
Horizontal
(“Bullet”)
Top Closure:
Flat
Hemispherical
Dome
Bottom Closure:
Flat
Hemispherical
Tank Taxonomy
Top
Bottom
Closure:
Flat
Hemispherical
Closure: N/A
Closure: N/A
Closure: N/A
Roof Types:
Aluminum Domes
Support Cone
Self Supported Cone
Umbrella Roof
Steel Dome
Other
Bottom Types:
Single bottom with RPB (HDPE)
Single bottom with no RPB
Double Bottom
Other, such as elevated onto grillage
Top Closure:
Cone
Dome
Hemispherical
Bottom Closure:
Cone
Hemispherical
Shell is:
Aboveground
Buried
Partially Buried
Shell is:
Anchored
Unanchored
Tank Shell Joint Construction:
Single Lap Welded
Double Lap Welded
Full Fusion Butt Welded
Riveted
Riveted Welded
Double wall or tanks with integral secondary containment
Floating Roof Type:
Double Deck
Steel Annular Pontoon
External Pan Roof
Other
None (special case for nonvolatile products)
Floating Roof Type:
Double Deck
Steel Annular Pontoon
Pan or Bulkheaded Roof
Aluminum Skin & Pontoon
Aluminum Honeycomb
Composite
Other
None / tank has insert gas blanketing
None
Note:
Floating roofs designed for open top tanks have
different design parameters than for covered or
fixed roof tanks. The floating roofs in open top
tanks which are later retrofitted with covers then
become a “covered external ---“
Top Closure:
Flat
Hemispherical
Shell is:
Anchored
Unanchored
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42
Types of Storage Tank Fixed Roofs
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Sources of Potential Releases at AST Facilities
• Aboveground storage tanks
• Piping systems
• Loading areas
• Ancillary equipment
• Operating systems
• overfills
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M M
Sources of Potential Releases at AST
Facilities
Ancillary Equipment
Operator
Error
Unloading AreasPiping
Loading Area
Release
AST
Vapor emissions
Shell
Bottom leaksMarine or pipeline receipts
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Aboveground
Storage
Tank
Secondary
Containment Dike
Dike
LinerRelease Prevention Barrier:
Double Bottom w/
Synthetic Liner
& CP
Protection Control Measures
Figure 5
Dike Liner:
Geosynthetic
"Claymax"
Overfill
Shell
Bottom
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Example Focus Area - Secondary Containment
• The ultimate insurance policy
• Historical
• Regulatory
• Most are never used
• Lack of standardization
• Proof testing
• Leaks
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Marsh Risk Engienering Position Paper 01
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SW Florida power plant- 80,000 gallon overfill
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Buncefield fuel depot
Before Dec 11 2005
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Buncefield fuel depot
Dec 11 2005 (a Sunday)
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Many tanks connected by manifold.
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Historical legacy - Newport
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Numerous Unstandardized Methods of Design and Construction
• A dirt pond
• A flat earthen area with a concrete dike surrounding it
• Fully concreted basis or resevoir
• A tank within a tank
• A large pan
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Secondary Containment
• No proof testing normally done; cannot be easily tested so we don’t know if it will really work
• But its not rocket science so qualified principles using qualified designs can reduce the risk
• Some principles: – Hydraulic pressure and tightness – Radian heat loads on joints and penetrations – Nature of underlying soil – Speed with which contents could permeate soil – Pros and cons of liners (lines can make things worse or distort the overall risk
picture) – Bouyancy effects for either spills or major storms/floods
• API 653 does not address secondary containment inspection
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Lessons from Buncefield
• Any concrete structure for retention of liquids should be designed to minimise the risk of cracks forming. If cracks do form they should be adequately repaired.
