TAM-EN-1100 Tank Maintenance

CAUTION: Based upon the publication date, this document may not contain the latest
guidance. The user is strongly advised to contact the Technology Manual Sponsor to
determine the appropriate subject matter expert for consultation on applicability to the
users specific case.
1100 Maintenance
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Abstract
This section discusses the general considerations and philosophy of maintenance for
tanks. Included are procedures for shutdown planning, tank cleaning, replacement
and repair of major components, in-service repairs, rerating and retiring corroded
tanks, and the application of coatings and paint. A tank shutdown checklist is also
attached.
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Contents
Tank Cleaning
1111
Tank Entry Precautions
1112
Company and Industry Documents
1113
1114
1115
1100-3
1110
Operating Methods to Minimize Sediment

Estimating Sludge Quantity
Determining Sludge Content
Sediment Types and Removal Procedures
1117
Separating Salvable from Non-salvable Material in Sludge
1118
Final Cleaning
1119
Levels of Cleaning Required
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1116
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1120
Gas Freeing
1121
Vapor Freeing Methods
1122
Vapor Freeing Equipment
1123
Safe Vapor Freeing Operations
1124
API 2015
1125
Degassing Operations
1126
Degassing Regulations
1127
Degassing Technologies
1128
Factors Affecting Degassing Time
1129
Degassing Safety
2000 Chevron USA Inc. All rights reserved.
1100-12
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In-Service Repairs
1100-30
1131
Safety Guidelines for In-service Work on Tanks
1132
In-service Shell Repairs
1133
Hot Tapping of Tanks in Service
1134
Fixed Roof Repairs
1135
Floating Roof Repairs
1136
Floating Roof Seal Systems
1137
Insulation
1138
Appurtenances
1140
Resources
1150
Tank Shutdown Checklist
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1130
1100-38
1100-45
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Revision History
1100-38
1100-2
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1100 Maintenance
1110 Tank Cleaning

Tanks are cleaned for various reasons:
Slop tanks which accumulate heavy sediment need to be cleaned periodically in
order to continue efficient operation.
Gasoline or jet fuel tanks sometimes must be cleaned in order to meet the
product specifications.
Tanks coming out of service for maintenance must be cleaned and gas freed
before they can be entered.
To change to a cleaner or non-compatible service
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This section gives general guidance on both in-service and out-of-service tank
cleaning and refers to various other Company and industry documents on this
subject. It is intended to be used as a guidehowever, local conditions and experience influence the actual procedures used.
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1111 Tank Entry Precautions
Both OSHAs confined space entry rules codified in 29 CFR 1910.146, as well as
API Standard 2015, apply to all tank entry conditions. Since these are standards
only, detailed checklists such as pre-planning checklists, isolation and tagging
procedures, work plans, equipment for listing and monitoring must be worked out in
the planning phases of the job.
1112 Company and Industry Documents
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Different Company organizations have prepared guidelines for venting and cleaning
tanks, some of which are listed below. Copies of Company publications are available through each department; the API publication may be obtained directly from
API (their address is given in Section 100).
API RP 2015, Cleaning Petroleum Storage Tanks.
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1.
Fire Prevention Manual, Fire Protection Through Inspection and

Maintenance.
3.
Manufacturing Department, Chevron U.S.A.
2.
July 2000
a.
ES-666, Cleaning and Repair of Tanks (El Segundo Refinery)
b.
Operating Standard AR-9240, Cleaning Tanks (Richmond Refinery)
c.
Operating Standard AR-9241, Cleaning and Repairing Leaded Gasoline

Tanks (Richmond Refinery)
4.
Marketing Department, Chevron U.S.A., Operations Standard, Section IX,

Part D, Tank Cleaning Instructions.
5.
Pipe Line Department, Chevron U.S.A., Safe Practice Regulations, 5.011.2

Tank Cleaning.
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1113 Operating Methods to Minimize Sediment

