DISMANTLING OF ABOVEGROUND LNG STORAGE TANKS AND THEIR AGING RESEARCH Hiroshi Nishigami Maki Yamashita Shunsuke Ohnishi Nobuhiro Wadama Osaka Gas Co., Ltd Hiroto Yamaoka Tatsuo Tsuji, Yu Murakami IHI Corporation Takehiro Inoue Naoki Saito Motohiro Okushima Nippon Steel & Sumitomo Metal Co., Ltd KEYWORDS: aboveground LNG storage tank, aging research, dismantling method] ABSTRACT In 2011, Osaka Gas commenced the dismantlement of two aboveground LNG storage tanks with a storage capacity of 45,000 m3 each at the Senboku 1 terminal. The said LNG storage tanks had been in commercial operation for approximately 40 years, and were the first to be dismantled in Japan. Concurrent with the dismantlement of the said LNG storage tanks, Osaka Gas also began the research on the deterioration due to their aging. Aging evaluation of the said LNG storage tanks will contribute to the LNG industry by not only potentially increasing its lifetime, but by improving its functions and safety as well. In this paper, the method of dismantling and the research results with regard to the aging for the two types of LNG storage tanks, respectively made of 9% Nickel steel and Aluminum alloy are reported. The contents of the research will be of the following criteria: (1) Mechanical properties of 9%Ni steel and Aluminum alloy (2) Thickness of steel pipe piles (3) Deterioration of instrument devices (4) Deterioration of insulation materials. After dismantling of the said LNG storage tanks, Osaka Gas decided to construct a large scale LNG storage tank applying newly developed 7% Ni-TMCP steel for its inner tank. The storage capacity of the new LNG storage tank will be 230,000m3, and is scheduled to be completed by November, 2015. The present state of the construction of the innovative LNG storage tank will be reported in this paper as well. 1. INTRODUCTION In 1972, IHI Corporation (IHI) built three LNG storage tanks with capacities of 45,000m3 in Osaka Gas Co., Ltd (Osaka Gas) Senboku I Terminal. Since then, the tanks, which were of the single containment type with double steel walls, had been successfully operated without any trouble for 40 years. However, the conventional LNG storage tanks were getting more inefficient in the use of receiving terminal because of its lower dike in comparison with the state-of-the-art full-containment LNG storage tanks. (Figure1)
1
Figure 1. One of the demolished LNG storage tanks
To keep up with the increasing demand for LNG and for effective practical use, Osaka Gas started to demolish the two conventional LNG storage tanks in 2011, and now a large LNG storage tank of 230,000m3 has been under construction since September 2012. Demolition of old LNG storage tanks was executed with paying sufficient attention to the safety in consideration of the influences on the other facilities in operation and neighboring companies. Then, Osaka Gas investigated the demolished LNG inner tank’s material and its thermal insulation material jointly with IHI as the constructor and Nippon Steel & Sumitomo Metal Co., LTD (NSSMC) as the supplier of tank’s steel products. Moreover, we examined the steel pipe piles and the instrumentation devices from Osaka Gas’s own point of view. This paper describes the study on dismantling method of LNG storage tanks, the results of the investigations, and also reports on the new material used for the LNG storage tank under construction. Investigation items: 1)
Base metal mechanical properties (chemical composition / macro-micro structure / tensile strength / Charpy absorbed energy / retained austenite)
2)
Weld metal mechanical properties (chemical composition / macro-micro structure / tensile strength / Charpy absorbed energy)
3)
Fracture toughness properties (CTOD test / duplex ESSO test / wide plate test)
4)
Corrosion of foundation piles (steel pipe piles)
5)
Deterioration of concrete
6)
Deterioration of instrumentation devices
7)
Deterioration of thermal insulation material
2. DISMANTLING METHOD OF THE LNG STORAGE TANKS 2.1 Specification of the tanks Table 2.1 and Figure 2.1 show the specifications of the two demolished tanks.
2
Table 2.1 Specification of the tanks 1
Internal liquid
2
Capacity
3
Type
4
LNG 45,000KL single containment type with double steel walls
Dimensions
inner tank
outer tank
Diameter
44,600mm
46,400mm
Height
28,820mm
31,850mm
Roof radius
35,700mm
36,600mm
-162℃
ambient temp.
0.12kg/cm2
50mmH2O
9%Ni steel(Al alloy)
carbon steel
5
Design temp.
