Recommended Practice - Inspection of Vertical Cylindrical Steel Atmospheric Storage Tanks1

Distribution Operational Excellence Approved for Use July 2006
Inspection of Vertical Steel Tanks Next Scheduled Update July 2007
Downstream - Supply and Distribution

Recommended Engineering Practices
Inspection of Vertical, Cylindrical Steel Atmospheric

Storage Tanks
Table of Contents
1. Introduction & Scope 4 11.3 Tank Nozzles 20
2. References 6 12. Tank Roof Inspection 21

3. Inspection Intervals 7 12.1 Plate Thickness 21
4. Operator - Routine in-service inspections 8 12.2 External Floating Roofs 21
4.1 API Statutory Surveillance 8 12.3 Roof Nozzles 21
4.2 Non API Surveillance 8 13. Tank Floor Inspection 22
5. In-Service Technical Inspections. 10 13.1 Plate Thickness 22
6. Out of Service Technical Inspection 11 13.2 Floor Plate Welds 23

13.3 Floor Plate Projection 23
7. Tank Integrity Assessor 12
14. Other Measurements 24
8. Inspection Equipment 13
14.1 Tank Settlement 24
8.1 Ultrasonic Equipment 13
14.2 Tank Tilt Survey 24
8.2 Magnetic Flux Floor Scanning/Mapping
Equipment 13 14.3 Out of Round Survey 24
8.3 Visual Inspection Equipment 14 15. Inspection Analysis 25
9. Plate Numbering and Datums 15 15.1 Repair Recommendations 25
10. Visual Inspection 16 15.2 Calculations 25
10.1 Tank Mapping and Layout 16 15.3 Remnant Life Next Inspection 26
10.2 Photography 17 16. Reporting 27

11. Tank Shell Inspection 18 16.1 Repair Report 28
11.1 Plate thickness 18 Appendix A Sample Non API Surveillance

11.2 Rivet Joints 20
Checklist 29
Version 1.0 Page 1 of 30 Confidential to Shell

Downstream - Supply and Distribution

Recommended Engineering Practices
The Inspection of Vertical Cylindrical Aboveground

Storage Tanks
Revision History
July 2006 First Issue 1.0 VN KB TJ

Date Description Rev. No Prepared By Reviewed By Approved By
Disclaimer:
Whilst every effort is made to ensure that information contained within this document is accurate and
presented in good faith to the respective business units operating within the Shell Global Distribution
business. The final decision to accept part or all of the recommended practices provided herein remains the
responsibility of the respective Engineering Manager who shall advise the asset owner, with whom ultimate
accountability resides, to the applicability or otherwise of these recommendations to the business.

Forward
Distribution engineers and operators manage our assets in hundreds of terminals in highly
scattered and remote locations across the world.
As we become a Downstream One global business, with a common set of processes, it has
become necessary to develop a consistent and controlled set of guidelines, practices and standards
that sit at the core of these global processes. These documents, being based on our collective
knowledge and experience and captured as global Best Practices, comprise the corporate
knowledge in managing the assets that have been placed under our care.
The Distribution business today is challenged in an unprecedented way, to resolve the conflicting
demands of lowering costs and an ever-increasing mandate to prevent our operations from
impacting on the community and environment. This has prompted the Operational Excellence (OE)
Engineering Team to develop these Best Practices within, where appropriate, a risk-based
framework of asset management.
To achieve the correct assessment of risk requires a deep level of understanding of technology
application, proper construction practices, modern plant maintenance management techniques, as
well as the modes and mechanisms of plant degradation.
With the release of the Distribution Engineering Best Practice Guidelines (BPEG) and the
associated, more detailed, Recommended Engineering Practices (REPs) we expect to begin the
journey of implementing the global standardization to the processes of asset management, which
are part of the bigger journey of Streamline and Downstream One.
These documents do not seek in any way to replace industry codes, and Shells own DEPs, but
only to recognize them and their application to the Distribution business. These OE Guidelines
therefore serve to act as a road map to the applicable standards, while giving cautions on their
application and interpretations for the less experienced or non-discipline engineers based on input
from Subject Matter Experts.
I urge you not only to make these documents available to your staff, but also to encourage you to
continue to support this effort by providing constructive criticism and improvements as you
contribute your own experiences to this continuously evolving body of knowledge.
Thomas Jenke
General Manager Distribution Operational Excellence

1. Introduction & Scope
The Engineering Guideline Atmospheric Vertical Above Ground Storage Tanks and the global
Tank Integrity Program (TIP) identify the need for regular tank inspection as part of the asset care
program.
Whilst in many countries tank inspection is a statutory requirement, there exist today considerable
variations in both the practices employed and the frequency of such inspections resulting in
variable outcomes in terms of asset integrity and operating safety.
This Engineering recommended practice, is a technical document and a tool that complements the
objectives of the TIP and serves to provide Distribution Engineering and operations with
1. Clear direction on the type and content of inspections to be performed
2. Recommendations on the types of inspection techniques and analysis tools expected to
be used.
3. Recommendations for analysis of inspection results
4. Recommendations for the management of rectification work
5. Record keeping requirements.
As stated in the guideline, there are two principal reasons why tank inspection is important to our
business;
1. It assists to ensure that the tank will be safe to operate until the next inspection hence
not release product between the inspection intervals
2. Determine if any deterioration has occurred and if so, prevent or retard the
deterioration, or estimate a likely replacement date.
These requirements are irrespective of what any statutory requirements might require they also
simply make operating sense.
All key references identify 3 types of inspection regimes as fundamental to the complete tank
inspection strategy. These are
o Operator surveillance or Routine in-service inspections
o In service, technical inspections
o Out of service, technical inspections.
Each has an important part to play in the assessment of a tanks condition and its suitability for
continued service. This recommended practice endorse these regimes as appropriate for our
business, and as such represents part of the basis for the tank integrity program.
This document can be used as a basis to either contract inspection companies or for Shell Staff to
conduct their own off-stream inspection of vertical bulk storage tanks provide they have adequate
experience, equipment and competency assessments.
The term Tank Integrity Assessor (TIA) has been adopted and referred to within this document and
is the person who has the responsibility for evaluating and completing the overall assessment
based on all test data available.

