PRESENTATION ON

STORAGE TANKINSPECTIONS

• Installations use tankages of various types and sizes to store

initial, intermediate and finished petroleum product and hence

the failure of any part of a tank may result in a disaster.

• Timely inspection an preventive maintenance will go a long

way in making a tank safer to store products for longer periods

of time

HORIZONTAL ABOVE GROUND TANKS

• INSTALLED ON PEDESTALS

• SMALLER CAPACITY (UPTO 400 KL)

VERTICAL ABOVE GROUND TANKS

• RESTED ON SAND / RCC FOUNDATION PADS

• MADE OF MILD STEEL PLATES

• WITH EITHER FIXED OR FLOATING ROOF

ABOVE GROUND TANKS

FITTINGS ON FIXED ROOF TANKS MANHOLES DIP HATCH DATUM PLATE TEMPERATURE / SAMPLE HATCH INLET / OUTLET VENTS PV VALVE WATER DRAW OFF LINE SAFETY RAILINGS STAIRWAYAS EARTHIING CONNECTIONS EXPANSION LINE FIRE WATER SPRINKLER SYSTEM FOAM POURER AUTO LEVEL GAUGES

FITTINGS ON FIXED ROOF TANKS

ADJUSTABLE LEGS FOAM SEAL ROOF BLEEDER VENTS ROOF WATER DRAIN EMERGENCY DRAIN ROOF LADDER WIND GIRDER GAUGEWELL PIPE MANHOLES ON SHELL & ROOF GAUGE HATCH WITH COVER DATUM PLATE PRODUCT INLET / OUTLET NOZZLE TANK WATER DRAIN VALVE FOAM NETWORK SPRINKLER LANDING PLATFORM STAIRWAY EARTHING EXPANSION LINES

FITTINGS ON FLOATING ROOF TANKS

SAFE OPN.OF FLOATING ROOF TANKS

• OPERATION OF FLOATING ROOF TANKS NEEDS CLOSER SUPERVISION AND ADDITIONAL MEASURES.

• ACCESS TO FLOATING ROOF SHALL BE RESTRICTED.

• WHENEVER ANY PERSON IS ALLOWED ON THE ROOF, KEEP STAND BY PERSON ON LANDING PLATFORM.

• CHECK FOR PETROLEUM VAPOUR ON THE ROOF. USE BREATHING APPARATUS WHENEVER NECESSARY.

• NO ONE SHOULD BE ALLOWED ON THE FLOATING ROOF DURING PRODUCT RECEIPT OR WHEN ROOF IS AT LOWER LEVELS.

• IF ABSOLUTELY NECESSARY TO GO ON THE ROOF, THE PERSON SHALL WEAR BREATHING APPARATUS AND STANDBY PERSONS ON LANDING PLATFORM.

SAFE OPN. OF FR TANKS (CONTD.)

• KEEP GAUGE HATCHES OR OTHER OPENINGS CLOSED EXCEPT FOR ESSENTIAL OPERATIONS

• GAUGE HATCH SHALL NOT BE SLAMMED WHILE CLOSING. IT SHOULD NOT BE LEFT OPEN AFTER GAUGING .

• GAUGING SHOULD NOT BE CARRIED OUT DURING THUNDER STORM OR LIGHTN1NG.

• DEVELOP PROCEDURES TO PREVENT OVERFILLING. IF FITTED, CHECK HIGH LEVEL ALARMS MONTHLY FOR OPERABILITY.

• ROOF SHOULD ALWAYS REMAIN IN FLOATING CONDITION WHILE TANK IS BEING FILLED OR EMPTIED OUT. DO NOT KEEP THE TANK IN SEMI FLOAT CONDITION

SAFE OPN. OF FR TANKS (CONTD.)

• KEEP THE ROOF AFLOAT DURING NORMAL OPERATION. LANDING OF ROOF CREATES VAPOUR SPACE SO THAT THE INHERENT SAFETY ADVANTAGES OF FLOATING ROOF TANKS ARE LOST.

• WITHDRAWAL OF PRODUCT FROM THE TANK SHALL BE AVOIDED WHEN THE ROOF IS EITHER RESTING ON ITS PIPE SUPPORTS OR IS IN SEMI FLOAT CONDITION, AS THIS RESULTS IN APPARENT PRODUCT LOSS.

SAFE OPN. OF FR TANKS (CONTD.)

