Section 3 - MFL Tank Floor Inspection - Rev 1

MFL Tank Floor Inspection
Improving Inspection Through Technology

MFL Tank Floor Inspection
 Aim
 To be aware of the limitations and requirements in order to
conduct a successful tank floor inspection with the system.
 Learning Outcomes
 Establish the types of corrosion typically found on tank floors.
 Recognise the limitations of scanning a tank floor.
 Identify the roles within the inspection team and additional
equipment required for a successful tank floor inspection.
 Assess the cleanliness of the tank floor for an MFL inspection.
 Demonstrate the correct plate setup required for scanning,
identify the tank entry requirements and in-tank preparation.
 Discover how to locate the MFL results for further prove up.
 Utilize a correct sequence of work for inspecting a tank floor.
2
Tank Floor Corrosion
 Corrosion attacks all areas of a storage tank however we
are interested in the tank floor corrosion.
 Bottom Surface – soil side.
 Top Surface – product side.
 Coating on tank floor can break down and fail.
Floor coating Product Side
Tank Floor
Soil Side
3
Tank Floor Corrosion
 Corrosion comes in many different shapes and sizes.
 Typically grouped into three categories based on shape.
 Their plan view tends to be circular / elliptical in outline
 As corrosion sites grow these basic shapes tend to merge
into more complex profiles.
CONICAL PIT LAKE TYPE PIPE TYPE
TYPE
4
Tank Floor Layout
 Tank floors typical consists of:
 Inner plates, usually rectangular in shape.
 Sketch plate, non rectangular usually at the edge.
 Annular plates, shell supporting.
 Critical zone 75mm [3inch]
inwards from the shell.
 Floor cones downward toward
the drain (sump).
 The mapping system can
inspect this floor layout
since the plates are laid in
parallel rows and have at
least one 90O corner.
5
Tank Floor Layout
 Petal design or Radial plates.
 Smaller tanks, typically aviation fuel.
 Floor cones downwards toward the drain (sump).
 The manual MFL system is required to inspect this type of
floor layout.
6
Scanning coverage
 Achieving 100% scanning coverage of the plate is not
possible due to mechanical constraints of the scanner.
Rectangular Plates
 Minimum non inspected “dead zone” areas include:
 10mm [3/8inch] around the plate edge.
 160mm x 160mm [6.3inch x 6.3inch] in each corner.
Annular Plates and Sketch Plates
 Non inspected “dead zone” area depends
upon the size and shape of the plates.
7
Tank Floor Obstructions
 Tank floor obstructions reduce the scan coverage area.
 Obstructions always exist within a tank and can include:
 Pipework and Heating coils.
 Roof support legs and strengthening plates.
 Undulating or buckled plates.
 Brackets and Support.
 Weldment and weld splatter.
 Patch repair plates.
 Sump.
8
Patch Repair Plates
 Do not attempt to scan over any patch repair plates.
 System cannot detect or size indications correctly.
 Two plates with a slight gap between.
 Magnetism flows though both plates reducing the sensitivity.
 Damage the scanner when passing over the weld.
 Treat patch repair plates as an obstruction.
9
Double floored tanks
 A minimum distance of 50mm [2inch] between the floors
must exist and the gap contain non-ferrous material.
 The inspection is for the replacement floor plates only.
 If this distance is less than 50mm [2inch]:
 Magnetic field flows through both plates.
 Corrosion pitting may not
be detected because no
flux leakage is created.
Replacement floor plates