6
Design pressure
7
Main material
8
Insulation
9
Thickness of insulation
10
Foundation slab
perlite & perlite concrete tank shell & roof; 900mm tank bottom ;1,100mm reinforced concrete diameter :44,600mm
thickness ;800mm
reinforced concrete 11
Dike
height :4,000mm(3,000mm from the ground) thickness ; 1,400mm
12
Earthquake history
13
Commercial operation
ground surface acceleration; 178gal Feb.1972. Note; (
) shows Al alloy tank
Figure 2.1 Configuration of the demolished LNG storage tank 3
2.2 Dismantling procedure The LNG tanks were demolished through the following procedure in Figure 2.2. 1. Setting of entering road into the dike
5. Removal of the inner tank roof
2. Perlite extraction from the annular space
6. Removal of the outer tank shell plate
3. Removal of the pipe, pipe frame etc.
7. Removal of the inner tank shell plate
4. Removal of the outer tank roof
8. Removal of the outer tank bottom plate & bottom insulation
Step 2 Perlite extraction from the annular space
Step 4 Removal of the outer tank roof
Step 6 Removal of the outer tank shell plate
Step 7 Removal of the inner tank shell plate
Figure 2.2. Dismantling procedure (1) Since the tank structure changes at every step during the tank dismantling, the dismantling steps should be observed by FEM analysis, ABAQUS. Figure2.3 shows some examples of the results by the analysis. (2) The tanks were dismantled by 150 tons cranes. (3) Perlite was removed by a new extraction machine. (4) Some samples for the study were taken before the tank dismantling. 4
Figure 2.3. The examples of the strain diagram 3. INSPECTION AND TEST RESULTS 3.1 Visual inspection 3.1.1 Inner tank K11 tank (9% Ni steel) and K31 tank (AL alloy) were found to be in good condition. No damages and buckling were detected due to the Hanshin Awaji Great Earthquake in 1995. There was no influence on the soundness of the tank. There was no damage to the instrumentation devices (level gauge, thermometer) installed in the tanks. 3.1.2 Outer tank (a) Manhole for perlite filling Some corrosion was found at the blind flange of perlite manhole. The doubling plate and the root of the manhole were also corroded. (b) Outer tank roof plate and shell plate Some corrosion was seen at the welding seam. It is estimated that the repair painting had not been done enough. (c) Roof walkway Corrosion was seen just right under the protecting seal due to the deterioration of it. In addition, corrosion was found at checker plate of walkway. (d) Anchor bolt Some anchor bolts especially under the pipe rack were corroded. After removing a weather seal, the surface of several bolts were corroded and decreased its thickness. (e) Inner tank anchor strap As a result of the investigation, the conspicuous deterioration, damage, deformation and corrosion were not seen. The reason of these phenomena was that the annular space had been filled with nitrogen since the time of the construction.
5
3.2.1 Base Metal of Inner Tank Table 3.1 shows sampling parts and investigation items of each tank. Details are given as follows. Table 3.1. Sampling Parts and Tests (Base Metal) Tank
Sampling Part
Chemical Component Analysis
Tensile Test
Charpy Impact Test
CTOD Test
Duplex Esso Test
K31 (A5083)
1st Course 13th Course Annular Plate Bottom Plate
○ ○ ○ -
○ ○ ○
-
-
-
K11 (9%Ni-Steel)
1st Course 13th Course Annular Plate Bottom Plate
○ ○ ○ -
○ ○ ○
○ ○ -
○ -
○ -
(a) Chemical Compositions of Base Metal Chemical analyses were carried out on representative samples taken from the 1st and 13th shell courses and annular bottom plate of each tank. Table 3.2 shows the results of K31 tank (made by aluminum alloy), and Table 3.3 shows that of K11 tank (made by 9%Ni steel). Table 3.2. Chemical Composition (A5083 Base Metal) Sampling Part Shell Plate 1st Course Shell Plate 13th Course Annular Plate Spec JIS H 4000
Si
Fe
Cu
Mn
Mg
Zn
Cr
Ti
B
0.08
0.10
0.01
0.67
4.51
<0.01
0.10
0.01
<0.005
0.08
0.12
0.01
0.65
4.39
<0.01
0.10
0.01
<0.005
0.11
0.13
0.01
<0.005
≦0.1
0.10 0.05 ~0.25
0.01
≦0.4
4.44 4.0 ~4.9
<0.01
≦0.4
0.67 0.3 ~1.0
≦0.15
-
≦0.25
Table 3.3. Chemical Composition (9%Ni-Steel Base Metal) Sampling Part Shell Plate 1st Course Shell Plate 13th Course Annular Plate Inspection Certificate
C
Si
Mn
P
S
Ni
0.09
0.30
0.59
0.006
0.005
8.76
0.08
0.28
0.59
0.004
0.002
8.80
0.09
0.28
0.62
0.0054
0.004
8.67
0.09
0.26
0.55
0.009
0.008
8.80
[K31 Tank (made by A5083)] These results conform to the specs of JIS (Japanese Industrial Standards) H 4000. And it is apparent that the base metal doesn’t across the ages by immersing LNG for a long time. Concentration of Mg, which influences the strength of A5083, was different among each sampling part, but there is no problem for soundness of tank. [K11 Tank (made by 9%Ni Steel)] The same as K31 tank, these results conform to the specs of JIS G 3127.
