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Integrity Report-Tank Inspection
A. Summary of Inspection Findings
An API 653 Inspection was carried out on Tank C9 at 11 Plc Apapa depot in accordance with API 653
and DPR guidelines on Aboveground storage Tank inspection. The inspection covered visual, vacuum
testing, magnetic-particle inspection, dye penetrant testing and ultrasonic thickness survey.
The inspection revealed there were gouges/pits on tank bottom plates. However, a vacuum test was
conducted on each gouge/pit and there was no indication of leak observed. The bottom plate was
also noted with mild to moderate coating deterioration. However, ultrasonic thickness measurement
was carried out on bottom plates without any significant metal loss detected.
The recommendations are as follows;
1. To arrest further deterioration or corrosion and prevent loss of containment, it is
recommended that before returning the tank to service, the tank bottom be thoroughly
cleaned to remove any rust element and debris and prevent further galvanic reaction within
the plate material. This could be achieved by high pressure steam-washing or use of other
industrial cleaning agents or absorbents, such as fine particle saw-dust materials. Also,
considering that the current plate thickness is adequate to guarantee the structural integrity
of the tank bottom, it recommended that the tank bottom is prepared for sand-blasting and
coating in the next internal inspection window but not later than 5 years.
2. The gouges are potential stress points when the tank is in service and therefore should be
repaired at the next internal inspection opportunity.
Please see details of inspection in the detail section below.
The tank is in good condition and considered fit for service.
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B. Details of Inspection Findings
Starbest Inspection Services Ltd
Inspector-Rotimi Owowa API ID 72308 Date-06-Nov-2020
Client: 11 Plc Apapa Lagos Project: Inspection and Calibration of Base Oil Tanks Tank Product No: 6383
No. C9
TANK OUT-OF-SERVICE INSPECTION CHECKLIST
Completed Photo (If any)
Item Comments
C.2.1 OVERVIEW
a. Check that tank has been cleaned, is gas free, and safe
for entry.
b. Check that the tank is completely isolated from product
lines, all electrical power, and steam lines.
c. Check that roof is adequately supported, including
fixed roof structure and floating roof legs (if any)
d. Check for presence of falling object hazards, such as
corroded-through roof rafters, asphalt stalactites, and
trapped hydrocarbons in unopened or plugged
equipment or appurtenances, ledges, etc.
e. Inspect for slipping hazards on the bottom and roof decks.
f. Inspect structural welds on accessways and clips.
g. Check surfaces needing inspection for a heavy-scale
buildup and check weld seams and oily surfaces where
welding is to be done. Note areas needing more
cleaning, including blasting.
h. Review cathodic protection potential readings. X No CP system identified
C.2.2 TANK EXTERIOR
a. Inspect appurtenances opened during cleaning such as X NA
lower floating swing sheave assemblies, nozzle interiors
(after removal of valves).
b. Hammer test or ultrasonically test the roof.
c. Enter and inspect the floating roof pontoon compartments. X NA
C.2.3 BOTTOM INTERIOR SURFACE
a. Using a flashlight held close to and parallel to the bottom Moderate coating failure on plate surface
plates, and using the bottom plate layout as a guide,
visually inspect and hammer test the entire bottom.
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b. Measure the depth of pitting and describe the pitting Eight (8) Nos. pits observed. Pits were vacuum
appearance (sharp edged, lake type, dense, scattered, tested with no indication of leak.
etc.)
c. Mark areas requiring patching or further inspection.
d. Mark locations for turning coupons for inspection. X No coupons installed
e. Inspect all welds for corrosion and leaks, particularly the
shell-to-bottom weld.
f. Inspect sketch plates for corrosion.
g. Check condition of internal sump, if applicable. Standing
liquid should be removed from the sump to allow for
complete inspection and vacuum testing of weld seams
as appropriate. Sump bottom and sidewall plate and
seams need to be evaluated
for bothand
product-side
mark voidsand soil-side corrosion.
h. Locate under the bottom. None found
i. Record bottom data on a layout sketch using the See attached sketches
existing bottom plates as a grid. List the number and
sizes of patches required.
j. Vacuum test the bottom lap welds. No leaks observed
k. Hammer test or ultrasonically examine any slightly
discolored spots or damp areas.
l. Check for reinforcing pads under all bottom attached clips, None observed
brackets, and supports.
m. Inspect floating roof leg pads for pitting or cutting, and X NA
excessive dimpling (indicating excessive loading).
n. Check the column bases of fixed roof supports for X NA
adequate pads and restraining clips.
o. In earthquake zones 3 and 4, check that roof supports X NA
are not welded down to the tank bottom, but are only
restrained from horizontal movement.
p. Check area beneath swing line cable for indications of X NA
cable cutting or dragging.
q. Mark old oil and air test connection for removal and X NA
patching.
r. Identify and report low areas on the bottom that do not None found
drain adequately.