• IF THE PRODUCT IS TO BE WITHDRAWN UP TO THE DEAD STOCK LEVEL, ENSURE THAT ALL PIPE SUPPORTS ARE IN RIGHT POSITION AND ROOF BLEEDER VENTS ARE IN OPERATING CONDITION

• IF AT ANY TIME THE ROOF GETS STUCK OR LIKELY TO GET STUCK, TANK SHALL NOT BE OPERATED TILL IT IS INSPECTED BY ENGG PERSONNEL

• REMOVE PROMPTLY ANY ACCUMULATION OF OIL ON A ROOF DECK. THE FIRE PROTECTION SYSTEM IS DESIGINED FOR RIM FIRE ONLY AND NOT FOR LARGE EXPOSED SURFACES OF OIL

• IF OIL APPEARS AT THE ROOF DRAIN OUTLET, CHECK THE ROOF IMMEDIATELY TO ESTABLISH ITS SOURCE.

CRITICAL LEVEL OF FLOATTNG ROOF TANKS

DURING OPERATION AND GAUGING OF FLOATJNG ROOF TANKS:

• IT IS NECESSARY TO KNOW THE POSITION OF THE ROOFi.e. WHETHER IT IS FULLY FLOATING, PARTIALLY IMMERSED OR RESTING ON LEGS

• WHEN ROOF IS FULLY FLOATING, IT DISPLACES ITS OWN WEIGHT OF OIL AND THE TANK CAN BE GAUGED

• WHEN THE ROOF IS PARTIALLY IMMERSED, ITS ACTUAL DISPLACEMENT IS UNCERTAIN. SO THE GAUGING OF THE TANK SHOULD NOT BE UNDERTAKEN, AS OIL QUANTITY CALCULATION WILL NOT BE ACURATE.

• WHEN ROOF IS RESTING ON LEGS, THE TANK IS LIKE CONVENTIONAL CONE ROOF TANK AND THUS TANK CAN BE GAUGED CORRECTLY. HOWEVER THERE WILL BE LOT OF VAPOUR LOSS IN THIS CONDITION.

RECALIBRATION OF TANKS – EXCISE REQUIREMENTS

GOVERNMENT OF INDIA HAS LAID DOWN THE FOLLOWING PROCEDURE FOR RECALIBRATION OF TANK :

VALIDITY OF CALIBRATION CHART

• BESIDES CPWD, WEIGHTS, & MEASURES DEPT. OF THE STATES / UNION TERRITORIES HAVE ALSO BEEN APPROVED FOR CALIBRATION OF STORAGE TANKS.

• FOR TANKS WITH WATER BOTTOM, RECALIBRATION SHOULD BE CARRIED OUT AFTER TEN YEARS

• FOR TANKS WITH OIL BOTTOM, RECALIBRATION SHOULD BE CARRIED OUT AFTER FIVE YEARS.

TANK FARM OPERATIONS

FOLLOWING DETAILS SHALL BE INDICATED ON THE TANK SHELL NEAR STAIRCASE:

• TANK NO., PRODUCT GRADE, CAPACITY IN LITRES, DATE LAST CLEANED AND DUE DATE OF NEXT CLEANING, DATE LAST CALIBRATED AND DATE OF LAST EARTH TEST. TANK NO. AND GRADE SHALL BE INDICATED BOLDLY ON THE UPPER STRAKE SO AS TO BE VISIBLE FROM A DISTANCE.

• TYPE OF VALVE, i.e. INLET, OUTLET, PRODUCT DRAIN, WATER DRAIN, SHALL BE INDICATED ON THE TANK SHELL BEHIND THE RESPECTIVE VALVES, WITH THE DIRECTION OF OPENING AND CLOSING MARKED WITH ARROWS.

• TANK EARTH RESISTANCE SHALL BE CHECKED AT LEAST ONCE IN SIX MONTHS AND SHALL BE MAXIMUM 7 OHMS.

• VENTS OF THE TANK SHALL BE CHECKED ONCE A QUARTER TO ENSURE THAT THEY ARE FREE OF ANY CLOGGING.

• SETTINGS OF PV VALVES SHALL BE CHECKED EVERY 6 MONTHS. THE SETTINGS IN TERMS OF W.G. FOR PRESSURE AND VACUUM RESPECTIVELY SHALL BE 21. 5” AND 2.5” FOR ABOVEGROUND TANKS AND 10” AND 1” FOR UNDERGROUND TANKS.

• SAFE HEIGHT (CORRESPONDING TO 95% OF THE TANK CAPACITY) AND PROOF LEVEL SHALL BE INDICATED NEAR THE DIP HATCH.