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Leak Through Rebar Holes
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Good Practices for Penetrations
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Good Practices for Joints
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Good Practices for New Joints
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Lining Secondary Containment
• Not normally used but regulatory pressure being applied
• Pros and Cons Not Clearcontroversial topic
• API 341 covers this in detail
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API 341 Results
• Vehicular traffic and daily operations cause damage • Material failures from uv radiation where exposed,
chemical reactions with soil, freeze cycles, loss of plasticizers, embrittlement with time
• Failures at penetrations and around structures • Subgrade failures due to settlement, liner movement stress
failures • API conclusion is that liner effectiveness is limited. • From a risk mitigation perspective, in most but not all
cases, the resources used for liners would be far better allocated to things like API inspections, better design and construction, management systems, overfill protection, etc (PEMY opinion)
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7/18/2013 THH\AST\FSS2002.PPT 68
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7/18/2013 THH\AST\FSS2002.PPT 69
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7/18/2013 THH\AST\FSS2002.PPT 70
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7/18/2013 THH\AST\FSS2002.PPT 71
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7/18/2013 THH\AST\FSS2002.PPT 72
Option 1 Geomembrane
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7/18/2013 THH\AST\FSS2002.PPT 73
Option 2 Geosynthetic Clay Liner
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Some Other Ways To Use Secondary Containment
• Severe settlement (+)
• Overfills (-)
• Seismic (-)
• Corrosion (+)
• Operational (-)
• Vandalism or Terrorism (-)
• And more (?)
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Purpose of Foundations
• Support tank (obviously)
• Minimize corrosion
• Allow internal (and external drainage)
• Prevent many different modes of settlement (differential, out of plane, edge, etc)
• Allowance for future settlement
• Provide anchorage for pressure tanks or for seismic
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Common Foundation Types
• Earthen
• Slab
• Crushed Stone Ringwall
• Concrete Ringwall
• Piled
• Others
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Tank Size
• Large Tanks (50 feet in diameter or greater) – use concrete ringwall (preferred)
• Small Tanks (20 feet in diameter or less) – use concrete slab foundation (preferred).
• Medium Tanks (20 to 50 feet in diameter) can be classified as either large or small at the discretion of the foundation designer and tank design engineer, for the purpose of choosing the type of foundations only.
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Caveat
• Do not just put a tank on a foundation (this is done all too often)
• Get a geotechnical engineering firm to assess and determine the soil and subsurface conditions
• Get a recommendation from them on the foundation type (but you will have to provide the criteria for acceptance)
• Make sure you consider RPBs
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Soil Type
• In some instances, large fixed roof tanks can be supported directly on properly prepared good native material. Choose this method only if recommended by the soils consultant. Pile supported concrete slab foundations are used for tanks on poor soils, regardless of the tank size
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Leak Detection Groove Patterns
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Settlement Data Real Tank
0 2 4 6 8 10 12 14 16 18 200.75
0.76
0.77
0.78
0.79
0.8
0.81
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Best Fit Cosine Curve
0 2 4 6 8 10 12 14 16 18 200.75
0.76
0.77
0.78
0.79
0.8
0.81
mse1 = 8.5875e-05
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0 2 4 6 8 10 12 14 16 18 200.75
0.76
0.77
0.78
0.79
0.8
0.81
mse2 = 4.1506e-05
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Best Fit Cosine Curve
-1 -0.50 0.5 1
-1-0.500.51
0.75
0.76
0.77
0.78
0.79
0.8
0.81
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Second Mode Fit
-1
-0.5
0
0.5
1
-1
-0.5
0
0.5
10.74
0.76
0.78
0.8
0.82
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Better “view”
-1-0.5
00.5
1
-1-0.5
00.5
1
0.75
0.76
0.77
0.78
0.79
0.8
0.81
0.82
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Better View Both Modes Shown
-1-0.5
00.5
1
-1-0.5
00.5
1
0.75
0.76
0.77
0.78
0.79
0.8
0.81
0.82
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Residuals
0 1 2 3 4 5 6 7-1
-0.5
0
0.5
1
0 1 2 3 4 5 6 7-1
-0.5
0
0.5
1
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Elephant Foot Buckle
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Tanques de Gasolinas (41, 40, 32) (MOGAS TKS)
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Tanque de almacenamiento (Diesel-22)
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BULLETS LPG (FUERA DE SERVICIO)(MOTHBALLED LPG BULLETS SANK AT ONE SIDE)
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TANQUE 10 DAÑADO (FUEL OIL)