Original floor plates
Minimum distance of 50mm
10
Inspection Team
 Team Leader (TL)
 Take overall responsibility for the inspection, including ensuring
the scanner has been correctly calibrated.
 Fully understands the operation and limitations of the scanner.
 Ensures the final inspection report is produced and indications
have been followed up (visual/handscan/ultrasonic).
 MFL Technician
 Fully understands the operation and limitations of the scanner.
 Ultrasonic Technician
 Trained and certified to a minimum of PCN, ASNT level II in the
use of A-Scan equipment and corrosion assessment.
 MFL inspection team require a minimum of two people.
11
Inspection Equipment
 Personal Protective Equipment (PPE)
 Safety footwear
 Overalls
 Hard hat
 Safety glasses
 Gloves
12
 Lighting
 Headlamps
 Flood lamps
 Marking out
 Tape measures
 Spray paints
 Marker pens
 Chalk sticks
13
 Cleaning tools for both scanner and inspection surface.
 Brushes
 Scrapers
 Industrial vacuum cleaner
14
 Complementary Inspection Equipment:
 Handscan – Inspection of areas not covered by the scanner.
 Ultrasonic flaw detector / thickness gauge.
 Coating thickness gauge (if inspecting coated floor plates).
 Pit gauge.
 Camera – Recording visual defects.
15
Tank Cleaning Requirements
 The condition of the inspection surface can affect the
quality and accuracy of MFL inspection results.
 Prior to the MFL inspection the tank product must be
drained and the tank floor cleaned so that it is free of any
product residue, scale, loose ferromagnetic material,
cleaning media and standing water from surface.
 The floor plates must be clean enough to conduct a
thorough visual inspection.
 Do not begin an MFL inspection of the tank floor if the
floor is not sufficiently clean.
 Remember you can not inspect what you can not see!
16
 Acceptable cleaning methods depend upon:
 Type of product stored in the tank.
 Duration since previous cleaning.
 Presence of any coating / lining within the tank.
 A tank floor good condition and contained light product
only a Jet wash may be required.
 A tank floor in poor condition with extensive levels of
scale or history of extensive top side corrosion will
require grit, shot or ultra high pressure water blasting.
17
 Acceptable for MFL Inspection
 The following are examples of tank floors cleaned to a sufficient
standard to allow a meaningful MFL inspection to take place
Image 1 – Floor plates cleaned to bare metal using Image 2 – Top surface corrosion visible after
Ultra High Pressure water jetting cleaning
18
standard to allow a meaningful MFL inspection to take place
Image 3 – Generally acceptable coated surface. Image 4 – Floor cleaned to acceptable standard.
Some spurious results possible from blistered areas. Corrosion at bottom of dents would not be detected
accurately.
19
standard to allow a meaningful MFL inspection to take place.
Image 5 – Floor cleaned to acceptable standard Image 6 – Floor cleaned to acceptable standard
with some very thin scale remaining. with some very thin scale remaining.
20
 Not acceptable for MFL Inspection
 The following either limit an MFL inspection to certain areas of
tank floor or prevent an MFL inspection take place
Image 7 – 60mm thick layer of product residue Image 8 – Product residue masking top surface
corrosion
21
Image 9 – Heavy Scale Image 10 – Layer of hardened scale and product

