API RECOMMENDED PRACTICE 575
INSPECTION OF ATMOSPHERIC AND LOW-
PRESSURE STORAGE TANKS
First Edition, November, 1995
Charlie Chong/ Fion Zhang
SECTION 1 - SCOPE
Atmospheric and low-pressure storage tanks that have been in service.
SECTION 3 - SELECTED NONDESTRUCTIVE EXAMINATION
(NDE) METHODS
3.1 Ultrasonic Thickness Measurement
This section is a discussion of thickness measurements and Dual-element
verses single-crystal transducers. The doubling phenomena is mentioned.
3.4 Magnetic Floor Testing
RP 575 now recognizes magnetic floor scanning. MFLT (Magnetic Flux
Leakage Testing) is one of the more common types of floor tests. It can be
used on bare floor or on some coatings. The principal is basically flooding the
area with a magnetic field and measuring any changes in the field. This
display will appear on a CRT (Cathode Ray Tube). One of the main
limitations of this type of testing is the problem of distinguishing between
surface roughness and a through floor pin hole. The process will not evaluate
the welds or weld areas. Even with those problems, this is one of the fastest,
best methods for inspecting the bottom side or soil side of most tanks.
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SECTION 4 - TYPES OF STORAGE TANKS
4.1 General
Storage tanks are used in a wide variety of industries for a wide range of
products. Basically, our discussion will deal primarily with those that store
crude oil, intermediate and finished products, chemicals, water and a general
assortment of other products.
For our purposes, the inspection, evaluation and comments dealing with
future service conditions and limitations can all be generally categorized
together, since conditions that would change the serviceability or repair needs
for a tank are basically identical, regardless of the product stored. Other than
diameter and height, the only other two (2) service factors to be considered
are the specific gravity and temperature of the product.
4.1.1 Linings as covered in API RP 652 and cathodic protection API RP 651.
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4.2 Atmospheric Storage Tanks
Those that have been designed to operate in their gas and vapor spaces at
internal pressures which approximate atmospheric pressure. (≤2.5psig)
4.2.2 Use of Tanks
Atmospheric storage tanks are used to store materials having a true
vapor pressure (at storage temperature) which is substantially less than
atmospheric pressure.
NOTE: Vapor Pressure is the pressure on the surface of the liquid caused by
the vapors of the liquid. Vapor pressure varies with temperature, inasmuch as
that more of the liquid vaporizes as the temperature rises.
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4.3 Low-Pressure Storage Tanks
4.3.1 Description and Design of Low-Pressure Storage Tanks
Low-pressure storage tanks are those designed to operate at pressures in
their gas or vapor spaces exceeding the 2.5 pounds per square inch gauge
pressure permissible in API Standard 560, but not exceeding 15 pounds
per square inch gauge. Low-pressure tanks are usually built to API
Standard 620.
■ Exceeding 15 pounds per square inch gauge API520
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SECTION 5 - REASONS FOR INSPECTION
AND CAUSES OF DETERIORATION
5.1 Reasons for Inspection
a. Reduce the potential for failure and the release of stored products.
b. Maintain safe operating conditions.
c. Make repairs or determine when repair or replacement of a tank may be
necessary.
d. Determine whether any deterioration has occurred and, if so, prevent or
retard further deterioration.
e. Keep ground water, nearby waterways and the air free of hydrocarbon and
chemical pollution.
5.2.1 External Corrosion
a. External (underside) tank bottom corrosion results from contamination in
the pad. Cinders contain sulfur compounds that become very corrosive
when moistened.
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b. Electrolytic corrosion (pitting type) results when clay, rocks, oyster shell,
wooden grade stakes, etc., come in contact with the underside bottom, as
they attract and hold moisture.
c. Poor drainage from faulty pad preparation.
d. Lower external shell corrosion due to:
i. Settlement, with corrosion at soil grade line
ii. Casual water collection point
iii. Insulation moisture “wicking”.
e. Shell appurtenances are subject to crevice corrosion at non-seal welded
joints (angles/flats).
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5.2.2 Internal Corrosion
a. Primarily dependent on product stored.
b. Corrosion resistant linings are most common preventative.
c. Normal locations and causes are:
i. Vapor space (above the liquid). Most commonly caused by H2S vapor,
water vapor, oxygen or a combination of the three.
ii. Liquid area. Most commonly caused by acid salts, H2S or other sulfur
compounds.
d. Other forms of internal attack, considered as forms of corrosion are:
i. Electrolytic corrosion.
ii. Hydrogen blistering.
iii. Caustic Embrittlement.
iv. Graphitic corrosion (cast iron parts).
v. Dezincification (brass parts).
In the areas covered by the stored liquid, corrosion is commonly
caused by acid salts, hydrogen sulfide or bottom sediment and
water (BS&W).
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5.3 Deterioration of Non-Steel Tanks
a. Both wooden and concrete tanks may require inspection.
b. Potential problem areas:
i. Wood - subject to rotting, attack by termites, subject to shrinkage,
corrosion of the steel bands.
ii. Concrete - internal corrosion, cracking due to settlement or temperature
change, spalling (exposes reinforcement and corrodes due to
atmosphere).
c. Tanks constructed of other materials (i.e., alloy or aluminum) can present
special problems, but are subject to the same mechanical damage
potential as steel tanks.
d. Other nonmetallic tanks (i.e., plastic, fiberglass or glass reinforced epoxy)
may present special problems, but will not be discussed in this
presentation.