•BUND ENCLOSURE DRAIN VALVE SHALL BE KEPT IN CLOSED POSITION EXCEPT WHEN DRAINING OUT RAIN WATER

•BUND AREA SHALL BE CLEAR OF VEGETATION.

•BUND WALL SHALL BE INTACT WITHOUT ANY GAPS.

•TANKS SHALL BE CLEANED EVERY 5 YEARS (EVERY YEAR IN CASE OF ATF AND EVERY 2 YEARS IN CASE OF HEXANE) OR MORE FREQUENTLY, DEPENDING ON THE NEED, LIKE CHANGE IN PRODUCT, EXCESSIVE SLUDGE FORMATION, ETC.

•AN ALL LEVEL SAMPLE AFTER RECEIPT OF FIRST PARCEL IN A NEWLY COMMISSIONED TANK / AFTER GRADE CHANGE OVER SHALL BE SUBJECTED TO BATCH FORMATION TEST.

• QUANTITY OF SLUDGE REMOVED DURING TANK CLEANING SHALL BE CERTIFIED BY THE LOCATION-IN-CHARGE AND APPROVAL SOUGHT CONCURRENCE IN LINE WITH MANUAL OF AUTHORITIES. THEREAFTER, IT SHALL BE DISPOSED OFF AFTER CHECKING FOR ANY LOCAL REGULATION PROHIBITING BURIAL OF SLUDGE.

• SLOT-SLIT DIPPING DEVICE SHALL BE FITTED ON VOLATILE PRODUCT TANKS. IT IS A FITTING WITH AN OPENING JUST SUFFICIENT TO ACCOMMODATE THE WIDTH AND THICKNESS OF THE DIP TAPE AND THEREBY PREVENT LOSS OF VAPOUR DURING GAUGING.

• ONLY ONE TANK SHALL BE OPERATED AT A TIME FOR ONE PARTICULAR OPERATION, EXCEPT IN AN EMERGENCY SITUATION OR FOR VALID REASONS (NORMALLY LOCATION SPECIFIC).

• INTERMEDIATE DIPS SHALL BE TAKEN AT THE END OF THE SHIFT OR IF A TANK IS USED FOR ANOTHER ACTIVITY DURING THE DAY TO ASSESS THE STOCK VARIATIONS DURING THE OPERATION.

• ALL TANKS SHALL BE GAUGED AT THE END OF THE DAY AND BOOK STOCKS UPDATED ACCORDINGLY.

• TANKWISE STOCK VARIATION SHOULD BE WORKED OUT FOR EACH PRODUCT AND ANY ABNORMAL VARIATION (MORE THAN THE SET TARGET) SHOULD BE INVESTIGATED.

• ZONE / RO SHOULD BE KEPT ADVISED OF THE ABNORMAL VARIATION AND CORRECTIVE ACTION TO BE TAKEN.

OIL WATER SEPARATOR

NEED AND CONSTRUCTION

• OIL WATER SEPARATOR (OWS), IS AN INTEGRAL PART OF TANK FARM OPERATIONS. IT IS A MANDATORY REQUIREMENT THAT DRAINS FROM LICENSED AREA SHALL PASS THROUGH AN INTERCEPTOR SO THAT OIL TRACES AND OIL SPILLAGES ARE TRAPPED BEFORE THE WATER IS LET OUT INTO THE OUTSIDE DRAINS.

• AN OWS IS OF RCC / CC/ BM CONSTRUCTION WITH 3 OR MORE CHAMBERS. EVERY CHAMBER HAS AN INLET AT THE TOP AND AN OUTLET AT ITS BOTTOM. FLOW INTO AND OUT OF THE OWS IS CONTROLLED BY INLET AND OUTLET VALVES. WHEN OIL-WATER MIXTURE ENTERS THE OWS, OIL BEING LIGHTER, REMAINS TRAPPED AND FLOATING ON WATER, WHILE WATER FLOWS INTO THE NEXT CHAMBER.

• INLET AND OUTLET VALVES SHALL BE OF RISING STEM TYPE AND WITH PROPER LOCKING ARRANGEMENT.

SAFETY CHECKLIST

SEWERS

WHETHER THE TANKFARM DRAINS ARE CLEAR?

WHETHER PROVISION EXISTS TO DIVERT TANK FARM DRAINAGE EITHER TO STORM WATER DRAIN OR TO OIL WATER SEPERATOR?

