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API 653 TANK INSPECTION,
TANK MAINTENANCE,
AND
CAUSES OF TANK FAILUREPresented for
FAR WEST AGRIBUSINESS ASSOCIATIONS
Presented by: Chris Brooks
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API 653 Tank Inspections
Why Inspect Your Tanks?
• Prevent leaks into your secondary containment or to groundwater (if you do not have a secondary containment system)
• Establish a baseline of tank condition and corrosion rates
• Identify problems to perform repairs before you have a significant leak or release - Maintain your capital asset
• Minimize chance of catastrophic tank failure
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PROPER INSPECTION PROTOCOL
INSPECTOR CREDENTIALS
• Certified API 653 Inspector
Four years minimum experience with storage tanks
Must pass test conducted by American Petroleum Institute (API)
Inspectors receive an individual inspector number
Inspector testing required every three years
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PROPER INSPECTION PROTOCOL
• Visual inspection of welds, plates, and appurtenances
• UT (Ultra-sonic Thickness) testing of shell courses, floor, and roof
• Vacuum testing of all floor weld seams – unless epoxy coated
• Identify bottom side corrosion on floors
• Settlement Survey
Checking for planar tilt
Check for floor bulges or depressions
• Provide calculations for safe or maximum fill height
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Weld deterioration
Plate corrosion
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Interior piping corrosion
Shell corrosion
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Interior piping corrosion
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Weld deterioration and four-way junction – NON API
Four-corner insert with reinforcing backup – NON API
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Evidence of interior shell corrosion
Foundation evaluation
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Floor plate corrosion
Lap-welded seam leak
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Floor coupon with bottom side corrosion
Floor top side corrosion
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Severe roof corrosion
Star light . . . Star bright!
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Salting out of liquid fertilizer in lined tank
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TANK INSPECTIONS ARE NOT ALWAYS A BAD THING
THIS IS A HAPPY TANK
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TANK MAINTENANCE – COMMON SENSE APPROACH
• Conduct monthly/weekly walk-around of your tank(s)
• Look for stains on steel where leak may be occurring
• Check valve function and nozzle welds
• Check associated piping
• Check foundation for wash-out/deterioration
• Keep good records of product in and out
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TANK MAINTENANCE – COMMON SENSE APPROACH
• Open up your tank a minimum of every two years and conduct your own visual inspection inside
• Check for weld deterioration and corrosion
• If tank is coated, visually check coating for blisters or cracks
• Keep a record of inspections and results
• If tank has an internal containment liner, check leak monitor weekly• Conduct an API-653 inspection of your tank every five years as
recommended by TFI (The Fertilizer Institute)
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WHAT IS THE API 650 SPECIFICATION
API - AMERICAN PETROLEUM INSTITUTEWorldwide Standard for Above Ground Storage Tank Design and New Tank Construction
• Provides requirements for calculations of shell plate thickness, man-way and nozzle design
• Provides procedures for shell, roof and floor construction
• Specifies material requirements and minimum thickness requirements
• Specifies weld construction requirements, weld spacing, and x-ray requirements
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CAUSES OF
CATASTROPHIC
TANK FAILURE
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TANK FAILURES – COMMON CAUSES
• #1 Cause: CorrosionWeld deterioration/corrosion – especially in lower horizontal
and vertical seams
• #2 Cause – Lack of Weld Penetration
Lack of full weld penetrations (lack of weld fusion)
Improper weld seam spacing
Lack of radiograph (x-ray) of newly constructed tanks or on repaired tanks
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TANK FAILURES – COMMON CAUSES
• # 3 Other CausesOperational errors
Over-filling of tank – excessive pressure
Brittle fracture of steel
Poorly designed or inappropriately installed
Lack of proper certified inspection
Tank erectors who know little about API Specifications and procedures – these companies attract customers with a “cheap” price. Make certain your contractor can verify that your tank meets API Specifications. DO YOUR OWN HOMEWORK
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Cut-down and re-welded tank
Improper weld spacing
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Double wall 500,000 gallon tank, Illinois 2008
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Original tank foundation
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