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s. Inspect coating for holes, disbonding, deterioration, and Coating failure, disbondment observed
discoloration.
C.2.4 SHELL SEAMS AND PLATE
a. On cone up bottoms, closely inspect and gauge the X NA
depth of metal loss on the lower 2 in. to 4 in. of the shell
(area of standing water).
b. Measure the depth of pitting on each course. None found
c. Inspect and estimate the amount of metal loss on the X NA
heads of rivets and bolts.
d. Inspect shell-to-bottom riveted lap joints. X NA
e. Inspect for vertical grooving damage from seal assembly X NA
protrusions.
f. Inspect existing protective coatings for damage, In good condition
deterioration, and disbonding.
g. Check for areas of rubbing (indicating too much pressure X NA
by the seal assembly shoes or inadequate annular
space).
h. Visually inspect the shell plates and seams for indications No leaks found
of leakage.
i. If the shell has riveted or bolted seams, record the leak X NA
locations by film or chart in case the locations are lost
during surface preparation for painting.
j. Measure annular space at 40-ft intervals. X NA
k. Survey the shell to check for roundness and plumb.
C.2.5 SHELL-MOUNTED OVERFLOWS
a. Inspect overflow for corrosion and adequate screening. X NA
b. Check location of overflow that it is not above any tank X NA
valves or equipment.
C.2.6 ROOF INTERIOR SURFACE
C.2.6.1 General
a. Visually inspect the underside surface of the roof plates
for holes, scale buildup, and pitting.
b. Hammer test or ultrasonically examine to check for thin
areas, particularly in the vapor space of floating roofs
and at edge of roof on cone roof tank.
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c. Check all clips, brackets, braces, etc., welded to X
the roof deck plate for welded reinforcing pads and
see that they have not broken free.
d. If no pad is present, penetrant test for cracking of the weld X
or deck plate.
e. Inspect for protective coating for breaks, disbondment,
and deterioration.
f. Spark test the interior surface coating if recoating is not X
planned.
C.2.6.2 Fixed Roof Support Structure
a. Inspect the support columns for thinning in the upper 2 ft. X NA
b. On API columns (two channels welded together) check X
for corrosion scale breaking the tack welds, unless the
joint between the channels is completely seal welded.
c. Check that the reinforcing pad on the bottom is seal- X
welded to the tank bottom with horizontal movement
restraining clips welded to the pad.
d. Determine if pipe column supports are concrete X NA
filled or open pipe. If open pipe, check for a drain
opening in the bottom of the pipe.
e. Inspect and gauge rafters for thinning, particularly near In good condition
the center of the roof. Report metal loss.
f. Check for loose or twisted rafters.
g. Inspect girders for thinning and check that they are X
attached securely to the top of the columns.
h. Report if the columns have cross bracing in the area X
between the low pump out of the top of the shell (for
future internal floating roof installation).
i. Inspect and report presence of any roof-mounted swing
line bumpers.
j. Photograph the roof structure if no rafter layout drawing
exists.
C.2.7 FIXED ROOF APPURTENANCES
C.2.7.1 Inspection and Light Hatches
a. Inspect the hatches for corrosion, paint and coating
failures, holes, and cover sealing.
b. On loose covers, check for a safety chain in good
condition.
c. On light hatches over 30 in. across, check for safety rods.
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d. Inspect the condition of the gaskets on bold or latched
down hatch covers.
C.2.7.2 Staging Support Connection
Inspect the condition of the staging support for corrosion.
C.2.7.3 Breathers and Vents
a. Inspect and service the breather. Breather inspected but not serviced
b. Inspect screens on vents and breathers.
C.2.7.4 Emergency P/V Hatches
a. Inspect and service pressure/vacuum hatches. (Setting X NA
should be high enough to pre- vent chattering of breather
during normal operation. See breather manufacturer’s
guide.)
b. Inspect liquid seal hatches for corrosion and proper liquid X NA
level in the seal.
C.2.7.5 Sample Hatch
a. Inspect sample hatch for corrosion.
b. Check that the cover operates properly.
c. If the tank has no gauge well, check for a hold-off
distance marker and check measurement.
p. On black oil and diesel services: if gauge well is also X NA
used for sampling, check for presence of a thief- and
gauge-type hatch to avoid spillage.
q. Visually inspect inside of pipe for pipe weld protrusions X NA
which could catch or damage vapor control float.
C.2.11.2 Sampling Systems: Roof Sample Hatches
a. Inspect roof-mounted sample hatches for reinforcing pads
and cracking.
b. Inspect cover for operation.
c. For tanks complying with Air Quality Monitoring District X
rules, inspect sample hatch covers for adequate
sealing.
d. Check horizontal alignment of internal floating roof X NA
sample hatches under fixed roof hatches.
e. Inspect the sealing system on the internal floating roof X NA
sample hatch cover.
f. Inspect floating roof sample hatch cover recoil reel and X NA
rope.
