INSPECTION OF TANKS

CONTENTS
S/N
1.0
2.0
3.0
4.0
5.0
6.0

SUBJECT

PAGE

SCOPE..
PURPOSE
..
INTRODUCTION .
PROCEDURE
RESPONSIBILITIES
REFERENCES

NO. OF PAGES: 05

DATE.
REV.

1
1
1
1
5
5

Prepared By:

VB

Approved By:

HIB

1.0

INSPECTION OF TANKS

Rev.: 0
No. of Pages 1 of 5
Date:

SCOPE:
This procedure describes various aspects of inspection of different types of tanks in
existence at plant. It covers basically the inspection of low pressure and atmospheric
storage tanks, like fixed roof tanks, including open roof tanks.

2.0

PURPOSE:
The purpose of this procedure is to establish a systematic method of tank inspection,
ensure that all concerned items are covered, provide guidance for inspection, as well as
help in preparation of shutdown of tanks.

3.0

INTRODUCTION:
Storage tanks generally are used to store Ammonia, Urea or finished products, chemicals
or water. Factors like volatility, type of products, pressure and temperature of storage
decide the type of tank construction. These tanks generally operates with true vapour
pressure at storage temperature, less than 15 PSI.
3.1

Fixed Roof Tanks:

There are different types of fixed roof tanks, like cone roof tanks, umbrella roof
tanks, dome roof tanks, etc., the most common one being the umbrella roof type.
Roofs are supported generally by internal structural members.

4.0

PROCEDURE:
4.1

Frequency of Inspection:
Frequency of inspection of storage tanks should be in conformance with our
procedure for Frequency of Engineering Inspection.
However, a detailed external visual inspection should be done for all storage
tanks annually while the tank is in service.

4.2

Inspection of Tanks:
Tank bottom levelling shall be checked after a year of initial commissioning and
then on once in ten years. Any uneven settlement shall be corrected.

4.2.2

External Inspection while Tank is in Service:

Careful visual inspection of the following parts must be done while the tanks is
in service.

Ladders, stairways and their handrail for wear, corrosion, cracks or other
deterioration. Platforms and walkways also should be inspected similarly.

Prepared By:

VB

Rev.: 0
No. of Pages 2 of 5

Approved By:

HIB

INSPECTION OF TANKS

Date:

The tank bottom outside sealing shall be checked to avoid chances of water
flowing under the tank bottom. Anchor bolts where provided should also be
visually checked.
-

All pipe connections to a tank should be inspected for external corrosion and
distortion or cracks on the nozzle. Visual inspection may be supplemented by
non destructive testing methods.

Condition of protective coating on tank shell and roof should be checked for rust
spots, blisters, film lifting, etc.

If the tank is insulated, the condition of the insulation should be checked. If

required, few samples of insulation may be cut to check the condition of the
shell metal under.

Cathodic protection system for NH3 storage tank should be tested as per the
attached test / inspection procedure. Inspection specification should be mainly
considered. This job will be done by electrical section.
Reading along with detailed report status should be submitted to inspection.

Shell and roof should be checked for any evidence of corrosion, cracks, bulges
or similar other deterioration. If any evidence of corrosion is suspected,
ultrasonic thickness measurements should be taken.

Auxiliary equipment like fire water headers should be visually inspected for any
corrosion or other deterioration.

4.2.3

Tank Shut down Inspection:

4.2.3.1

External Inspection:
With the tank out of service, detailed external inspection of all
the parts should be done. The following are the main items with
a brief description of the inspection activities that shall be
carried out.

4.2.3.2.1

Tank Shell:
Shell be inspected all over with closer inspection at accessible
areas. External paint shall be checked for rust stains, colour
fading, paint peeling and general deterioration. More attention
shall be given to sharp corners and edges where paint film is
most vulnerable.

Prepared By:

4.2.3.1.2

Fire water ring shall be inspected for leaky valves, plugging, and
paint failure.

4.2.3.1.3

All accessible weld areas shall be closely inspected.

VB

Rev.: 0
No. of Pages 3 of 5
3

Approved By:

HIB

INSPECTION OF TANKS

4.2.3.1.4

Ultrasonic thickness measurement shall be taken on all

accessible shell plates with minimum two readings per each
plate.

4.2.3.1.5

Externally insulated tanks shall have (1 ft. x 1 ft.) area removed

at specified locations and inspected.