Upon completion of the Integrity assessment the Engineering Manager will normally have the
responsibility to make the final recommendation as to the tanks suitability for continued service or
recommend the extent of repair works to be undertaken prior to the tank re-entering service.
These requirements are intended to be consistent with the internationally recognised codes. They
do not provide all detailed working instructions, these can be found in the referenced codes, but
provide recommendations where code interpretation and techniques can vary to achieve a
consistent result across all business units.
Where local existing tank inspection regimes, both company and regulatory derived, are
consistent with these recommended practices, then there is no need for any changes. However
where gaps are evident in these current practices when compared to these recommendations,
steps should be introduced to reduce the gap.
These recommendations cover both inspection and reporting requirements. Additional inspection
work maybe required as the inspection progresses and extent of degradation becomes apparent.
All work should be overseen and supervised by an appropriately experienced Engineer or
technician able to respond inquiries and be able to direct the integrity assessor as necessary
during the inspection process.
It is noted that many of the Shell tanks found within distribution terminals were built to codes of
the day, including BS2654, API650, pre BS2654, DIN, JIS etc. The TIA needs to aware of this,
and apply the correct inspection principals and use sound judgement when evaluating the tanks
suitability for continued service.
Should any ambiguities exist within this document the requirements of API 653, EEMUA 159 or
statutory requirements where they are more stringent should take precedence.
The overriding principals that should be uppermost concerning the applicability of the relevant
codes are;
Use API 653 for the evaluation of API specification tanks
Use EEMUA 159 for the evaluation of BS2654, and now EN14015 code tanks
Where the code of construction is unknown, use either but not both and apply it
consistently, do not switch codes.
Statutory requirements must always be met as a minimum.

2. References
Whilst there exists a number of different references and publications on this subject, there are
some specific documents to which frequent reference is made and which are considered by the
industry and Distribution as fundamental to this subject.
Personnel engaged in tank inspection and maintenance work should have access to these
documents, all of which are available from the Shell External Standards web site, the DEP web site
or Global Live Link. Copyright restrictions at this time; do not allow us to store these documents in
a single location.
Document Number/Ref Title
API std 653 Tank Inspection, Repair, Alteration and Reconstruction
EEMUA Pub 159 Users Guide to the Inspection, Maintenance and Repair of
Aboveground Vertical Cylindrical Steel Storage Tanks.
API RP 575 Guidelines and Methods for Inspection of Existing Atmospheric

and Low-pressure Storage Tanks.
EEMUA Pub 183 Guide for the Prevention of Bottom Leakage from Vertical,
Cylindrical Steel Storage Tanks.
DEP 70.51.10.11-Gen Field Inspection, Maintenance and Repair of Vertical Steel Storage
Tanks.
Shell Pipeline Company Tank and Pressure Vessel Inspection and Maintenance Manual
LP December 2004. (Links provided to reference documents)
Distribution Engineering Atmospheric Vertical Above Ground Storage Tanks

Guideline

3. Inspection Intervals
The establishment of initial tank inspection intervals are provided in the Engineering Guideline
document Atmospheric Vertical Above Ground Storage Tanks (Section 4.4).
The establishment of the next tank inspection interval, be it in-service or out of service will depend
on the outcome of the previous inspection conducted the results obtained, the repairs conducted
and the recommendation s of the Tank Integrity Assessor (refer Section 15).

4. Operator - Routine in-service inspections
4.1 API Statutory Surveillance

To satisfy API 653 code requirements and where API codes are legislated as part of
statutory requirements, these must be performed monthly.
Surveillance of this type is limited to operations personnel identifying significant changes,
and raising any identified issues to a suitably qualified technician or Engineer for further
investigation. Hence a documentation and feedback process is a requirement.
This routine inspection is generally limited to a visual examination of the tank exterior and
surrounding area, with visual checks for any major changes that may indicate;
o Leaks
o Shell distortions
o Signs of settlement
o Signs of corrosion
o Condition of the foundation, paint coatings, insulation systems and general
appearance.
o Evidence of cracks
o Faulty tank equipment
It is unreasonable to expect an operator to do more than this on such a frequent basis and
to documented these surveillance activities.
An example form for use T-172 is contained within the SPLC I&M manual section 3.4.1.
It must be noted that training in undertaking tanks surveillance may be a legislated
requirement. In any case, operators should be instructed in what to observe, the types of
changes they might expect to see and how they are to record and report their
observations.
4.2 Non API Surveillance

Where API 653 requirements are not a statutory requirement then an alternate
arrangement as advocated by EEMUA 159 is recommended and preferred which will
allow more to be inspected hence the potential to notice smaller more subtle changes,
without being too onerous on the operators.
With these more extensive inspections, it is possible to cover more operational safety
related matters such as;
Vents and Pressure/Vacuum vents (where fitted)
Bund/Dike drain valves
Grounding/Earthing equipment connections
IFC seal and general condition
Testing high level alarm systems
For floating roof tanks, items such as;
Roof drain valves

Roof drain sump

Emergency roof drains
Pontoon compartments
Seal weather shield and metallic shunts
Ladders
These fittings and devices may undergo a slower deterioration process, hence small
changes may not be observed though a simple monthly surveillance inspection regime.
Hence for Non API requirements, the interval of 3 months is endorsed as per EEMUA 159,
and Shell DEP recommendations. This may be varied though the use of Risk Based
Inspection (RBI) regimes, where accepted by authorities and is advocated by the
Distribution Tank Integrity program.
A sample inspection sheet, based upon DEP and EEMUA recommendations for this type of
extended operator surveillance recommendations is contained within Appendix A.

5. In-Service Technical Inspections.
The technical in service inspection requires the services of an API, EEMUA or similarly
qualified accredited tank inspector/assessor (TIA) refer to section 7.
Access to the previous external and out of service inspections reports is required along
with records of the operator surveillance undertaken recently.
All references API653, EEMUA 159 and Shell DEP, are basically aligned with these
requirements.
The primary function of this inspection is to identify if there is any discernable change in
the tank condition that may impact upon the next scheduled out of service inspection, that
is to identify the need to bring this forward.
It is rare that a planned out of service inspection would be postponed based on this type of
inspection, unless a specific mode of failure was being monitored and specific details are
known. It may be used as an input to any RBI process.
This inspection comprises
A detailed and thorough visual inspection of all the tank shell, roof and fittings,
evaluating external corrosion and corrosion under insulation. This includes an
evaluation of the need for tank settlement measurement and the inspection of the
tank foundation and surrounding bund/dike area. This is combined with;
o Ultrasonic thickness measurement of the external surfaces of the shell and
roof. Refer to sections 10, 11, 12, and 14 in this REP for specific details
o The possible use of acoustic emission and other non-invasive techniques for
condition monitoring if there is cause for additional concern. (Refer
EEMUA 183 Sect 5.2.3)
Check lists and reporting formats are provided in Appendix B1 of EEMUA 159, and
Appendix C1 in API 653.
Reference should be made to DEP 70.51.10.11, section 4.3, which supplements these
checklists for external inspection requirements.