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5.4 Leaks, Cracks and Mechanical Deterioration
a. Leaks, whatever the cause, can cause serious economic losses or
environmental damage resulting in fines or penalties by governmental
agencies. These, however, pale in comparison to the problems associated
with the instantaneous (catastrophic) failure of a shell with resulting loss of
the entire tank, the product stored, plus perhaps all surrounding structures.
b. Plate cracking is always of prime importance when inspecting tanks.
Cracks can result from a wide variety of causes. The more frequent
causes are:
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i. Faulty welding.
ii. Unrelieved stress concentrations (i.e., stress raisers) around fittings or
appurtenances.
iii. Stress caused by settlement or earth movement, especially differential
settlement
iv. Vibration
v. Poorly designed repair or “sloppy” craftsmanship.
vi. most likely points of occurrence are:
• Shell to bottom junction.
• Around nozzle and manway connections.
• Around rivet holes.
• At welded brackets.
• At welded seams.
NOTE: The lower shell to bottom sketch plate is especially critical in
relatively larger or hot tanks. It can act as a plastic hinge with the
potential for cracking. See API 650 (Appendix “M”).
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c. Many other kinds of mechanical deterioration can develop. In earthquake
areas, sloshing damage may occur to roofs. Shell buckling (directly above
bottom) can occur in tanks having relatively large height to diameter ratios.
d. Another form of mechanical deterioration is settlement. Frequent causes
are:
i. Freezing/thawing of the ground.
ii. Unusually high tides in tidal areas.
iii. Slow lateral flowing of the soil.
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5.5 Failure of Auxiliary Equipment
a. Frequent problem areas are associated with pressure/vacuum
conservation vents.
b. Most common problems are:
i. Collection of “gummy” residue on pallets.
ii. Moving parts, guide and seat corrosion.
iii. Foreign deposits (by birds or insects).
iv. Ice formation.
v. Tampering.
vi. Adding extra weights to pallets (which changes release point of vapor).
vii. Lay-down of sand from abrasive blasting.
NOTE: Quite often, vents are the only safety relief device available to prevent
pressure or vacuum damage.
c. Other potential auxiliary problem areas:
i. Malfunction of gauging system.
ii. Floating roof drains.
iii. Plugged drain sumps (debris or ice).
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SECTION 6 - FREQUENCY OF INSPECTION
API Standard 653 provides requirements for inspection frequency, including
factors to consider in determining inspection frequency.
SECTION 7 - METHODS OF INSPECTION AND INSPECTION
SCHEDULING
The first part of this section deals with safety aspects of entry. The next
section is a current list of tools commonly used in tank inspection and a
suggested list of equipment that might be needed in tank inspection.
7.2 External Inspection of In-Service Tank
See Appendix C, Table C-1 and C-2 of this RP.
7.2.3 Foundation Inspection Refer to API Standard 653 for limitation.
7.2.4 Anchor Bolt Inspection
The condition of anchor bolts can usually be determined by visual
inspection. The hammer and UT thickness methods are also described in
this section.
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7.2.6 Grounding Connection Inspection
The total resistance from tank to earth should not exceed approximately
25 ohms.
7.2.8 Insulation Inspection
Under insulation corrosion is now considered to be a more severe
problem than previously thought.
a. A visual examination is usually, but not always, sufficient to spot problem
areas.
b. Areas to be more closely checked include:
i. Around all nozzles and appurtenances, especially if the caulking bond is
loose or points for casual water entry is evident.
ii. Around saddles where movement or expansion may have damaged
insulation or seal.
iii. Around open-bubbles on polyurethane foam systems.
iv. Along bottom edge where moisture “wicking” may have occurred.
v. Along roof to shell junction, unless this area is protected by an overhand
“rat-guard” type insulation support brackets (where block insulation is
used).
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[Link] Thickness Measurements
Ultrasonic-thickness measurements should be conducted only by trained
personnel using a properly calibrated thickness measurement instrument and
an appropriate thickness measurement procedure.
[Link] Caustic Cracking
If caustic or amine is stored in a tank, the tank should be checked for
evidence of damage from caustic stress corrosion cracking
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7.4.4 Tank Bottoms
This section suggests inspection of the entire tank bottom by using
Magnetic Flux Leakage, looking for bottom side corrosion. Other UT type
techniques may also be used. A-scan or shear wave ultrasonic testing
may be used under specific conditions. Hammer-testing is also mentioned
as a testing technique.
7.4.6 Testing for Leaks
The usual types of tests are mentioned, hydrostatic tests, vacuum box
tests, external water bottom tests and tracer gas tests. Another method
being used successfully is the injection of inert gas with a tracer gas under
the tank. Instruments capable of detecting a few parts per million (PPM)
of the tracer gas are then used for “sniffing” for leaks on the topside of
the tank floor. An advantage of such a method is that welded repairs can
be made immediately with the inert gas under the bottom and a re-check
can be made immediately after repairs.
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7.5 Testing of Tanks
The word testing, as used in this subsection, applies only to the process of
filling the tank with a liquid or gaseous fluid, at the appropriate level or
pressure, test the tank for strength or leaks.
7.6 Inspection Scheduling
The two main aspects to consider when inspecting a tank:
a. the rate at which deterioration is proceeding; And
b. the safe limit of deterioration.
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The following may be used for most common forms of deterioration, metal
corrosion, the rate of metal loss and the remaining life of a tank component.
Corrosion Rate = Δt/ interval
7.7 Inspection Checklists
Inspection checklists should be used judiciously by the inspector as “memory
joggers” for issues and items to be checked during inspection, both internal
and external.
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