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C.2.11.3 Shell Nozzles
a. Inspect shell nozzles for thinning and pitting.
b. Inspect hot tap nozzles for trimming of holes. X NA
c. Identify type of shell nozzles. Welded Neck
d. Identify and describe internal piping, including elbow-up
and elbow-down types.
C.2.11.4 For Nozzles Extended Into the Tank
a. Inspect pipe support pads welded to tank bottom.
b. Inspect to see that pipe is free to move along support
without strain or tearing action on bottom plate.
c. Inspect nozzle valves for packing leaks and damaged X NA
flange faces.
d. Inspect heater stream nozzle flanges and valves for wire X NA
cutting.
e. Report which nozzles have thermal pressure relief bosses X NA
and valves.
f. In internal elbow-down fill line nozzles, inspect the wear X NA
plate on the tank bottom.
g. On elbow-up fill lines in floating roof tanks, check that X NA
opening is directed against underside of roof, not
against vapor space. Inspect impact are for erosion.
C.2.12 ACCESS STRUCTURES
C.2.12.1 Handrails
a. Identify and report type (steel pipe, galvanized pipe, In good condition
square tube, angle) and size of handrails.
b. Inspect for pitting and holes, paint failure. In good condition
c. Inspect attachment welds. In good condition
d. Identify cold joints and sharp edges. Inspect the handrails In good condition
and midrails.
e. Inspect safety drop bar (or safety chain) for corrosion, In good condition
functioning, and length.
f. Inspect the handrail between the rolling ladder and the X NA
gaging platform for a hazard- ous opening when the
floating roof is at its lowest level.
C.2.12.2 Platform Frame
a. Inspect frame for corrosion and paint failure.
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b. Inspect the attachment of frame to supports and
supports to tank for corrosion and weld failure.
c. Check reinforcing pads where supports are attached to
shell or roof.
d. Inspect the surface that deck plate or grating rests on, for
thinning and holes.
e. Check that flat-surface-to-flat-surface junctures are seal-
welded.
C.2.12.3 Deck Plate and Grating
a. Inspect deck plate for corrosion-caused thinning or In good condition
holes (not drain holes) and paint failure.
b. Inspect plate-to-frame weld for rust scale buildup. In good condition
c. Inspect grating for corrosion-caused thinning of bars and In good condition
failure of welds.
d. Check grating tie down clips. Where grating has been In good condition
retrofitted to replace plate, measure the rise of the step
below and above the grating surface and compare with
other risers on the stairway.
C.2.12.4 Stairway Stringers
a. Inspect spiral stairway stringers for corrosion, paint In good condition
failure, and weld failure. Inspect attachment of stairway
treads to stringer.
C.1.1 FOUNDATION
Measure foundation levelness and bottom elevations X Visuals only. Foundation in good condition
C.1.1.1 Concrete Ring
a. Inspect for broken concrete, spalling, and cracks, In good condition
particularly under backup bars used in welding butt-
welded annular rings under theback
shell.of waterdraw
b. Inspect drain openings in ring, In good condition. No leak in found. Tank
basins and top surface of ring for indications of bottom drained/emptied as at the time of inspection
leakage.
c. Inspect for cavities under foundation and vegetation In good condition.
against bottom of tank.
d. Check that runoff rainwater from the shell drains away X NA
from tank.
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e. Check for settlement around perimeter of tank. In good condition. No visible tilt or settlement
observed.
C.1.1.2 Asphalt
a. Check for settling of tank into asphalt base which would In good condition.
direct runoff rain water under the tank instead of away
from it.
b. Look for areas where leaching of oil has left rock X NA
filler exposed, which indicates hydrocarbon
leakage.
C.1.1.3 Oiled Dirt or Sand
Check for settlement into the base which would direct In good condition.
runoff rain water under the tank rather than away from it.
C.1.1.4 Rock
Presence of crushed rock under the steel bottom usually X NA
results in severe underside corrosion. Make a note to do
additional bottom plate examination (ultrasonic, hammer
testing, or turning of coupons) when the tank is out of
service.
C.1.1.5 Site Drainage
a. Check site for drainage away from the tank and In good condition.
associated piping and manifolds.
b. Check operating condition of the dike drains. In good condition.
C.1.1.6 Housekeeping
Inspect the area for buildup of trash, vegetation, and other In good condition. Isolated areas with overgrown
inflammables buildup. vegetation.
C.1.1.7 Cathodic Protection
Review cathodic protection potential readings. X NA
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Photo-description of Inspection Findings-Tank C9
Overview of Tank C9 Name Plate Overview of Roof
Roof Supports/Rafters Tank Shell -Internal Overview of Tank Bottom
Valve and Nozzle on C9 Overgrown Weeds around C9 Uncoated Patch Repair on Tank Shell
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