6. Out of Service Technical Inspection
The fundamental requirement is to ascertain that the tank is fit for service until the next inspection,
in accordance with the appropriate code/ guideline requirements generally API 653 or EEMUA
159, but can include local statutory requirements where these are more stringent or considered
technically equivalent.
The work must be conducted by a qualified TIA, and the work scope is the following;
a) A visual inspection of the tank to determine the condition of the foundation, shell strakes,
roof, roof/blanket seals, floor, protective coating, appurtenances and fittings in
accordance with the checklists and guidelines outlined in API 653 and/or EEMUA 159
including an assessment of propagating defects and corrosion.
b) An ultrasonic thickness survey of the shell strakes.
c) An ultrasonic thickness survey of the roof plates on cone roof and sphere dome roof or
floating roof-design storage tanks.
d) A thickness survey of the floor plates.
e) A survey of tank settlement (internal and external), and its tilt.
f) A visual inspection and profile gauging of rivet connections and lap joints where
applicable.
g) The preparation of a report scheduling thickness survey results on the specified forms plus
details of visual inspection findings, including photographs, of defects.
h) A review of the tanks suitability for ongoing service, including if necessary a summary of
the recommended repairs to made in accordance with API 653, and/or tank re-rating as
appropriate.
i) A calculation of the maximum corrosion rates based on current and historical data, to be
used in calculating the tanks remnant life, and the next inspection period. Reference to
EEMUA 159 and API 653 RBI methodology are to be used to substantiate this.
j) Vacuum box testing (or magnetic particle inspection or dye penetrant testing) of bottom
sketch plate and corner welds)
k) Inspection and ultrasonic testing of manhole and nozzle walls
l) Initial visual inspection of welded seams and roof frangible joint
Check lists and reporting formats are provided in Appendix B2 of EEMUA 159, and Appendix C2
in API 653.
Reference should be made to DEP 70.51.10.11, section 4.5, which supplements these checklists
for internal inspection requirements.
SPLC form T-171 and technical specification 18TS006 contain further examples of API 653
internal inspection checklists and reporting requirements.

7. Tank Integrity Assessor
The tank integrity inspector should be qualified as an API653 inspector or trained for the
interpretation of EEMUA 159 for:
Visual inspection
Interpretation of NDT results, and
Sign off on final reports
The Tank Integrity Assessor (TIA) and/or their operators should have qualifications that
can satisfy any countries requirements for certification in the use and application of non-
destructive inspection techniques. Specifically this can include qualification to PCN/ASNT
level II and are expected to have experience in operating and calibrating the equipment.
Whilst operation of testing equipment is critical to the satisfactory completion of any tank
inspection, the fundamental requirement is to observe for any evidence of corrosion or
other defects that may render the tank unsuitable for continued service. This observation
work is more critical than obtaining a set of numbers from electronic recording
equipment.
The assessor should only supply staff that can demonstrate that they have knowledge of
tank construction and have had relevant experience with tank inspections. They need to be
knowledgeable in the operation and calibration of all equipment they bring to site to
complete the works. It is the TIAs responsibility to ensure that staff is trained in the
equipments use, and that the equipment is in good working order.
Only a Tank Engineer experienced in Tank design and stress analysis should be engaged
to perform any stress analysis work required.

8. Inspection Equipment
8.1 Ultrasonic Equipment

To carry out satisfactory ultrasonic thickness scans the testing equipment should possess;
A system accuracy conforming to the requirements of ASNT, and/or other
location relevant codes applicable.
An A scan display with a twin crystal probe and able to separate coating
thickness
A copy of the calibration certificate (manufacturer and NIST or equivalent) for the
equipment.
A monitoring range capability to suit the thickness range of the plate being
inspected; to an accuracy of +/-0.1mm or better and negate paint thickness. The
unit should be able to show the reading in waveform as a minimum.
Provide the necessary fixed and angle probes to complete the inspections
specified.
For tank shells;
A crawler-type magnetic hand or winch drawn trolley on which the probe can be
mounted, with a continuous pressure-fed supply of coupulant.
The calibration should be checked prior to the commencement of work, at the
completion of each vertical run and after the unit has been temporarily switched
off using a steel plate step-wedge gauge.
If a display showing net plate thickness recordings directly is not available),
sample paint thickness readings should be taken to determine the coverage
correction factor to be subtracted to give the corrected net plate thicknesses.
8.2 Magnetic Flux Floor Scanning/Mapping Equipment

The floor scanning equipment is used to detect magnetic flux leakage fields from corrosion
pitting on the top and bottom surfaces of floor plates. The unit should possess the following
characteristics
The floor-mapping unit should be of a permanent magnet and preference is for it
to be able to provide a C scan type mapping representation with colour coding
for different percentage material loss. A minimum image resolution of 25mm
x25mm or better is required.
Be equipped with coloured images and digital readout to provide the image
resolution stated above.
In the absence of C scan equipment B Scan equipment can be used provided
report output as required is not compromised.
Have a monitoring range to suit the thickness of the plate being inspected and be
able to identify the areas of the floor with corrosion with 40% material loss.
Must be able to negate paint thickness
As MFL scanning and mapping provides a screening tool, ultrasonic measurement
equipment (100%Ut B Scan) should be used to close grid and accurately define the extent

of plate condition where corrosion is evident over the nominated threshold and to establish
the extent (width and thickness) of an affected area.
The calibration of the instrument should be checked prior to the commencement and after
completion of work, at appropriate intervals during the scanning process and after the unit
has been temporarily switched off during inspection.
Calibration of Magnetic Flux Leakage Floor Scanning Equipment should be performed in
accordance with the manufacturers instructions.
The use of test plates is a valuable addition to ensure accuracy of result. These have known
defects and plate thicknesses already mapped, and can be used to check the overall
machine and operator accuracy.
Where possible the operator should be independently certified for the operation of a
specific piece of scanning equipment should be and be able to provide details of the
certification before commencing work.
8.3 Visual Inspection Equipment

The TIA should provide all necessary equipment in addition to the ultrasonic flaw detector
and probes required to complete the inspections as specified. This equipment should also
comply with the requirements of the respective organisation applying at the location of the
tank being inspected.

