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Assessing the corrosion degradation of aboveground tank bottom plates is a critical challenge for the industry. Internal inspections are a useful way of assessing the integrity of assets but might severely impact normal plant operation. In 2006, Chang et al. conducted a study on storage tank accidents and concluded that 74% of reported accidents occurred in petrochemical refineries, and 85% of them had caused fire and explosions.
Aboveground storage tanks require regular inspections of possible corrosion attacks on the tank bottom which typically calls for internal access leading to downtime and increased operational cost. A failure probability-based inspection approach utilizing non-intrusive technologies is the ultimate goal for operating above ground storage tanks in the most cost-beneficial way.This article describes a novel approach that combines ElectroMagnetic Acoustic Transducer (EMAT) technology with Finite Element Method (FEM) modeling for the detection and prediction of corrosion growth and the remaining structural strength of the tank while remaining in service.The tank bottom is scanned from the outside by EMAT technology. The resulting B-scan with identification of the corrosion attack locations is post-processed and mapped on a virtual twin model of the tank. The corrosion conditions at the bottom tank plate are determined based on polarization measurements in a drain water sample taken from the tank and inserted into the model. A 3D FEM model with intelligent high-resolution meshing around the defect areas allows calculating the current distribution and thus estimating the corrosion rate at the defect locations. This model with high-resolution meshing is then also further used for calculating the mechanical stress on the tank bottom while accounting for the wall thickness loss at the defect locations.Periodic inspections, combined with virtual twin model simulations, allow for monitoring the structural health of assets and optimizing a failure probability-based inspection strategy.
In industrial plants such as oil & gas and chemical plants, the plant piping is covered with insulative materials such as mineral wools and metal cladding for thermal insulation. The piping under insulation is subject to more severe corrosive environment than that exposed to the outdoor, due to rainwater entering through the cladding joints and condensation caused by temperature fluctuation. In addition, since the piping is covered with the insulation materials, it is impossible to identify the corrosion from the outside, increasing the risk of leakage accidents due to delays in corrosion mitigations.
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Mineral wool has been widely used for several decades as the primary thermal insulation on piping and equipment to save energy, protect personnel, and reduce emissions. The products have been favored because they are non-combustible, cost effective, provide excellent (and reliable) thermal performance and are safe, easy, and efficient to install.
Corrosion is not just a sustainment concern that impacts the availability and safety of critical structural assets; it is also a damage mechanism that should be considered during the initial design phase. By considering the corrosion process and associated preventive strategies during the design phase it is possible to reduce total ownership cost and improve equipment readiness. The Department of Defense spends more than $23 billion each year to control corrosion on aircraft and other equipment in its operations around the world.