6
(b) Tensile Properties Tensile tests were carried out by using specimens: a full thickness specimen in accordance with JIS Z 2201 No.1A. The tests were performed in both the L and C rolling directions at room temperature in accordance with JIS Z 2241. Table 3.4 shows the results of K31 tank, and Table3.5 shows that of K11 tank. Table 3.4. Results of Tensile Test (A5083-O Base Metal) Sampling Part Shell Plate 1st Course Shell Plate 13th Course Bottom Plate Requirement
1)
Rolling Direction L C L C L C -
0.2% Proof Stress [MPa] 136 139 153 139 160 139 125 (0.8
Tensile Stress [MPa] 297 303 304 302 299 303
Elongation [%] 23 24 20 21 18 22
275 (0.8
-
Table 3.5. Results of Tensile Test (9%Ni-Steel Base Metal) Sampling Part Shell Plate 1st Course Shell Plate 13th Course Bottom Plate Inspection Certification 1) Requirement
Rolling Direction L C L C L C
0.2% Proof Stress [MPa] 708 706 722 719 723 714
Tensile Stress [MPa] 761 762 767 767 776 769
Elongation [%] 36 36 29 27 28 28
-
723
779
35
-
590
690
-
[K31 Tank (made by A5083)] These results on 0.2% proof stress and tensile strength at room temperature satisfy the requirements1), and shows enough elongation, too. It seems that soundness of tank was kept. [K11 Tank (made by 9%Ni Steel)] The same as K31 tank, all results satisfy the requirements1). And as compared with inspection certification, it is apparent that the base metal doesn’t deteriorate with age. (c) Charpy Impact Properties Charpy impact tests for the base metal of the 1st and 13th shell course of K11 tank were carried out using specimens in accordance with JIS Z 2242. The test specimens were taken from the both L and C rolling directions. The central axis of the specimen taken from 1st shell course was in the plate of 1/4 thickness under the inner-side surface, and that taken from 13th shell course was 7mm. The tests were carried out at -196 deg C in accordance with JIS Z 2242. Figure 3.1 shows the results of Charpy impact tests. These values are lower than that of current 9%Ni steel, but all plates conform to the requirements1), and as compared with inspection certification, it is apparent that the base metal doesn’t deteriorate with age, too. 7
Figure 3.1. Results of Charpy Impact Test (9%Ni-Steel Base Metal) Test Temperature:-196℃ (d) Other For the 1st shell courses of K11 tank, CTOD test and duplex Esso test were carried out and we make sure of the soundness of material used in the construction days. The details are omitted due to space limitation. 3.2.2 Weld Joint of Inner Tank Table 3.6 shows sampling parts and investigation items of each tank. Details are given as follows. Table 3.7 shows the welding procedure of each weld joint. Table 3.8 shows the pictures of macro structure of vertical weld joint of shell plate 1st course. Table 3.6. Sampling Parts and Tests (Weld Joint) Tank
Sampling Part
Weld Joint
Chemical Component Analysis
Tensile Test
Charpy Impact Test
CTOD Test
Wide Plate Test
Bending Fatigue Test
K31 (A5083)
1st Course 1st&2nd Course 13th Course Annular Plate
Vertical Horizontal Vertical Fillet
○ ○ ○ ○
○ ○ ○ -
-
-
-
○
K11 (9%Ni-Steel)
1st Course 1st&2nd Course 13th Course Annular Plate
Vertical Horizontal Vertical Fillet
○ ○ ○ ○
○ ○ ○ -
○ ○ ○ -
○ ○ -
○ -
○
8
Table 3.7. Welding Procedure of Each Weld Joint Sampling Part
Process
K31 (Aluminum) Material Groove
Process
K11 (9%Ni-Steel) Material Groove
Shell Plate 1st Course Vertical Weld Joint Large Current MIG Shell Plate 1st&2nd Course Horizontal Weld Joint JIS Z 3232 A5183-WY SMAW
Shell Plate 13th Course Vertical Weld Joint
Shell Plate 1st Course & Annular Plate Fillet Weld Joint
JIS Z 3224 ENi 6133
(AWS 5.10 ER5183)
(AWS 5.11 ENiCrFe-2)
MIG
Bottom Plate One Side Lap Weld Joint
Table 3.8. Macro Structure of Vertical Weld Joint of Shell Plate 1st Course K31 Aluminum Tank
K11 9%Ni-Steel Tank
(a) Chemical composition of weld metal Chemical analyses were carried out on representative samples taken from the different parts of weld metal. Table 3.9 shows the results of weld metal of K31 tank, and Table 3.10 shows that of K11 tank.