9. Plate Numbering and Datums
The TIA should check historical mapping standards that have been used in setting the key plan for
floor, shell, and roof for the tank and follow the existing practices. Where there is no existing or it
is found to be inconsistent then the following is a recommended process for establishing
repeatable results during the course of the tank life and for consistent reporting.
All drawings should clearly mark the datum and survey points.
Floor and Roof
a. The number is the datum point for the plate.
b. The number is the corner where the X and Y axis are at their longest.
c. Numbering should commence from the plate that is the NW corner of the tank.
d. Subsequent plates are numbered by proceeding east across the first row then west
across the second row continuing in a zigzag fashion until all plates are
numbered.
e. Where annular plates are present the numbering continues from the last plate
numbered in d) being subsequent to adjacent annular plate. All other annular
plates are numbered in a clockwise direction.
The tank map should be orientated with the long axis of the plates horizontal to the page. True
North should be to the top of page as best the orientation of the tank plates allow.
When numbering the top half of the floor the plate number should be written in the bottom left or
right corner of the plate. When numbering the lower half of the floor the number should be
written on the top left or right corner of the plate.
Shell
Shell strakes are to be numbered sequentially, starting with the bottom strake as being the first
strake.
Shell plates are to be identified alphabetically, sequentially from the bottom of the tanks stairway
from the first full strake in a clockwise direction.
Nozzles, manholes, stairways, and fittings to be accurately shown on the drawings.
Settlement
The tank datum for settlement measurements and thickness measurements is the first vertical weld,
on strake one from the bottom of tank stairway in a clockwise direction.
Settlement measurements should be referenced to the Site Datum and where appropriate the local
survey datum.
The number and location of the survey points are to be in accordance with API 653

10. Visual Inspection
Visual inspection is the primary requirement of the external inspections and a similar inspection is
conducted during the out of service inspection that is extended to include the internal surfaces and
floor plates. The requirements for each are the same, although he results are generally recorded
on different forms and in different reports to reflect the status and the extent of the inspection.
Both API 653 (appendix C) and EEMUA 159 (Appendix B1 &B2) provide examples of detailed
inspection checklists for this activity depending if it just an external or a part of the full out of
service inspection. Most inspection companies or individual inspectors may have their own format,
which should be checked against the API or EEMUA versions for compliance and completeness.
A further detailed inspection checklist and report is contained within the SPLC Tank I&M Manual,
section 3.4.2, form T-170 and T171. Which is suitable for general use particularly where API
requirements are statutory requirements or where API tanks are in service.
These inspection schedules (referenced above) are provided as a guide to the TIA to ensure that
the condition of the tank and associated appurtenances and fittings are thoroughly investigated
and reported on. However, particular attention is to be paid to areas of concentrated corrosion
and accelerated degradation on surfaces or fittings identified.
The TIA may choose to use their own visual inspection schedule, notwithstanding that:
a. The inspection schedule, including visual and non visual inspections, should satisfy the
requirements of the schedules listed in API653 or EEMUA 159, and
b. The inspection schedule is reviewed for completeness by the Engineer or persons
experienced in this type of work.
The scope of the visual inspection is initially limited to those areas that can be readily inspected
from ground level and the existing stairways and platforms of the tank. Tools such as mirrors and
flashlights (as approved on the work permit) can be used. Upon the identification of corroded or
questionable sections of the tank by this initial inspection, the Engineering Manager may authorise
further inspections and revised access.
10.1 Tank Mapping and Layout

The TIA should determine what previous tank drawings (either CAD or manual) are
available to avoid rework. If existing sketches or drawings are to be used then it is the
TIAs responsibility to verify their accuracy.
The scope of the visual inspection includes completion of accurate tank maps for:
Floor
Draw a map of the plate layout with each plate numbered as per section 9. Plates are to
be drawn with the long axis horizontal on the page, and the location north is to be
indicated. North should generally be pointing to the top half of the page. Location and
size of ground level appurtences are to be shown, including nozzles, man-ways, sumps,
internal piping, dip plates, etc.

Roof
The roof should be drawn in plan view, with each plate numbered in accordance with
Section 9. Generally plates are to be drawn with the long axis horizontal to the page.
True North is to be shown on the drawing, and should generally be pointing to the top
half of the page. Include all roof top appurtences and fittings.
Shell
The Shell will be drawn in developed plan view, showing location of stairs, nozzles, man-
ways, and other appurtences.
Strakes are to be numbered in accordance with Section 9 with the compass locations and
all survey points identified.
10.2 Photography
Digital photographs are to be taken of specific defects that are detected, and areas of
general interest, including areas of high corrosion.
The photographer should ensure that the subject matter can be easily identified, by plate
number or other satisfactory means, and that scale can be interpreted where appropriate.

11. Tank Shell Inspection
11.1 Plate thickness

As part of both the external and internal code inspections, the tank shell thickness is measured to
determine the corrosion and pitting on the tank shell to a allow confirmation of the fill height for
the tank with respect to hydrostatic and seismic loads as well as the general condition of the tank.
The following procedure can be used in the absence of any particular requirements, being
consistent with API and EEMUA requirements.
11.1.1 Selection of Scans

For convenience, vertical shell scans should be located at the cardinal points of
the tank (N, S, E, W), and referenced distance from the defined reference point
nominated in Section 9. The location of all succeeding vertical scans should be
established and recorded in a field report logbook by accurate measurement
with a steel tape in a clockwise direction from the reference point. Care should
be taken with any markings so as not to detrimentally affect the shell protective
coating.
The number of scans finally taken will depend on the diameter and condition of
the tank shell, but it is recommended that the number of scans taken in the initial
survey be not less than shown below.
Tank Diameter No. Initial Vertical
Scans
Up to 18m 4 N, E, S, W
Over 18m to 36m 8 N, NE, E, SE, S, SW, W, NW
Over 36m At intervals around N, E, S, W + intermediate scans,
the tank equidistant spaced.
circumference not
greater than 15m
Vertical scans should be at approximately equal intervals around the tank

circumference, but the interval should be varied where necessary to allow a clear
and unobstructed vertical run by the crawler mounted probe. Drawing of the
shell and scan points should be drawn as a development view.
If some initial scans show significant loss of plate thickness due to severe internal
corrosion, additional scans located between initial scans should be taken to
more clearly define the areas of shell plate having the highest material loss.
11.1.2 External Scanning

The vertical scans in the locations selected are carried out as nearly as possible
over the full height of the tank shell from floor level to the top curb angle.
The magnetic trolley fitted with a 5Mhz immersion or dry probe is towed
vertically up or lowered down the face of the tank shell by cable from a ground
level constant speed winch which passes over a pulley fixed to the tank roof
hand railing or primary wind girder.