4.2.3.1.6

External inspection of Cone Roofs

4.2.3.1.7

Visual inspection of roof plates shall be carried out. General paint

deterioration, mechanical distortion like bulges or dents, and any
other type of failure shall be reported. The inspector shall
ensure that the roof plates would not collapse during his
inspection.
-

Roof plate shall be ultrasonically monitored with 2 to 4 readings

per plate. A hammer test could be used as necessary.

Vent breathers shall be checked for plugging.

Gage funnels, center and peripheral roof vents, manways, etc.

shall be examined for paint deterioration, mechanical wear and
any other distortion.

External Inspection General:

4.2.3

Tank foundation should be inspected for all types of

deterioration, cracks, Spalling, etc.

Corrosion / deterioration of electrical / instrument mounting

should be checked.

Internal Inspection:
4.2.3.1

Prepared By:

Date:

Tank Bottom:

Before cleaning commences, tanks shall be inspected in as

found condition. Areas with sludge and deposit accumulation
shall be noted.

Bottom plates shall be visually checked for defects bulging,

deformation and deteriorated areas. All scales and corrosion
products shall be removed and plates shall be closely inspected
for pitting, cracks and other defects.

Ultrasonic thickness measurement shall be carried out for all

bottom plates with minimum of two readings on each plate.

VB

Rev.: 0
No. of Pages 4 of 5

Approved By:

HIB

INSPECTION OF TANKS

All auxiliaries like, draw of sumps, steam heaters, drain pipes,

metallic shoe, etc. shall be visually inspected.

Supporting columns shall be examined for deformation, sliding

and any other type of failure. Ultrasonic thickness measurement
shall be carried out at heavily corroded areas or other areas
found required.

Weld of shell to annular plate shall be thoroughly cleaned.

Close visual inspection shall be performed on all the weld zones.
The inspector may utilize, at suspected areas, like dyes
penetrant, vacuum box testing, etc.

Test plates of 300 mm x 300 mm may be cut out for checking

the soil side condition. Repairing of the removed section shall
be done as per API 650 with backing strip.

4.2.3.2

Tank Shell:

Tank walls shall be thoroughly inspected for any sign of corrosion

damage. Mechanical wear, pitting, distortion and buckling
(particularly if over spilling or rotation of F.R. is detected)

Main inlet and outlet piping, heater supports, rest plates, etc. shall
undergo close visual inspection, particularly at confined areas
and places of contact.

4.2.3.3

Prepared By:

Date:

Inspection of internally painted Tanks:

Tank interior shall be thoroughly cleaned by appropriate means.

No chemical cleaning is permitted which could affect paint
condition.

Painted areas shall be examined for general paint failures like

blistering, peeling, wrinkling, mud cracking etc.

Paint shall be removed completely around defective areas and

plate surface shall be examined.
Ultrasonic thickness
measurement, pit measuring device and other equipment shall be
used to assess the plate condition.

Surface where paint had failed shall be prepared, paint applied

according to a previously written and approved repainting
procedure.

Areas with paint failures shall undergo paint destructive testing

to determine the extent of the attack.

VB

Rev.: 0
No. of Pages 5 of 5
5

Approved By:

5.0

HIB

INSPECTION OF TANKS

Date:

RESPONSIBILITIES:
Inspection shall prepare the schedule of inspection for all storage tanks as well as the
shut down inspection worklist for each tank in advance. Inspection shall inspect and
identify areas of corrosion or other deterioration, recommend repair procedures and
perform quality control test during and after repair. Inspection should also approve any
chemical cleaning that will be used inside internally painted tanks. Inspection shall
prepare and maintain all relevant records.
Maintenance will plan and execute the maintenance activities on the tank based on the
schedule of inspection. Maintenance will provide necessary assistance to inspection, like
scaffolding, cleaning, etc.
Maintenance will be responsible on the tanks cathodic protection. Copy of the routine
readings should be submitted to inspection along with the detailed report.
Operations in coordination with planning will be responsible for the release of tank at the
scheduled time, as well as in a condition safe for prsonnel to carry out the inspection and
maintenance work. Any problem experienced on the tank during operation should be
brought to the attention of inspection and maintenance during the turnaround by
operations.

6.0

REFERENCES:
(2)

Welded steel storage tanks -

API 650