9
Table 3.9. Chemical Composition (K31 Aluminum Tank Weld Metal) Sampling Part Shell Plate 1st Course Vertical Weld Joint Shell Plate 1st&2nd Course Horizontal Weld Joint Shell Plate 13th Course Vertical Weld Joint Shell Plate 1st Course & Annular Plate Fillet Weld Joint Spec JIS Z 3232
Si
Fe
Cu
Mn
Mg
Zn
Cr
Ti
B
0.08
0.10
0.01
0.67
4.51
<0.01
0.10
0.01
<0.005
0.09
0.11
<0.01
0.66
4.35
<0.01
0.10
0.01
<0.005
0.08
0.12
0.01
0.65
4.39
<0.01
0.10
0.01
<0.005
0.11
0.13
0.01
0.67
4.44
<0.01
0.10
0.01
<0.005
≦0.40
≦0.40
≦0.10
0.50 ~1.0
4.3 ~5.2
0.05 ~0.25
≦0.25
≦0.15
-
Table 3.10. Chemical Composition (K11 9%Ni-Steel Tank Weld Metal) Sampling Part Shell Plate 1st Course Vertical Welded Joint Shell Plate 1st&2nd Course Horizontal Welded Joint Shell Plate 13th Course Vertical Welded Joint Shell Plate 1st Course & Annular Plate Fillet Weld Joint Inspection Certification of Electrode
C
Si
Mn
P
S
Cu
Ni
Cr
Mo
Nb
Al
Fe
0.06
0.26
1.79
0.010
0.0032
0.05
63.9
13.6
0.69
2.18
0.098
Bal.
0.08
0.26
1.89
0.009
0.0028
0.10
67.0
15.7
0.73
2.17
0.105
Bal.
0.07
0.22
1.77
0.009
0.0028
0.05
62.5
12.2
0.65
1.90
0.102
Bal.
0.08
0.28
1.90
0.010
0.0023
0.00
66.7
15.0
0.73
2.20
0.091
Bal.
0.05
0.29
1.92
0.008
0.010
-
68.3
15.5
0.73
2.29 (+ Ta)
-
10.8
[K31] As the base metal, these results conform to the specs of JIS Z 3232 (AWS 5.10 ER 5183). It is apparent that the weld metal doesn’t across the ages. [K11] The same as K11 tank, these results conform to the specs of JIS Z 3224 (AWS 5.11 ENiCrFe-2). (b) Tensile properties Tensile tests were carried out using specimens: a full thickness specimen taken from different parts of the welded joints in accordance with JIS Z 3121 No.1A, but the excess weld metal was not ground. Each tensile test was performed at room temperature in accordance with JIS Z 2241. Table 3.11 shows the results of K31 tank, and Table3.12 shows that of K11 tank. Table 3.11. Results of Tensile Test (K31 Aluminum Tank Weld Metal) Sampling Part
Tensile Stress [MPa]
Shell Plate 1st Course Vertical Welded Joint
297
Shell Plate 1st&2nd Course Horizontal Weld Joint
303
Fusion Line ~HAZ
Shell Plate 13th Course Vertical Welded Joint
298
Base Metal
275
-
Requirement
1)
10
Fracture Location Fusion Line ~HAZ
Table 3.12. Results of Tensile Test (K11 9%Ni-Steel Tank Weld Metal)
Tensile Stress [MPa]
Fracture Location
Construction Management Test Tensile Stress [MPa]
Shell Plate 1st Course Vertical Welded Joint
756
Weld Metal
761
Shell Plate 1st&2nd Course Horizontal Weld Joint
756
Base Metal
767
Shell Plate 13th Course Vertical Welded Joint
781
Base Metal
788
655 (at 20 deg C)
-
-
Test after Dismantling Sampling Part
Requirement
1)
[K31] These results on tensile strength at room temperature satisfy the requirements1), and fracture locations are not particular. It is apparent that soundness of tank was kept. [K11] The same as K31 tank, all results satisfy the requirements1), it is apparent that soundness of tank was kept. (c) Charpy Impact Properties Charpy impact tests were carried out on weld joints of K11 tank, machining the notch at center of weld metal, fusion line (FL: 50% weld metal + 50% heat affected zone), FL+1mm, FL+3mm, FL+5mm, using specimens in accordance with JIS Z 2202 and 3128. Notch is 2mm depth, V shape. The central axis of the specimen was the same as base metal. The tests were carried out at -196 deg C in accordance with JIS Z 2242. Figure 3.2 shows the results of Charpy impact tests. All plates conform to the requirements1). Those results have indicated that the weld joints don’t deteriorate with age.