residue
22
Image 11 – Thick build up of scale Image 12 – Uneven coated surface. The marked
area cannot be inspected.
23
Plate Setup for Scanning
 How does the scanner determine which tank floor plate
it is inspecting and where on that plate is the scanner
located?
 Before inspecting a plate the following information must
be entered:
 Tank Datum.
 Plate Numbering System.
 Plate Reference.
 Plate Size.
 Plate Orientation.
 Scanning Mode.
24
 Tank Datum
 It is a reference point that exists outside of the tank.
 Referenced to Tank Datum are:
 Plate Numbering System
 Plate Reference
 Plate Orientation
 To position tank datum
1. View floor from above
2. Align plate row so they are
parallel
3. Look perpendicular to the rows
4. Tank Datum is located in the
bottom left corner of the tank
5. Mark location on the tank shell
25
 Tank Datum
 If the parallel rows are not obvious from looking from above
then rotate yourself when stood in the tank
26
 Question: Where should tank datum be located?
 Identify the parallel rows and stand perpendicular.
Here Here
?
Here Here
27
 The system scans one plate at a time so must know which plate
is being inspected.
 Reporting software relies on numbering to generate the layout.
 During the inspection the Row / Plate layout must be used.
 For reporting an alternative system can be selected.
 Numbering begins in the top left hand corner, Tank datum is
located in the bottom left hand corner.
28
1. Identify tank datum.
2. Number rows from top to bottom.
3. Number plates from left to right.
4. Combine rows and plate numbers.
ROW 1 1/1
P1 1/2
P2 1/3
P3 1/4
P4 1/5 P6 1/7
P5 1/6 P7
ROW 2 P1
2/1 P2
2/2 P3
2/3
ROW 3 P1
3/1 3/2
P2 P3
3/3 P4
3/4
ROW 4 P1
4/1 4/2
P2 P3
4/3
ROW 5 5/1
P1 P2
5/2 5/3
P3 P4
5/4
ROW 6 P1
6/1 6/2
P2 P3
6/3
ROW 7 7/1
P1 7/2
P2 7/3
P3 P4
7/4
ROW 8 8/1
P1 8/2
P2 8/3
P3
ROW 9 P1
9/1 9/2
P2 P3
9/3 P4
9/4
ROW 10 P1
10/1 P2
10/2 P3
10/3
ROW 11 P1 11/2
11/1 P2 P311/4
P4 P511/6 P7
P6 11/7
11/3 11/5
29
 What about numbering the tank floor layout below?
 Issue with numbering the following rows:
 Look closer ROW 1
ROW 2
ROW 3
ROW 4
ROW 5
ROW 6
ROW 7
ROW 8
ROW 9
ROW 10
ROW 11
30
 The plates on Row 1, Row 2 and Row 4 are simple to number, as
the plates only lie left to right.
 The plates in Row 3 cause problems due to having horizontal
and vertical plates in the same row.
 There are various numbering orders.
 Keep the numbering system
logical and the same for the ROW 1 1/1 1/2 1/3 1/4 1/5 1/6 1/7 1/8
ROW 2 2/1 2/2 2/3
whole tank.
3/3
3/1
ROW 3 3/4 3/5 3/6 3/7 3/8 3/9 3/ 3/ 3/ 3/
3/2
3/1 10 11 12 13
3/1
3/2
3/3
ROW 4 4/1 4/2 4/3 4/4
31
 The reporting software is unaware of the tank floor layout.
 It relies on the row/plate numbering system to position the
plates in the correct order, working from left to right.
 Manual adjustment of the plates is avaiable in the reporting
software using the Tank Layout Modification tool.
32
 Plate Reference
 It is a 90O corner of a plate where scanning begins.
 It is identified relative to Tank Datum (bottom left).
 Rectangular Plate:
 There are 4 possible corners for Plate Reference. Choose a suitable
corner and mark the plate.
 If possible select Bottom Left, since Plate Reference and Tank Datum
have the same orientation. However this may not always be possible
due to obstructions.
Top Left Top Right
Bottom Left Bottom Right

33
 Plate Reference
 Sketch Plate (non rectangular plates)
 Consider following plates:
 PR for 1/2
 PR for 1/7 1/2 1/7
 PR for 11/4
BL
TL TR
11/
BL BR 4
34
 Plate Size
 Every plate must be measured.
 Enter the longest length and longest width for each plate.
 Consider plates:
 4/2 Width
1/2 4/2
 11/4
 1/2 4/2 Length
 Measurements are not always the plate weld Width
 Longest side is always plate length
 Plate width cannot be greater than length Longest 11/4
Length
Longest
1/2 Width 11/
4
Length
35
 Plate Orientation
 Identified relative to tank datum.
 Determined by the longest length of a plate.
 Consider plates:
 4/2
Horizontal
 11/4
4/2
Length
Vertical
Vertical
Length
11/
4
Horizontal
36
 Scanning Mode
 Begin scanning at plate reference and scan along length of plate
 Plates can be scanned in one of two modes:
Raster Scanning Parallel Scanning
The plate must have four 90O corners. A plate with at least one 90O corner.
Most efficient way of scanning a plate. Always return to plate reference edge.
Preferred method for plates with no 4/2 Preferred method for plate with
obstructions. obstruction.
11/
4
37
 Plate setup details are entered into the plate tab in the
new plate window before inspecting a plate.
Plate
Numbering
Plate Size Plate

Reference
Orientation
Scan Type Tank Datum
38
Annular Plate Setup for Scanning
 Annular plate setup does not require Tank Datum.
 Each annular is in a different orientation to the tank datum.
 The system is provided with the following information:
 Annular Numbering System.
 Annular Plate Size.
 Annular Plate Reference.
 Scanning Mode.
 Typically annular plates are thicker than the floor plates
in a tank.
 Ensure the correct calibration is used before inspecting.
39
 In order for the system to map annular plate correctly:
 Every Annular plate must be identical in size and shape.
 Straight edge annular plates are easier for scanning.
 Parallel edge annular plates are difficult to scan because the
scanner does not travel in curves.
 Manual scanning will be required.
 Possibility to skip the first track.
Annular shape with parallel edge Annular shape with straight edge
No straight edge Straight edge
40
 Annular Numbering System
 Numbered in a clockwise direction beginning at A1.
 Location of A1 is not important as Annular plates can be
rotated. 10 A1
A
A9
A2
A8
A3
A7
A4
A6 A5
41
 Annular Plate Size
 Every annular plate must be measured.
 The following measurements are required for each annular:
 A: Annular length, inner straight edge distance
 B: Annular width, weld between two annular plates
 C: Maximum overall length
 D: Maximum overall width
42
 Annular Plate Reference
 Annular Plate Reference does not consider Tank Datum.
 The Plate Reference requires a right angle corner so by looking
at tank shell it is either:
 Bottom Left Corner.
 Bottom Right Corner.
BL BR
 Annular Scanning Mode