This section discusses equipment and procedures to use while the tank is in operation to reduce the amount of sludge to be removed.
Variable Angle Mixers
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Variable angle (or swivel) mixers have been used for cleaning gas oil, heavy oil, and
crude tanks. The flow patterns created by these mixers significantly reduce oily
waste disposal problems. The changing patterns reduce the areas of sediment
buildup and keep the sediments in suspension with the stored fluid or with a flush
fluid. They are then removed by pumping the mixture out of the tank. When
compared to conventional manual cleaning, this method may be faster and more
economical.
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A variable angle mixer has a ball-type stuffing box mounted in a special manway
cover that allows angular movement. Figure 1100-1 shows the variable angle mixer,
which has 60-degree angular adjustment. The flow patterns established by the
normal fixed angle mixer allow sediment accumulations in dead spots
(Figure 1100-2). The variable angle mixer can direct flow patterns to almost any
area of the tank and eliminates most dead spots. (Small-diameter tanks may not
need a variable angle mixer). The advantages of using the variable angle mixer are:
Valuable oil is recovered from oily solids and is easily transported to the
refining units.
2.
Tank capacity is increased because solid waste does not accumulate in the tank.
3.
Tank downtime is reduced.
4.
Very little solid waste must be disposed of.
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1.
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Fig. 1100-1 Variable Angle Mixer with 60-degree Angular Adjustment Courtesy of Jensen
Mixers
1100-4
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Fig. 1100-2 Sludge Buildup for Fixed Angle Mixer Compared to Variable Angle Mixer.
Courtesy of Jensen Mixers
Area of Severe Sludge Buildup
Fixed Angle Mixer
Variable Angle Mixer
Overall cleaning costs are reduced.
6.
Cleaning operation is essentially all done from outside the tank.
7.
Exposure of people to the tanks atmosphere can be minimized or eliminated.
8.
Recovered oil may pay for the cleanup costs, such as: mixer cost, labor
costs, etc.
9.
The costs for variable angle and fixed angle mixers are very competitive.
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5.
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Variable angle mixers are often used during normal operation to minimize sludge
buildup. These mixers can be purchased with a motor drive to change the mixer
position on a continuous cycle, eliminating the need for manual adjustment.
Section 780 discusses the sizing requirements for mixers.
Procedure for Using a Variable Angle Mixer to Clean a Tank
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The following is a general procedure for the use of a variable angle mixer prior to
taking a tank out of service. This procedure is being used less frequently for two
reasons: a large amount of solvent is required; and the oil/solids separation systems
are much improved.
July 2000
1.
Determine the composition of the sediment. This analysis is the basis for
selecting the solvent for cleaning.
2.
Add the solvent to the tank to at least 6 feet above the mixer. This is the
minimum level of liquid during operation of the mixer to avoid cavitation of the
fluid while mixing.
3.
The mixers are run from 5 to 15 days in positions ranging from 30 degrees right
to 30 degrees left. Manufacturers recommend that the position be changed
every 24 hours (Company practice has frequently been to change the position
every 8 hours).
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4.
The spent solvent is pumped out of the tank and may be refined. More than one
cleaning cycle may be required to thoroughly clean a tank.
5.
If the tank is not satisfactorily cleaned, then sediment may need to be removed
mechanically.
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Figure 1100-3 shows typical mixer arrangements for different size tanks. Arrangements will vary depending on the type of tank bottom, tank volume, stock properties, maintenance access and power available. Experience suggests a 50-hp mixer
normally has the capacity to clean a tank up to 150-foot diameter. For tanks of
150-foot diameter and larger, consider using two or more mixers. Small tanks would
require a mixer of about 25 hp, depending on the stored fluid.
Mixers used for both cleaning and blending service usually require more horsepower than those required for cleaning only. Mixer size and numbers should be verified by analysis of the sludge to be removed and consultation with the manufacturer.
Hydraulic Jet Nozzles
1114 Estimating Sludge Quantity
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Hydraulic jet nozzles can be installed inside a tank to perform the same function as
the variable angle mixer. These nozzles require both pumping pressure and volume.
Both the jet nozzles and the mixers perform the same function, injecting energy into
the tank to remove sediment from the bottom and suspend it temporarily in the
liquid. Section 780 discusses mixing nozzles in more detail.
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After as much stock is drained from the tank as possible, a mixture of oil, water, and
solids remains. This mixture is referred to as sludge or sediment. You must have a
good understanding of the type and quantity of sludge to be removed from the tank
to make sound decisions regarding:
Sludge removal procedures

The cost of the job
Waste disposal requirements
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This section discusses the methods for estimating the quantity of sludge.
1100-6
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Fig. 1100-3 Typical Mixer Arrangement for Different Size Tanks Courtesy of Jensen Mixers
Gauging Sludge Depth

Two special tips which replace the plumb bob on the typical operators reel gauge
can be fabricated and used to measure the sediment level. The tip to determine the
distance from the gauging point to the tank bottom is a long, sharp-ended probe
weighing 5 to 8 pounds. Its weight combined with the reduced friction area is used
to penetrate the sludge. The second tip should weigh about to 1 pound and have a
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wide disc at the bottom. This tip is designed to sink through the stock but to be too
light to rapidly sink into the bottom sludge. Take several readings of the bottom and
sludge levels in different locations to obtain an accurate profile. These readings can
be taken through the gauge well, roof hatches, and roof legs, if necessary, using
proper safety procedures. Caution should be given using this procedure, due to
potential to damage of bottom coating.
Visual Survey Through Open Shell Manway
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After the tank is pumped out and the shell manway is opened, use natural sunlight
and a large mirror, or a strong spotlight, to visually inspect the sediment. Using
internal appurtenances of known height, such as portions of the roof drain fixed
pipe, bottom supports for swing lines, or fixed roof column supports, estimate
sludge depth. If necessary, the depth can be closely estimated by use of a survey
level (with allowance for the bottom slope). As many readings should be made as
reasonable, at different locations.
From the readings, use a simple volume calculation to estimate the quantity of
sludge to be removed.
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Caution Sludge rarely builds up evenly over the entire bottom.
1115 Determining Sludge Content
We collect and test sludge samples to know which waste disposal requirements
apply and also what hazards personnel may be exposed to while ridding a tank of
sediment.
Tanks Unsafe to Enter
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For tanks which are unsafe to enter, samples will have to be taken from the
manway(s). Each phase (solid, water and oil) will have to be sampled separately
according to the following instructions.
If the liquid layer is deep enough to collect a sample, collect a 1-quart sample
of each liquid phase (oil and water) from any one manway. Label the depth of
each liquid layer sampled. If the liquid layer is too shallow to get a sample (less
than 1 inch) ignore the liquid and sample only the solids.
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1.
2.
Sample the solid phase from all available manways using the solids sampler.
Collect equal amounts of sample from each manway until gallon has been
collected. Include the depth of the solids layer on the tag.
Tanks Safe To Enter

