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Presented to TX LA NACE Chapter
Presented by
Carl Matherne - Engineer, BASF Port Arthur
Application of NACE Standards for Sulfuric Acid Storage and Delivery – Tanks and Piping
June 15, 2010 – NACE
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Background
93-98% Sulfuric Tank Storage and Delivery at Facility
Storage Capacity 2035 ft^3( 13,200 gallons)
Shell Construction 3/8(0.375)inch with 1/8(0.1875)inch corrosion allowance
Built in 1999
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Background
Maintenance Issues
Storage tank observed numerous leaks
Venting of gas from roof vent common during loading
Accelerated corrosion band noted in tank during on stream monitoring of tank thickness
General area in disrepair
Operators regard area as hazardous
Numerous leaks reported annually
Tank identified for nozzle repair and clamp removal during turnaround and tank internal inspection
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Findings
Tank entered for inspectionBand of corrosion verified at top of liquid to inert pad interface Pump recirculation or minimum flow nozzle severely corroded – noted for replacementPump suction nozzle corrosion erosion notedFloor scanned for integrity – nominal wall found
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Damage Photo Findings – Min Flow Return (Clamped and Stainless Liner)
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Damage Photo Findings – Shell Damage
0.100 INCH WALL LOSSES FOUND
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Damage Photo Findings – Tank Fill Nozzle
DAMAGE TO HEAT AFFECTED ZONE
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Damage Photo Findings – Pump Suction
0.110 INCH WALL LOSSES FOUND
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Data Mining Results
Contacted Sulfuric Acid Vendor for RecommendationsRecommended NACE Standards– SP0294-2006(formerly RP0294-94) – Design,
Fabrication, and Inspection for Sulfuric at Ambient Temperatures
– RP0391-2001 – Materials for Sulfuric Acid
Received copies of suppliers specifications for different concentrations – corresponded to NACE recommendations
Contacted internal technical engineers
Recommended rule of reduced velocity <2 ft/sec Carbon
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Tank Changes Made During Outage
Initiated Management of Change to change return and suction nozzles to conform to RP0294
Pump suction to change from 4" A-53-B to 4" SCH80 A20 SB464 Min flow recirculation line change from 2" sch 80 A-53-B to 2" sch 80 A20 SB464Modify recirculation line to direct flow to below tank liquid level using extension into tank at recirculation Add wear plate at pump suction and returnAdd positioning stabilizer to return line
Repairs as noted per API 653(API 650)Weld repairs to tank sumpWeld repairs to nozzle heat affected zones
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Schematic of Recommended Design
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Schematic of Nozzle Liners
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Schematic of Suction Return Design
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Schematic of Top Return Design
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Field Modifications – Tank Return
RETURN LINE TOP PENETRATION INSERT
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Field Modifications – Tank Suction Return
SUCTION RETURN MODIFICATION
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Conclusion
Recommendations:
Check for applicable NACE standards
Check velocities of streams for materials
Monitor storage vessels with accelerated corrosion risk
Reference applicable standards
Contact material suppliers for recommendations
BASF FINA Petrochemicals Limited PartnershipBASF FINA Petrochemicals Limited Partnership
Questions
Thank you for your time!