Alternatively, the cable can pass over a pulley mounted on top of a long
telescopic pole temporarily braced at an angle against the external face of the
tank shell.
The equipment is calibrated against the step-wedge gauge immediately before
and after each scanning run by applying the probe to the appropriate gauge
steps covering the range of shell strake plate thicknesses being measured.
The chart recorder and probe travel speeds must be correlated and controlled by
interconnection through a common switch to give simultaneous stop/start
movement.
While the probe is in motion, the readings should be continuously monitored by
the inspector so that plate flaws such as non-metallic inclusions, laminations and
deep corrosive pitting are correctly identified and recorded and to ensure that
there is a continuing match between thickness readings and recordings.
For each shell location, the crawler is to scan the height of the plate and record
a minimum of 5 readings, which should be equally spaced along the height of
each plate.
A close grid thickness reading should also be carried out on the shell vapour
space area of about 300mm (1 ft) from the top curb angle. This should be
conducted at the nominated crawler runs.
11.1.3 Internal Shell Measurements

This procedure is carried out using a hand held digital instrument, to support a
detailed visual inspection where evidence of corrosion has been observed and it
is necessary to conduct further investigations.
The initial assessment maybe conducted with strong lights and binoculars with
the follow up work completed from internal scaffolding which allows access to
part or all of the tank shell as considered necessary.
Readings should be taken over each strake at areas that show signs of corrosion
and shell thinning as determined by the inspection.
11.1.4 Additional Readings

In addition to the readings obtained at each of the scan locations, where
practical additional readings should be taken on each strake from the stairway
with a hand held digital instrument.
During the inspection of the first two strakes, it is important to determine the
extent of any possible grooving caused by product/water interface, or other
defects. This can be done via internal inspection.
In the event that plate defects are detected within the areas of the above scans,
(which may cause localised weakness such as laminations, grooving, inclusions
or internal mechanical damage) the profiles of such defects should be plotted
and identified with crayon on the plate surface as well as on the shell elevation
drawing.
Where preferential corrosion is detected during visual inspection at the stair
tread/shell plate and stanchion or brace/shell plate connections, the minimum

thickness should be determined by scanning the perimeter of the welded joints

and checking pit depth measurements.
Paint and scale adjacent to welds should be chipped back as required. In areas
where the tank has become partially buried due to foundation settlement, or
erosion and migration of bund wall material, etc., the extent of corrosion that
may have occurred at the false grade line or below should be confirmed.
11.2 Rivet Joints

All accessible rivet joints require inspection with particular attention to the shell-to-annular
ring connection. Weeping rivets are to be identified on the shell elevation drawings plus
any rivet heads or swaged tails which have corroded to less than 60% of their original
profile. The TIA should check the extent of preferential corrosion to the perimeter of the
rivet head. It is necessary to inspect for cracks around the rivet hole, the elongation of the
hole and for crevice corrosion. Hammer testing of any rivets that have corroded in excess
of above parameters or appear loose may be required.
The average head height and diameter of random rivets should be recorded plus a profile
of the swaged tail. Note loss of thickness of lap plate and accurately plot the profile of the
lap joint. Random sections of the lap should be scanned to detect interface corrosion.
11.3 Tank Nozzles

Carry out ultrasonic thickness measurement on tank nozzles up to the first flange. A
minimum of 4 readings at 00, 900, 1800 and 2700 around the nozzles shall be recorded.
UT measurements will also include the reinforcement pad of the tank nozzles and man-
ways.
The following should be determined and recorded for each manhole and nozzles:
Wall thickness of manhole and nozzles exclusive pits
Average wall thickness
Maximum wall thickness
Minimum wall thickness
Result of the thickness reading should be compared with the nominal wall thickness
specified in the tank code applicable of the corresponding manhole/nozzle size.

12. Tank Roof Inspection
12.1 Plate Thickness

The ultrasonic thickness measurement of roof plates can be carried out using hand held
digital instruments using the recommended practices below;
12.1.1 Scanning Procedure

The preferred scanning procedure consists of the use of the crawler mechanism
used for the tank shell. It should be tracked circumferentially around the tank
roof, in three (3) continuous concentric ultrasonic scans.
The three scans should be located:
Near and as close as practical to the frangible joint
Lower third
Mid point
For each concentric scan the inspector should monitor the results and record:
The least thickness in an area of corrosion exclusive of pits.
The depth, extent and location of identifiable internal corrosion and
pitting.
The average plate thickness.
The maximum depth of isolated pitting.
The density of pitting (%) to the surface.
In areas where thickness measurements show significant variations in roof plate
thickness and where extensive underside roof corrosion is suspected, an
increased number of readings should be taken.
Where excessive plate thinning is found by ultrasonic inspection, it should be
investigated by an internal inspection. This investigation may require the
cleaning of the tanks plates in the designated location.
The inspector should monitor and log details of any visible plate defects such as
non-metallic inclusions, laminations and deep corrosive pitting, as observed from
the visual inspection.
12.2 External Floating Roofs

Wherever possible a visual inspection should be made of all pontoons.
In addition the inspection will consist of five UT readings per plate, one at each corner of
the plate and the fifth at the plates centre including all pontoon plates.
12.3 Roof Nozzles

Refer to Tank nozzles, which should follow the same measurement procedures.