TANKS

WHETHER TANKS PROPERLY PAINTED AND IMPORTANT SPECIFICATIONS ARE MARKED ON THE TANK ?

WHETHER ALL TANKS ARE PROVIDED WITH CIRCUMFERENTIAL RAILINGS?

WHETHER THE ROOF DRAIN OF FLOATING ROOF TANKS IS PROVIDED WITH A CHECK VALVE

WHETHER ANY DEPRESSION DUE TO TANK SETTLEMENT OBSERVED ON THE TANK PAD ALONG THE CIRCUMFERENCE?

WHETHER FOAM/NEOPRENE SEALS ARE CHECKED REGULARLY FOR PERFECT SEALING AND RECORD MAINTAINED.

WHETHER ANY DOCUMENIED PROCEDURE EXISTS FOR TANK CLEANING? WHAT IS THE METHODOLOGY TO ENSURE STRICT ADHERENCE?

WHETHER THE LADDERS, STAIRWAYS ARE IN GOOD CONDITION WHETHER THE PIPELINE RELIEF VALVES ARE KEPT RELIEVING TO TANKS OR TO

OUTSIDE? WHETHER ANY INSPECTIONS ARE CARRIED OUT ON REPAIRED TANKS BEFORE

TAKING THEM INTO OPERATION? WHAT ARE THE SCHEDULES FOR PAINTING OF TANKS?

SAFETY CHECKLIST ( Contd.)

INSPECTION & MAINTENANCE :

GAUGING

GAUGING IS THE PROCESS OF TAKING ALL THE NECESSARY MEASUREMENTS IN A TANK

IN ORDER TO DETERMINE THE QUANTITY OF LIQUID CONTAINED IN IT.

GAUGING INVOLVES :1)TAKING OIL DIP IN THE TANK2)TAKING WATER DIP IN THE TANK3)OBSERVE TANK TEMPERATURE4)OBSERVE DENSITY & TEMPERATURE OF THE TANK SAMPLE.

GAUGING EQUIPMENTS:•1) DIP TAPE 5) THERMOMETER•2) DIP BOB 6) HYDROMETER•3) WATER FINDING PASTE 7) SAMPLING EQUIPMENT•4) OIL FINDING PASTE 8) SAMPLE CONTAINER

GAUGING

GAUGING IS THE PROCESS OF TAKING ALL THE NECESSARY MEASUREMENTS IN A TANK

IN ORDER TO DETERMINE THE QUANTITY OF LIQUID CONTAINED IN IT.

GAUGING TERMS:•1) GROSS DIP 10) REFERENCE HEIGHT•2) WATER DIP 11) REFERENCE POINT•3) ULLAGE DIP 12) SAFE HEIGHT•4) DIP HATCH •5) DATUM PLATE 13) DEAD STOCK•6) TEMPERATURE / SAMPLE HATCH 14) GROSS CAPACITY•7) TANK TEMPERATURE 15) SAFE CAPACITY•8) SAMPLE TEMPERATURE 16) WATER BOTTOM•9) SAMPLE DENSITY

Rev-0

Sl.No CHECKS Compliance

1 Any dripping / sweating is observed in foundation No Dripping/ Sweating

2 Proper tightening of earth strips to the tank shell No looseness

3 Whether level gauge fittings are properly secured and working properly Fully secured and wotking fine

4Condition of Roof plates / staircase/ handrails/ shell plates, any rusting observed,give location No rusting / Greasing done

5 Condition of roof and bottom nozzle welding joints No rusting/ pitting

6 Display details on tank are updated and found correct Updated details

7 Whether sprinkler lines are properly supported Fully secured

8 Proper closing of dip hatch/ other nozzles at roof Fully closed

9 Is Pressure Relief Valves / Vents are functioning properly Working fine

10Condition of rubber seal of roof ,Gushing of vapours through rubber seal if any No vapour escape

11 Condition of roof plate welding joints No rusting/ pitting

12 Continuity of wire between roof plate and Ladder, ladder and Shell plate Continuity should be there

13 Condition of paint/ protective coating

deterioration, rust spots, mechanical damage, blisters and film lifting

14 Roof drain check valve - inlet end No breakage / Blockage

Activities carried by Signature of Technicians:

Start Time :

End Time :

Signature EE

Remarks:

MAINTENANCE CHECK LIST

Working standard

CHECK LIST # INTER FACE TANK-101

Sl No/Code No : PMHBL/DKN/IF TANK/101 Date:

• Thank YouThank You