 Parallel Scanning only.
43
 Annular plate setup details are entered into the annular
tab within new plate window before inspecting a plate.
Plate
Numbering
Plate
Plate Size
Reference
44
Tank entry with the scanner
 What must be done before entering into a storage tank?
 Ensure the correct safety measures have been taken and permit
to work within the storage tank obtained.
 Safety measures must comply with client / site specific safety
regulations and Local legislation.
 Ensure the tank is gas free and is safe to enter.
 Establish if Scaffolding is required in order to gain access to the
man-way.
45
Tank entry with the scanner
 Minimum man-way entry for scanner is 500mm [20inch].
 The entry process required two people.
 One person inside and one person outside of the tank.
 Lift and pass the scanner though the man-way without causing
damage.
 Remove the battery and Sitemaster before entry.
46
In-tank preparation before scanning
 Erect suitable lighting to illuminate the working area.
 Assess the cleanliness of the inspection surface.
 Visually inspect each plate and mark potential hazards
such as obstruction, weldments and repair plates.
 DONOT scan across these. They can cause damage and lead to
false indications. If possible weldments should be ground down.
47
 Identify a suitable Tank Datum Position.
 Mark on every tank floor plate:
 Plate Number.
 Plate Reference.
 Plate Length.
 Plate Width.
 Track Width Interval.
 Recommended to mark up a few plates in the first row
and begin scanning in a logical order.
 Avoid having to stop scanning in order to mark up the
next plate. Ensure someone is marking ahead of the
scanner so the plates are ready to be scanned.
48
 Correct positioning of the scanner is important to ensure
that the location of detected corrosion can be found.
 Track width intervals must be marked at either end of the
plate, measuring away from plate reference.
 Add further marks near obstructions and on long plates.
 Marks are dependant upon scan overlap.
Interval = Scan Width – Scan Overlap
= 300 – 50 (default)
= 250mm [10inch]
1750mm
1500mm
1250mm
1000mm
750mm
500mm
250mm
49
 Marking can be done using a tape measure but can be
difficult to identifying the correct measurement.
 Recommended to have a purpose made pre-marked tool
as this can increase the speed of marking the floor.
 Remember to mark away from plate reference, at either
end of the plate, mid plate and around any obstructions.
50
 To mark the track width intervals on an annular plate a
right angle corner is required at the plate reference.
 The track width intervals are marked along the right
angle edge at either side of the annular and around
obstructions, measuring away from plate reference.
 Spacing is identical to floor plates, 250mm [10inch].
51
 When scanning Annular plates with a parallel edge it is
important to determine the straight edge between the
two inner corners.
 Use a large square to help draw the right angle line.
 Mark the track width intervals and determine which
tracks cannot be scanned.
52
Locating and prove up of MFL results
 In order to prove up results it is important to correctly
locate the detected MFL indications on the plate.
 The onscreen cursor displays the X and Y co-ordinates
measured from Plate Reference of that particular plate.
 The X and Y directions are taken relative to the tank view.
 X is measured along the horizontal length
 Y is measure along the vertical length
 Co-ordinates for the plates below:
y – vertical
x
y y
x x - horizontal
53
Locating and prove up of MFL results
 Once the correct location on the plate has been
identified then methods used to prove up MFL
indications include:
 Visual Inspection.
 Pit gauging.
 Ultrasonic Inspection.
 The tank floor surface condition can make the prove up
difficult especially on highly pitted tank floors.
54
Inspection Process
 The following flow chart shows the sequence of work
required to perform a successful inspection with the system.
In Office Obtain
Site induction Obtain (hot)
Check for confined space
Equipment if required work permit
permits
latest check
version of including Arrival
software spares Organise Arrange for Safety man,
access to tank electrical gas monitor
for equipment & power
Tank cleaning Risk team
requirements Assessment
Arrange for
Work safety man Out of Tank
Procedures (confined space)
Check all Check Input
Battery
cables are sensor inspection
Tank history,
check
Electrical power secure heights details
floor plate
requirements &
thickness &
tank access
coatings
Carry out Conduct Calibrate on If required use
Ensure personnel have current safety gas verification suitable coating
passports / confined space / BA monitoring scan reference plate simulation sheets
certificates (if required)
55
Inspection Process
In Tank
Setup Investigate Verify Mark
Check tank Identify Tank Verify Plate
suitable tank coating weldments &
cleanliness Datum Thickness
lighting environment thickness obstructions
Ensure all floor Measure