13. Tank Floor Inspection
13.1 Plate Thickness

The purpose of this inspection is to determine corrosion pitting primarily on the underside
of tank floors where visual inspection is impractical but also on the top surface hence
providing a 100% floor thickness survey.
Importantly before the commencement of any scanning work, the floor surface condition
should be inspected and its condition assessed for its suitability for the scanning activity.
This should be recorded as acceptable by the scanner operator/inspector. If not then the
Engineer will need to arrange additional cleaning to be performed.
The scanning method consists of the utilisation of a magnetic flux leakage floor scanner, as
described in section 8.2, as well as the use of a ultrasonic probe whereby floor plates are
scanned & inspected with the maximum possible coverage. A combination of these two
techniques allows a 100% floor thickness survey to be achieved.
All significant internal and underside pits and corrosion should be identified, measured
and recorded along with their location.
If significant pitting, corrosion or thickness readings exceeding 40% thickness loss are
recorded a more detailed thickness scanning survey should be taken covering the
suspected areas of floor plate using the hand held ultrasonic unit B-Scan to determine the
severity.
Areas not accessible for mapping such as under pipes should be subjected to 100%
corrosion scan by hand.
For each individual floor plate, the following measurements should be determined and
recorded by the inspector:
The least thickness in an area of corrosion exclusive of pits.
The depth, extent & location of significant identifiable Top surface pitting (TSP) and
under floor corrosion (UFC)
The average plate thickness.
The maximum depth of isolated pitting.
The density of pitting (%) to the surface.
The removal of floor coupons is recommended in cases where abnormally aggressive UFC
or inconclusive NDT readings are observed.
Floor Sump
Readings to the floor, sidewall and rim of the floor sump(s) should be obtained to identify
the extent of corrosion and pitting and achieve a 100% survey of thickness. Any
preferential corrosion, undercutting or other weld defects that could undermine the
integrity of the sump should be identified
Roof Columns
The inspector should complete a scan of the lower section (300mm) of the roof columns,
associated base plates and gussets to check for corrosion and pitting. In addition, the TIA
should ensure the floor plates adjacent to the areas providing bearing to the columns are
scanned, where accessible, and particularly where water entrapment occurs.

13.2 Floor Plate Welds
13.2.1 Floor Sketch Plates

Floor sketch plate welds should be inspected visually and preferably by vacuum
box testing, magnetic particle testing, or dye penetrant testing to detect for weld
cracks or defects. A minimum of three weld positions per sketcher or annular
plate should be checked.
13.2.2 Circumferential Floor to Shell Welds

If the protective coating is in poor condition or significant weld defects are
noted, the Inspector should complete a random survey of the internal and
external circumferential welds using vacuum box testing, magnetic particle
testing or a dye penetrant test to detect cracks or weld defects. A minimum of
three weld positions per stretcher or annular plate should be checked.
The Inspector should complete a random survey of the heat-affected zone of the
floor to shell joint using a shear wave probe (ultrasonic flaw detection). If this is
not possible then a visual inspection from a hole under the joint may be
required. Specific approval should be obtained from the Shell Engineer before
proceeding with any excavations.
13.3 Floor Plate Projection

The ultrasonic thickness measurement of floor plate projection can be carried out using
hand held digital instruments.
Readings should be taken at approximately equal intervals around the floor plate
projection starting from the tank datum point and the location plotted on a sketch or
drawing of the floor plate layout.
The thickness readings should be taken at 2m intervals around the tank circumference.
In areas where thickness measurements show significant variations in floor plate projection
thickness and if extensive underside corrosion is suspected, an increased number of
readings should be taken.

14. Other Measurements
14.1 Tank Settlement

Settlement phenomenon requiring measurements are
Circumferential settlement
Settlement across diameter
Edge Settlement
Shell plate bulges at the bottom plate to shell area
The tank settlement inspection consists of measuring the extent of settlement of the tank
perimeter to a fixed datum outside the tank compound bund wall
Each survey point should be identified numerically in a clockwise direction from the
permanent reference point marked on the floor plate projection or the tank shell. The
permanent reference point is the first vertical weld on the bottom strake from the stair
termination in a clockwise direction.
The number and location of the survey points are to be in accordance with API 653 or
EEMUA 159. The survey should be closed to ensure accuracy in levels of 2mm.
Settlement Measurement on Local Depressions and Bulges

In conjunction with the bottom plate inspection, inspect and record bulges or depressions
on the tank bottom and shell plates.
14.2 Tank Tilt Survey

Measurements should be taken at equidistant points around the circumference of the tank.
The distance between the points of measurement should not exceed 9m (30ft). The table
below gives guidance on the number of measurements required.
Diameter of tank (m) No of measurement points
1 - 10 4 (N, S, E, W)
11 23 8
>23 16
The differential at the roof level should be expressed as positive (+), and at the floor level
as negative (-).
The TIA should determine the procedures to determine tilt, and typically this will be by one
of two methods
Laser level, or
Plumb bob and string line.
14.3 Out of Round Survey

The out of round survey should be completed in accordance with API 653 if requested by
the site Engineer. This is normally only conducted where it is expected that an internal
floating cover is to be fitted in the near term.

15. Inspection Analysis
The TIA is to review the tanks suitability for ongoing service based on the acceptance criteria
based in API653, and/or EEMUA 159 as applicable. The TIA should determine from the codes
and tank construction details that criteria are to be applied.
The tanks suitability for ongoing service will consider any repairs that are recommended by the
TIA, and include a discussion as to their impact.
15.1 Repair Recommendations

The TIA should recommend repairs to the tank for the following reasons:
Compliance with the appropriate codes, insofar as the tanks original construction
standard can no longer be considered satisfactory for ongoing service (as
measured by API 653/EEMUA 159).
Meet or exceed minimum rejection criteria
Avoid significant down grading of tank capacity as result of re-rating.
Achieve a target of approximately 15 years before the tank requires its next out of
service inspection (May depends on intended service conditions)
Repair requirements would normally be discussed immediately with the site Engineer with
a hand written report to allow immediate action, unless significant calculation and analysis
is required before final recommendations can be made.
Further discussions may also be required with business and operations staff, where options
exist concerning extent (hence cost) of repair and the interval to the next out of service
inspection.
All repairs carried out should be certified by the Tank Integrity Assessor as being
compliant with the relevant code and documented prior to closing up of the tank.(Refer
section 16 reporting)
15.2 Calculations
15.2.1 Tank Re-rating and Stability

Taking into consideration of the condition of tank, and if appropriate any
repairs that will be implemented (after discussion and agreement with Shell) the
tank should be re-rated, specifically with regard to safe fill height.
This is primarily appropriate for hydrostatic and/or seismic compliance, but
other Code considerations should also be taken into account.
Tank re-rating calculations may need to be completed to determine the impact of
any recommended repairs, to determine benefit on tank duty.
Refer to DEP 70.51.10.11 appendix 5, for stability calculations and analysis.
15.2.2 Venting Calculations

The tanks venting capacity may require be verified by calculation. This includes
emergency venting requirements. Any requirement for this will be at the
discretion of the Company Engineer.