Figure 3.2. Results of Charpy Impact Test (K11 9%Ni-Steel Tank Welded Joint)
11
(d) Other For the vertical weld joint of 1st shell courses of K11 tank, CTOD test and wide plate test were carried out and we make sure of the soundness of welded joints. The details are omitted due to space limitation. 3.3 Corrosion survey on corrosion of foundation piles 3.3.1 Purpose and method Corrosion countermeasure for foundation piles is important for maintenance of LNG tank substructure. Osaka Gas adopts a corrosion allowance by adding 2mm margin to the specification of foundation piles in construction design as a corrosion countermeasure. Meanwhile, heads of piles are bonded in advance during construction so that a cathodic protection can be applied in preparation for significant corrosion progression in service. Moreover, the installation method of electrodes using a horizontal boring technique for cathodic protection has been developed, and the corrosion condition has been monitored in order to judge the necessity of cathodic protection. The corrosion condition has been judged according to the thickness measurement which is executed by remote field testing and actual pile investigation by excavating the upper portion of piles. Based on the evaluation in this way indicated that there was no necessity of corrosion countermeasure for the next 50 years at least. Because actual measurement data is still not enough, we conducted a survey on actual piles that pulled out on this occasion of tank demolition in order to make up for scant data of actual corrosion condition. Figure 3.3 shows the section view of the LNG tank. There were 496 foundation piles in total that driven with steel pipe piles; length 25m, outer diameter 406.4mm, thickness of upper pile 12.7mm and lower pile 9.5mm. As shown in Figure 3.4, the survey was conducted with 31 piles among all foundation ones of LNG storage tank. The thickness of pile was measured down to 6m below pile head, where the lateral bearing force is susceptible due to corrosion. In addition, 5 piles among them were measured over the entire length of pile. The measurement of thickness was carried out after removing extraneous matters such as corrosion products and residual material. Then the averages of pile thickness were calculated from measured thickness and weight for each 1m. Also note that the cathodic protection of impressed current method had been applied to the removed tank from one year after start-up.
12
Steel pipe pile Length: 25.0m Outer diameter: 406.4mm Diameter of base slab: 48.0m
Thickness: (Upper part) 12.7mm (Lower part) 9.5mm Number: 496
Figure 3.3. Specification of tank foundation
(Measurement range) From pile head to 6m below Whole length
Figure 3.4. Framing plan of piles and the measured piles in corrosion survey 3.3.2 Result Observing the appearance of piles, corrosion is found on the outside surface evenly, where local corrosion of particular part is not found, nor rust inside of the steel pipe. Therefore, the corrosion content is estimated from the outer wall of a pile by reducing the measured value from the initial thickness of a pile. Figure3.5 shows the corrosion content according to the depth. The corrosion content is about 0.6mm at a maximum, so it is kept within 2.0mm margin. Also, no specific difference is found in the corrosion conditions between each depth. The averaged corrosion rate is obtained as 0.014mm/year at a maximum. It also stays within the confines of normal corrosion rate that reported various research literatures. The evaluation criterion is estimated at up to 0.073mm/year before this corrosion survey; the total corrosion rating was calculated from adding 0.042mm/year as macro-cell corrosion rate of steel in concrete to 0.031mm/year as maximum natural corrosion rate. However, the corrosion rate obtained from this survey resulted in far below the conventional value we estimated. 13
The effective range of cathodic protection related to the arrangement of foundation piles could not be ascertained because there was no specific difference found between the outer and the center piles due to the too small corrosion content.
Depth(m)
Corrosion allowance Corrosion content (mm) Figure 3.5. Corrosion content 3.4 Deterioration survey for concrete 3.4.1 Purpose and scope Diagnostic evaluation for concrete structure used for 40 years was undertaken based on chloride ion content, carbonation depth and compressive strength of concrete used for the base slab and dike of LNG storage tank. Measure points are selected at the marked point in Figure 3.6; 5 points on underside of base slab, 4 points on side surface of base slab, each 4points on outer and inner side of dike. ▲ Underside of base slab ▲ Side surface of base slab
▲ Outer and inner side of dike
*Only from K031LNG tank on east side.
Figure 3.6. Measure points for concrete deterioration survey 14
3.4.2 Result (a) Chloride ion content Chloride ion content as measured at each 20cm depth for 7 measuring points at t underside of base slab and for 5 measuring points at each side surface of foundation slab and dike. Figure 3.7 shows the chloride ion content. The covering depth of base slab and dike is 85~105mm, and the chloride ion content at the reinforcing steels was lower than 2.5kg/m3 that specified as criteria of corrosion durability. Also, it shows that almost no chloride ion content made inroad into the underside of base slab.
― ― ―
Underside of base slab Side surface of base slab Dike
Criteria of corrosion durability Chloride ion content (kg/m3)
Depth from concrete surface (cm) Figure 3.7. Chloride ion content (b) Carbonation depth Figure 3.8 shows the measurement result of carbonation depth. Almost no carbonation progress is found at base slab. Even the carbonation found at side surface of base slab and dike wall are 25mm at a maximum, it shows that the carbonation depth does not reach to the reinforcing steels.