Mark out Select &
plates & annular Analyse plate
scan mark plate
have been data width &
tracks reference
scanned length
SCAN
Identify areas of
Backup data interest, verify
to USB indications (UT
visual)
Out of Tank Leave site

Sign off site
Calibration Equipment Pack up all permits, ensure
verification check equipment all paperwork
In Office
complete
Ensure ALL Analyse
equipment is clean collected data &
ready & available prepare report
56
Practical Session
 Identifying the plate setup information
 Layout 1 Tank Datum
Answer a

b

Tank Datum
Plate Number Plate Reference Plate Orientation Scanning Mode

a 4/2
2/2
Top Left Top Right Horizontal X
Bottom Left X Bottom Right Vertical X

b 3/1
3/4
Bottom Left X Bottom Right X Vertical

X
57
Practical Session
 Layout 2
Answer Tank Datum
b a
Tank Datum

a 16/4
2/1
Top Left Top Right Horizontal X X
Bottom Left X Bottom Right X Vertical

b 10/4
8/2
Bottom Left
X Bottom Right Vertical X

c 17/4
1/6
Top Left Top Right X Horizontal X
Bottom Left X Bottom Right Vertical

X
58
Practical Session
 Layout 3 Tank Datum
Answer a

Tank Datum c
Top Left Top Right Horizontal
a 5/13
3/7 Bottom Left X Bottom Right Vertical X X

b 5/19
3/1
Bottom Left
X Bottom Right X Vertical

c 1/6
7/4

X
59
Practical Session
 Layout 4
Answer Tank Datum a
Tank Datum
c

a 2/15

1/9
b 3/6 Bottom Left

X Bottom Right Vertical
X

c 2/2
2/20
Bottom Left
X Bottom Right X Vertical
60
Practical Session
 Layout 5
Answer Tank Datum c
Tank Datum
b

a 4/14
b 3/28
3/2 Bottom Left
X Bottom Right Vertical
X X

c 2/16
4/6
Top Left Top Right X Horizontal X X
61
Practical Session
 Reviewing the Learning Outcomes
 Establish the types of corrosion typically found on tank floors.
 Recognise the limitations of scanning a tank floor.
 Identify the roles within the inspection team and additional
equipment required for a successful tank floor inspection.
 Assess the cleanliness of the tank floor for an MFL inspection.
 Demonstrate the correct plate setup required for scanning,
identify the tank entry requirements and in-tank preparation.
 Discover how to locate the MFL results for further prove up.
 Utilize a correct sequence of work for inspecting a tank floor.
62

Section 3 - MFL Tank Floor Inspection - Rev 1

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Section 3 - MFL Tank Floor Inspection - Rev 1

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MFL Tank Floor Inspection

Improving Inspection Through Technology

Floor coating Product Side

Replacement floor plates

Image 9 – Heavy Scale Image 10 – Layer of hardened scale and product

Top Left Top Right

Bottom Left Bottom Right

Plate Size Plate

Scan Type Tank Datum

No straight edge Straight edge

 Annular Scanning Mode

Ensure all floor Measure

Out of Tank Leave site

Plate Number Plate Reference Plate Orientation Scanning Mode

Bottom Left X Bottom Right X Vertical

Plate Number Plate Reference Plate Orientation Scanning Mode

Bottom Left X Bottom Right Vertical

Bottom Left X Bottom Right Vertical

Plate Number Plate Reference Plate Orientation Scanning Mode

b 3/6 Bottom Left

Plate Number Plate Reference Plate Orientation Scanning Mode

Top Left Top Right Horizontal

Bottom Left X Bottom Right Vertical

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