Tank venting requirements should be determined in accordance with API2000.

Further examples of venting calculations can be found in DEP 70.50.10.11
appendix 4
15.3 Remnant Life Next Inspection

The TIA should determine the tanks remnant life by determining the corrosion rates,
against historical data, and the test data retrieved from the inspection. The minimum
acceptable thickness t min should be based on the relevant codes.
In their simplest form the corrosion rates determine the next theoretical inspection period.
However it is expected that the TIA should use their knowledge, and experience, taking
consideration of other factors, such as risks and reliability of data in determining this
period.
The TIA should also consider what is likely to be the dominant failure mode, taking into
consideration the likelihood based on experience and data provided from recent and
historical inspections.
In addition other trend able failures, such as tilt and settlement, should be considered
where the data is available.
In order to complete this analysis the TIA will be provided with historical inspection data
that Shell has on record.
EEMUA 159/API 653 RBI Analysis

The TIA can use as a reference and input into the remnant life calculation the
tables/matrices from EEMUA 159 and API 653. However, this should not be the sole
judge of the next inspection period as other considerations, as listed above, should also be
taken into.
All final decisions concerning tank remanent life and next inspection intervals will be at the
discretion of the Engineering Manager.

16. Reporting
The TIA should maintain daily communication with the Shell Engineer during the inspection period
with progress reports.
Specifically the TIA will note any concerns or non-compliances that may impact on the time that
the tank can be recommissioned.
A draft (site) report will be completed before the TIA leaves the site. The draft report will outline
any issues that should be addressed before the tank is recommissioned. As a minimum the draft
report should include a discussion on the necessary repairs or uncertainties that will impact on
whether the tank can be recommissioned.
If the TIA is immediately uncertain of the data, and would need to verify compliance that cannot
be done immediately then this must be completed within 2 days of the inspection. This time can be
extended after agreement from the Engineer.
The final report should normally be complete within 2 weeks of the inspection.
The reports are to be supplied in PDF, HTML on CD and in hard copy formats. It should be signed
by the Tank Integrity Assessor.
The items that are expected to be in the report will vary depending on final inspection scope, but
should generally include:
Report Cover Sheet (refer below for details)
Tank Data Sheet (refer below for details)
Summary of Results for tests completed
Recommendations for tank repairs and/or re-rating.
Remnant life calculations and recommendations for RBI regime going forward
Test details and procedures used, including equipment (can reference standard TIA
company in-house procedures as appropriate).
Restrictions of the data
Tank layout drawings for shell, floor, and roof. Areas of corrosion to be identified.
Floor corrosion mapping as can be determined from MFL and ultrasonic floor scanning.
Thickness data sheets for roof, shell and floor, manholes and nozzles. Highlighting areas
of corrosion.
Confirmation that al plates have had an inspection activity regardless whether they have
any non-conformance noted.
Other NDT results, such as MPI, settlement, or tilt data. Key NDT data should have X-Y
coordinates identified.
Completed visual inspection checklist and detailed visual plate report with corresponding
maintenance recommendation.
Calculations of corrosion rates, remaining life, Code minimum allowable thickness and
next inspection date.
Records of coupons removed, repaired etc, with number, size, plate number and x-y
coordinate of center.

Photographs, preferably digital.
Report Cover Sheet

The report cover sheet is to be fully completed, together with a colour photograph of the tank. This
will constitute the first page. It will include as a minimum:
Tank No
Terminal
Location
Date of Inspection
Inspection Company name of company, name of inspector, and signatory
TIA individual report number.
Tank Data Sheet

The TIA will be required to confirm or complete the tank data that is to contain detailed
information on the tank, including such information as:
History year constructed, design code, last painted (internal and external), last inspected
(on stream and off stream).
Service product stored, lead contaminated, sg.
General details diameter, height, nominal capacity, safe fill height
Shell number strakes, height and thickness of each strake, weld type (or rivets), joint
efficiency, shell material, external insulation
Nozzles list duty and size of all nozzles.
Foundation type, hold down bolts, seal design
Floor cone up/down, no sumps and location, construction details, number plates,
number annular plates, original design thickness of plates, cathodic protection
Roof roof type, construction, frangible joint installed, emergency venting, nominal plate
thickness, support structure design, roof manholes, number of vents.
Tank fittings vent type and size, level gauge type, Hi level alarm, IFC and other fittings of
note.
16.1 Repair Report
Upon completion of the tank repairs, the TIA should be requested to return to site to certify
that all repairs to the tank have been correctly executed and to document accurately, all
works undertaken.
This may be a supplementary report, with reference to the original reports
recommendations.

Appendix A Sample Non API Surveillance Checklist
Operation Surveillance Check for Vertical Above Ground Tanks
Site Name Surveillance Conducted By Surveillance Date
Organisation
Name
Tank No.
Compliance9
Item Item Acceptance Criteria/Ref. Yes No Note Fault & Rectification

No Completed/Action
Standard
Required.
1.0 Tank Structure

1.1 Tank Shell Any areas of flaking paint or corrosion.
Note wind girder and floor to shell areas?
Tank Shell joints Any signs of any weeping, leaks or
wetness from any of the welded or
riveted shell joints?
1.2 Stairs, handrails Any corrosion areas or flaking paint on
and walkways. stairways, treads, walkways, handrails. &
underside of stair landings. Any structural
damage?
1.3 Fixed Roof Any visible damage, excessive corrosion
or abnormal penetrations in roof plates?
2.0 Foundation
2.1 Foundation shape Is the original foundation shape retained?
2.2 Foundation Are there signs of cracks or differential
settlement? Does it allow water to drain
away from the tank edge?
2.3 Foundation water Are there signs that water is retained on
retention shoulder areas?
3.0 Tank Fittings
3.1 Valve operation Are the valves free to operate and do the
spindles have lubrication?
3.2 Security Valve and Are all the valves not open/in use locked?
openings Are all spare nozzles, drain points etc
positively secured by cap, plug or blank?
3.3 Vents Are vents operating correctly, no blockage
by insects or bird nests?
3.4 Pressure vacuum Is the vent sealing? Are there sources of
vent operation vapour leakage from other tank roof
fittings?
3.5 Manometer Correct operation, no cracks or damage?
3.6 Earthing connection Is there any fraying of cables, or
and conductors damaged or corroded conductors,
connections or earth stakes?
3.7 Other tank roof Are they all in serviceable condition, free
fittings from damage and corrosion?