Minimum covering depth
Carbonation depth (mm)
Underside of base slab
Side surface of base slab
Figure 3.8. Carbonation depth 15
Dike
(c) Compressive strength Figure 3.9 shows the measurement result of compressive strength. The survey of compressive strength shows that all the specimens satisfy the design compressive strength of 24.0N/mm2.
Design compressive strength
Compressive strength (N/mm2)
Underside of base slab
Side surface of base slab
Dike
Figure 3.9. Compressive strength 3.5 Deterioration of Instrumentation Devices The following are the report of deterioration investigation of instrumentation devices. The devices below are selected as objectives for investigation among the instrumentation devices mounted on the tank.
Thermometer for Roll-over detection
Guide wire for Float Type Level Meter
These devices have not renewed since the construction of the tanks, and they have been in service without any failure. However, major renovation work including hot-up and opening of LNG tank would be necessary if these devices had failure and needed to be repaired. Also, operation of the entire LNG terminal might be interrupted. Therefore, it is important to investigate the deterioration of these devices for better approach to future construction and maintenance of LNG tanks. 3.5.1 Thermometer for Roll-over (a) Outline of Thermometer for Roll-over Here is the detail of Thermometer for Roll-over. This thermometer has a very important role in monitoring LNG stratification that is considered as a warning symptom of roll-over phenomenon. As shown in Figure 3.10, 15 thermometers are arranged at intervals of 2m from the top of LNG tank. According to the indicated values of the thermometers, supervised computer system (hereafter SCS) judges the occurrence of LNG stratification. When SCS detects stratification, it sends an alert signal to the center control room (hereafter CCR) and requires the operator to take measures, such as sending out, transfer or circulation.
16
Figure 3.10. Arranged thermometers
(b) Objective for Investigation 30 thermometers for roll-over taken from the two removed LNG tanks are used for investigation. The specifications of the thermometer are described below: Model
: Metal-sheathed resistance thermometer sensor
Sheath material
: SUS316
Sheath outer diameter
: φ4.8mm
Sheath length
: 13m~41m (at intervals of 2m)
Classification
: 0.5
Detection element
: Platinum resistor (Standard resistance value : Pt100Ω at 0℃ (JPt100Ω))
Conductor
: 3-wire type
(c) Investigation Contents / Method It has already reported that there are some thermometers indicating the signs of insulation degradation before the LNG tanks removal. If the insulation degradation occurred, the ability of measuring temperature deteriorated. Furthermore, if the insulation completely damaged, temperature measurement became impossible subsequently. Prior to the investigation, we implemented insulation resistance test (applied voltage: 100CV) for all thermometers just before removing them to identify the thermometers having the insulation degradation. Then we cut off the sheath off from the head of the thermometer having insulation degradation and implemented insulation resistance test (Figure 3.11) again to investigate the region where insulation degradation occurred.
Figure 3.11. Insulation resistance test
(d) Result of Investigation Table 3.13 shows the result of the insulation resistance test. There were 5 thermometers that had lower insulation resistance value than 20MΩ at the time of measurement before removing. However these thermometers had more than 20MΩ of insulation resistance in the second test after cutting the sheath for 1m off from the head. Therefore, it can be said that insulation degradation of the thermometers occurred within 1m from the head. 17
Table 3.13. The result of insulation resistance test and region of insulation degradation Insulation resistance
Thermometer No.
No.1 LNG tank
No.3LNG tank
[MΩ]
Region of insulation degradation [m] (distance from the head)
1
1
1
3
6
1
5
2
1
12
11
1
1
0.1
1
(e) Conclusion The insulation degradation was found on 5 thermometers among all 30 objective thermometers. However, they did not have severe degradation to the extent of influencing the measuring ability of thermometers. The degradation occurred within 1m from the thermometer’s head according to the investigation of region. It is assumed that the cause of insulation degradation was the influent water from the terminal area covered with epoxide resin. The epoxide resin used for insulating the terminal area had deteriorated. The insulation degradation was solved by cutting off the deteriorated region in upper 1m. We conclude that the thermometer should be installed with extra length to deal with insulation degradation. 3.5.2 Guide wire for Float type level meter (a) Outline of Float type level meter Here is the detail of Float type level meter. Figure 3.12 shows the float type level meter removed from the tank on this occasion. It is used to measure the liquid level according to the length of the tape that goes up and down depending on the float on the liquid surface. The float moves along the guide wires. Therefore, friction arises between the float and the guide wires every time when the float moves. In this investigation, the deterioration condition of guide wires were inspected for taking into account the risk of broken guide wires.
