Tank Inspection Checklist: Steps to Ensure Safety and Extend Service Life
Introduction: Tanks are an essential component of many industrial processes. It is vital to ensure their safe operation and extend their service life. Proper inspection and maintenance are crucial for preventing accidents and minimizing the risk of failure. This article provides a tank inspection checklist to ensure safety, extend service life, and comply with industry standards and codes.
Step 1: Check the Tank Drawing and Material of Construction Before starting the inspection, review the tank drawing, construction codes, and material of construction. This step will help you to identify the tank’s internal parts and dimensions, such as diameter, height, and thickness. Knowing the tank’s history will give you an idea of its current condition and help you to plan the inspection accordingly.
Step 2: Obtain Entry Permit and Carry Out Joint Inspection Ensure that the tank is safe to enter and inspect by carrying out a joint inspection. Check ventilation, blinds, scaffolds, and lighting. Obtain an entry permit from the operation to enter the tank. During the inspection, keep a man watch for safety.
Step 3: Primarily Carry out External Inspection Carry out an external inspection of the tank for external leaks, external damage, insulation, or paint damage, and external corrosion. Ensure the tank is isolated with proper blinds. Before internal inspection, obtain an entry permit from operation and perform an entry gas test to ensure no toxic gases are released.
Step 4: Start Preliminary Inspection at All Manways Start the preliminary inspection at all manways going from bottom to top. Record the observations on a notepad at each level. Assess the conditions of nozzles, tank bottom plates, tank shell plates, and tank internal hardware such as columns, float, supports/legs, and sumps. Identify each item and note the observations for your inspection evaluation.
Step 5: Perform Detailed Inspection While performing detailed inspection, look for pitting corrosion, erosion/corrosion, channeling, weld erosion/corrosion and cracks, mechanical damages while opening and closing, environmental cracking, bulging and blistering. Coating conditions, if coated, should also be evaluated. A Fitness for Service inspection (FFS) assessment may be required, and a full evaluation from design, operation, and history of operation can increase the service life of the tank.
Step 6: Request Repairs and Cleaning as Applicable After the full inspection, request any other needs for cleaning or removal and cleaning of internals for detail inspection and repairs or renewal if any. Follow up on the recommendations and related repairs per industry standards and codes, including ASME and API.
Step 7: Conduct Final Inspection Carry out the final inspection upon completion of repairs and cleaning as applicable. Assess the tank’s condition for operation during the next EIS period. If the tank has undergone a Fitness for Service assessment and can go through minimally the EIS period, then request a change of EIS schedule. If necessary, request replacement of the tank plates.
Step 8: Comply with Industry Standards and Codes Ensure that all inspections, tests, and repairs comply with industry standards and codes, including SAEP-20, SAEP-302, SAEP-326, SAES-D-008, SAES-W-010, SAES-W-015, ASME SEC VIII D1, API STD 510, and API STD 653. Any repair to the tank will be hydrostatically tested per SAES-A-004. Test procedure shall be provided by the operation engineer of the unit, or waivers shall be submitted per SAEP-20 in advance. The test or waiver documents shall be filed for reference.
In conclusion, inspecting and evaluating tanks is a crucial step in ensuring their safety and longevity. By following the proper steps and complying with industry standards and codes, such as SAEP-20, SAEP-302, SAEP-326, SAES-D-008, SAES-W-010, SAES-W-015, ASME SEC VIII D1, API STD 510, and API STD 653, you can identify any potential issues and take necessary measures to address them. Remember to prioritize safety during inspections by obtaining entry permits, isolating the tank with proper blinds, and performing gas tests. By conducting regular inspections and maintenance, you can extend the service life of your tanks and avoid costly repairs or replacements down the line.