Tank No.
Compliance9
Item Item Acceptance Criteria/Ref. Yes No Note Fault & Rectification

No Completed/Action
Standard
Required.
4.0 Fire Protection (Where fitted)

4.1 Cooling sprays & Any blockage with debris or any visible
deflector plates corrosion?
4.2 Base foam injection Is the valve open?
valve
4.3 Top foam pourer Are there any signs of corrosion or
blockage to the pourer, aerator or supply
piping? Are pipe brackets to tank secure?
5.0 Internal Floating
Cover- Floating
Roof
5.1 Internal Floating Observe floating roof through air scoop.
Cover (IFC) Is there any product or product stains on
the blanket? Any evidence of damage?
5.2 IFC seal Is there sign of damage? Is the seal in
the correct position and evenly located
around the tank shell?
5.3 Floating Roof (FR) Are roof pontoons free from water and
product?
5.4 FR drain Is the drain free of debris & no blockage?
5.5 FR Drain non return Is the NRV free to operate?
valve
5.6 FR siphon drain Are the siphon pans to be full of water?
6.0 Overfill
Protection
6.1 Independent hi-hi Does the alarm operate correctly?
level alarm
6.2 Tank hi level alarm Does the alarm operate correctly?
7.0 Other
7.1 Floating Suction If fitted, using the lifting cable is the
floating suction free to operate?
Are lifting cable bonding wires fitted
correctly and free from damage.
7.2 Stock Control Are tank losses within acceptance criteria?
7.3 Insulation Is the insulation cladding weather proof
(If applicable) and free from damage? Is there evidence
of corrosion under the insulation? Is there
evidence of water penetration?
7.4 Auto Level Gauges Is the Auto-level gauge functioning? Is
(Where fitted) the temperature device functioning? Are
the still pipe bellows or fittings in good
condition? Is all cabling in good
condition?
7.5 Tank Side Gauge Is the side gauge functioning correctly?
7.6 Bund (Dyke) Is the bund valve closed and free to
operate? Is the bund area sound?

Recommended Practice - Inspection of Vertical Cylindrical Steel Atmospheric Storage Tanks1

Enviado por

Dados do documento

Direitos autorais

Formatos disponíveis

Compartilhar este documento

Compartilhar ou incorporar documento

Opções de compartilhamento

Você considera este documento útil?

Este conteúdo é inapropriado?

Direitos autorais:

Formatos disponíveis

Recommended Practice - Inspection of Vertical Cylindrical Steel Atmospheric Storage Tanks1

Enviado por

Direitos autorais:

Formatos disponíveis

Distribution Operational Excellence Approved for Use July 2006

Inspection of Vertical Steel Tanks Next Scheduled Update July 2007

Downstream - Supply and Distribution

Inspection of Vertical, Cylindrical Steel Atmospheric

1. Introduction & Scope 4 11.3 Tank Nozzles 20

2. References 6 12. Tank Roof Inspection 21

4. Operator - Routine in-service inspections 8 12.2 External Floating Roofs 21

4.1 API Statutory Surveillance 8 12.3 Roof Nozzles 21

4.2 Non API Surveillance 8 13. Tank Floor Inspection 22

5. In-Service Technical Inspections. 10 13.1 Plate Thickness 22

6. Out of Service Technical Inspection 11 13.2 Floor Plate Welds 23

10.2 Photography 17 16. Reporting 27

11.1 Plate thickness 18 Appendix A Sample Non API Surveillance

Version 1.0 Page 1 of 30 Confidential to Shell

Downstream - Supply and Distribution

The Inspection of Vertical Cylindrical Aboveground

July 2006 First Issue 1.0 VN KB TJ

Version 1.0 Page 2 of 30 Confidential to Shell

Version 1.0 Page 3 of 30 Confidential to Shell

1. Introduction & Scope

Version 1.0 Page 4 of 30 Confidential to Shell

Version 1.0 Page 5 of 30 Confidential to Shell

Document Number/Ref Title

API std 653 Tank Inspection, Repair, Alteration and Reconstruction

API RP 575 Guidelines and Methods for Inspection of Existing Atmospheric

Distribution Engineering Atmospheric Vertical Above Ground Storage Tanks

Version 1.0 Page 6 of 30 Confidential to Shell

Version 1.0 Page 7 of 30 Confidential to Shell

4. Operator - Routine in-service inspections

4.1 API Statutory Surveillance

4.2 Non API Surveillance

Version 1.0 Page 8 of 30 Confidential to Shell

Roof drain sump

Version 1.0 Page 9 of 30 Confidential to Shell

5. In-Service Technical Inspections.

Version 1.0 Page 10 of 30 Confidential to Shell

6. Out of Service Technical Inspection

Version 1.0 Page 11 of 30 Confidential to Shell

7. Tank Integrity Assessor

Version 1.0 Page 12 of 30 Confidential to Shell

8.1 Ultrasonic Equipment

8.2 Magnetic Flux Floor Scanning/Mapping Equipment

Version 1.0 Page 13 of 30 Confidential to Shell

8.3 Visual Inspection Equipment

Version 1.0 Page 14 of 30 Confidential to Shell

9. Plate Numbering and Datums

Version 1.0 Page 15 of 30 Confidential to Shell

10. Visual Inspection

10.1 Tank Mapping and Layout

Version 1.0 Page 16 of 30 Confidential to Shell

Version 1.0 Page 17 of 30 Confidential to Shell

11. Tank Shell Inspection

11.1 Plate thickness

11.1.1 Selection of Scans

Vertical scans should be at approximately equal intervals around the tank

11.1.2 External Scanning

Version 1.0 Page 18 of 30 Confidential to Shell

11.1.3 Internal Shell Measurements

11.1.4 Additional Readings

Version 1.0 Page 19 of 30 Confidential to Shell

thickness should be determined by scanning the perimeter of the welded joints

11.2 Rivet Joints

11.3 Tank Nozzles

Version 1.0 Page 20 of 30 Confidential to Shell