Figure 3.12. Float type level meter (b) Objective for investigation There were 2 floating type level meter mounted on each removed LNG tank. One of the guide wires on each LNG tank was selected as objectives. Specification of the guide wire is described below. 18
Applied standard
: JIS G 3550
Material
: SUS304
Product name
: Independent strand core rope
Constructive number
: 7×19
Length
: approx. 37.5m
Diameter of wire
: 10mm
Diameter of strand
: 0.67mm
(c) Investigation Contents / Method We supposed that the worn volumes were different depending on the positions of a guide wire in consideration of normal liquid level; too high and too low level were less frequent. Therefore, the samples for investigation were picked up for each 1000mm from three positions, upper, middle and lower part. Table 3.14 shows the details of samples. Then we made a comparison of deterioration degree of these guide wires. Table 3.14. Details of samples Distance from the bottom of
Total times of
tank [m]
round-trip [time]*
Sample 1 (upper)
33
0
Sample 2 (middle)
17
1,000
Sample 3 (lower)
6
200
* Total times of round-trip after the installation are estimated from liquid level change for a year in 2010. 1) Observation of appearance / gauging of diameter We inspected the worn volume of sampled wires and their strands by visual and a digital microscope. Also, we gauged the diameters of each sample to compare the values to the standard criterion of JIS and among the samples obtained from each position. 2) Tensile test We implemented tensile test of sample wires if these wires satisfy the breaking force specified in JIS G 3550; for tensile test, both edges of wires were bonded by white metal. We picked up 1 strand of each 6 strand excluding the core as objectives for tensile test of wire, and implemented tensile test if these wires satisfied the breaking force specified in JIS G 4314 under the condition; length of specimen between grips 100mm, tension rate 50mm/min. (d) Result of inspection 1) Observation of appearance / gauging of diameter Figure 3.13 shows the pictures of wire’s appearance and their diameters. There was no thinner wire than 10mm (the criterion specified in JIS G 3550) and no difference was found among each position. Red rust was found on some wires however it could be wiped off easily (it is supposed that this red rust adhered at the removing work). Figure 3.14 shows the pictures of strand’s appearance and their diameters observed by a digital microscope. There were small wears found at the parts marked with red arrows. However these wears were not serious and the wires had enough diameters over the 0.67mm of regulation size. It can be said that there was no wear on the wires. 19
Figure 3.13. Wire’s diameters
Figure 3.14. Strand’s diameters
2) Tensile test Table 3.15 shows the result of tensile test for wires. All wires at each position satisfy the level of standard breaking force 61.8kN for 10mm wire. Also, no difference was found among each position. Therefore, it can be said that there was no deterioration of wires. Table 3.16 shows the result of tensile test for strands. Some strands of No.3 LNG tank exceeded over the maximum level of standard breaking force 1850~2100MPa for 0.67mm wire. However, no strands exceeded the minimum level and no difference was found among each position. Therefore, it can be said that there was no deterioration of strands. Table 3.15. The result of tensile test for wires Breaking force of wire [kN]
Standard breaking force of wire [kN] Upper 61.8
Middle Lower
No.1 LNG tank
No.3 LNG tank
64.0
68.2
64.8
71.4
66.8
72.2
Table 3.16. The result of tensile test for strands Breaking force of strand [MPa] No.1 LNG tank
No.3 LNG tank
Upper
Middle
Lower
Upper
Middle
Lower
1
2037
2036
2009
2102
2179
2169
2
2030
1996
2044
2089
2185
2094
3
2100
1962
2052
2089
2127
2149
4
1996
2000
2016
2169
2146
2163
5
2038
1978
2036
2137
2194
2135
6
2056
1989
1990
2143
2165
2114
Average
2043
1994
2025
2121
2166
2137
Standard breaking force of strand [MPa]
1850~2100
(e) Conclusion We investigated the deterioration condition of guide wires for Float type level meter that had been installed in two LNG tanks. The guide wires have no specific wear and satisfy the standard specifications for both diameter and breaking force. We conclude that the guide wires for Float type level meter have enough properties that allow continuous use for 40 years. 20
3.6 Thermal insulation material The following thermal insulation materials (i.e. perlite, Mesalite (Mitsui Expanded Shell Light-Weight Aggregate) concrete, perlite concrete block and cylindrical perlite concrete) were investigated (Figure.3.15).
Figure 3.15. Structural drawing of thermal insulation 3.6.1 Perlite Perlite was sampled from the top, the middle, and the bottom of annular space, and also from inside of the cylindrical concrete. (a) Thermal conductivity Thermal conductivities were measured under the temperature condition of 3 steps(-20~30℃, 5~35℃, 20~50 ℃). We calculated these values by using the regression equation and obtained the thermal conductivities at the zero Celsius degree. Thermal conductivities of each sample of perlite satisfy the specifications at the time of the construction. Table 3.17. Thermal conductivity of perlite Sample Location
Thermal conductivity(T.C.) （W/mK)(at 0℃）
Ratio
*1
Top of annular space
0.0433
0.98
Middle of annular space
0.0429
0.97
Bottom of annular space
0.0391
0.88
In cylindrical perlite concrete
0.0399
0.90
specification
0.0442
1.00
note;*1:The ratio of the measured values to the specification value
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3.6.2 Mesalite concrete (a) Compressive strength The test was carried out in accordance with JIS A1108 (this standard follows ISO 1920-4). The test results are shown in Table 3.18. Compressive strength of the samples satisfies the specification value at the time of the construction. The specific gravity was almost the same as the value at the time of the construction. Table 3.18. Compressive strength of Mesalite concrete 2
2
*1
specification (N/cm )
Test result (N/cm )
Ratio
1470
1955
1.33
note;*1: The ratio of the measured values to the specification value (b) Thermal conductivity The test was carried out in accordance with ISO 8301(Heat Flow meter apparatus Method). Thermal conductivity was calculated at zero Celsius degree by the equation regression as same as perlite. The test result value shown in Table 3.19 was less for approximately 67% than the construction specification and was a good value. Table 3.19. Thermal conductivity of Mesalite concrete *1
Specification (W/mK)
Test result (W/mK)
Ratio
0.93
0.309
0.33
note;*1: The ratio of the measured values to the specification value The properties of Mesalite concrete have not been changed since the days of construction. 3.6.3 Perlite concrete (a) Thermal conductivity The test was carried out in accordance with ISO 8301(Heat Flow meter apparatus Method).The test result value shown in Table3.20 was less for approximately 14% than construction specification and was a good value. Table 3.20. Thermal conductivity of perlite concrete *1
Specification (W/mK)
Test result (W/mK)
Ratio
0.1163
0.10028
0.86
note;*1: The ratio of the measured values to the specification value 3.6.4 Cylindrical perlite concrete (a) Thermal conductivity The test was carried out in accordance with ISO 8301(Heat Flow meter apparatus Method). The test result value shown in Table 3.21 was less for approximately 7% than construction specification and was a good value.
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Table 3.21. Thermal conductivity of Cylindrical perlite concrete Specification (W/mK)
Test result (W/mK)
Ratio*1
0.1163
0.10782
0.93
note;*1: The ratio of the measured values to the specification value 4. PRESENT SITUATION OF THE TANKS UNDER CONSTRUCTION The inner tank material for above ground LNG storage tanks has mostly been made of 9% Ni steel plate over the 50 years as it has excellent mechanical properties under -160deg.C. During this period, the LNG storage tanks made of 9%Ni steel plate have safety operated. It is known that 9%Ni steel has excellent cryogenic fracture toughness due to the retained austenite and refinement microstructure obtained by nickel content and heat treatment process. NSSMC, Toyo Kanetsu K.K (TKK) and Osaka Gas jointly developed 7%Ni-TMCP steel having the comparable performance to 9%Ni steel. Newly developed 7%Ni-TMCP is achieved 2% reduction of nickel content from the conventional 9%Ni steel by adopting Thermo Mechanical Control Process (TMCP). Various basic performance tests and fracture toughness tests in development process showed that the base metal and welded joints satisfy the regulatory and technical requirements for LNG storage tanks. In 2010, Japanese Ministry of Economy, Trade and Industry (METI) approved the use of 7%Ni-TMCP steel for newly-built tank of Osaka Gas. The development of 7%Ni-TMCP steel realizes the reduction of rare metal nickel to be used. Therefore, not only the cost of inner tank’s material but also the cost of nickel in rising market can be saved. From September 2012, Osaka Gas started the construction of 230,000m3 full-containment tank in Senboku I Terminal. Installation of steel pipe piles had been done at the time of October 2012 and the base slab is now under construction (Figure4). The construction of the tank will be completed by November 2015.
Figure 4. The picture of present situation at construction area
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5. CONCLUSION Osaka Gas demolished the two LNG storage tanks that had actually been used for about 40 years. On this occasion, we assured the secure dismantling method and verified that the mechanical properties (including chemical composition, tensile strength and Charpy absorbed energy) of 9%Ni steel and Al alloy used as inner tank’s material satisfied sufficient levels. Thermal insulation material, steel pipe piles and instrumentation devices have no significant deterioration. These investigations proved the high integrity of the LNG storage tanks. The results of these investigations obtained from the demolished LNG storage tanks that had been used for about 40 years provide invaluable actual data and it contributes to the progress of LNG storage tank market in the future. REFERENCE 1) Recommended Practice for LNG Aboveground Storage; Japan Gas Association 2012
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