For tanks where entry is possible, the solids and liquids should be sampled
according to the following procedure:
1100-8
1.
Collect a sample of each liquid layer as outlined in Step 1 above.
2.
Estimate the number of barrels of solids remaining in the tank according to the
following formula:
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Barrels left = 0.14 d2 h

(Eq. 1100-1)
where:
d = tank diameter (ft)
h = height of waste (ft)
3.
Determine the number of sample points to be included in the composite sample

according to the following table.
Barrels Left
No. of Sample Points

3
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0-3000
3000-6000
6000-12,000
12,000-20,000
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Collect the samples at the points shown in Figure 1100-4. If only three points are to
be sampled, sample at points 1, 2 and 3. Prepare a -gallon composite sample by
collecting equal amounts at each sample point.
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Fig. 1100-4 Sludge Sampling Locations
Testing Sludge Content

Consult with your local waste disposal organization to determine the specific tests
to run.
1116 Sediment Types and Removal Procedures

Most sediments are normally one of four types: pumpable sediment, non-pumpable
sediment, scale, and catalyst fines. However, there can be combinations of these
types to remove.
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Pumpable Sediment
This sediment can be pumped out of the tank by use of a vacuum truck or, if necessary, diaphragm pumps. Manual methods (squeegees) may be required to move the
sediment to the hose. Many crudes, gas-oils, etc., are typical of this class. Sometimes steam lances can turn non-pumpable sediment into pumpable sediment.
Solvents and mixers or jet nozzles, and heat, are also potential methods.
Non-pumpable Sediment
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Residual sediment that cannot be pumped but must be mined, scraped, or shoveled
is very expensive to remove. On larger tanks, entering the tank with mechanical
equipment (front-end loaders, or small bulldozers) may be more economical even
with the need for cutting a door sheet in the shell or roof. Asphalt, asphaltines, and
baked sediment (from tank heaters) are typical examples of non-pumpable sediment.
Scale
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Scale corrosion product, mostly from the shell but also from the roof and bottom, is
the third category of sediment to be removed. This scale can contain trapped stock,
water, and possibly hazardous gases. Typical services that produce scale include
gasoline, thinners and solvents, jet fuels and pentane-hexanes. Until all scale has
been removed, personnel should wear full-body protective equipment, and the tank
interior should be continuously tested for explosive gas, aromatics, and H2S.
Normally the scale can be moved by water (hydroblasting) and pumped out by
vacuum truck or diaphragm pump. Caution: if the scale is over 1 to 2 inches deep,
movement by water can release trapped gas causing an explosive mixture to form in
the vapor space. If water washing cannot be done, it may be necessary to remove the
majority of the scale by bucket and shovel after the tank is safe to enter.
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Catalyst Fines
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Refineries with catalytic crackers will usually have one or more tanks containing a
large amount of catalyst fines. Catalyst fines are usually too heavy for easy pumping
and too soft for mining. Mixers and regular cycling of the tank contents through a
solids extraction system while the tank is in service are recommended to keep the
catalyst fine level low. Normally tanks with catalyst fines are cleaned by shoveling
the fines into the suction of a vacuum truck or conveyor belt. Entering a tank with
fines can be hazardous. The fines trap cycle oil. Piles of fines can collapse causing a
hazardous flow of cycle oil and fines. Some contractors are able to remove catalyst
fines and centrifuge to help reduce the amount disposed.
Protection Against Spillage

Cleaning a tank can result in material being spilled on the ground outside of the tank
unless precautions are taken. This spillage can be avoided by doing the following:
Frequently Cleaned Tanks. For tanks which must be cleaned frequently (more
than once every 5 years), design the tank with facilities to impound any spills:
1100-10
Flush-mounted cleanout connection(s) designed to API 650.

A concrete cleanout basin around each connection to contain any spillage.
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Tanks Cleaned Less Often. For tanks which are only cleaned as part of their scheduled maintenance shutdown, the above facilities are normally not justified. Instead,
the cleaning contractor should build a temporary dike around the manway(s) used
for cleanout and line the area with plastic to contain spills.
1117 Separating Salvable from Non-salvable Material in Sludge

Heavy hydrocarbons and sediment normally drop to the bottom of a tank. Simple
removal and disposal of this material is uneconomical. Our objective should be to
maximize oil recovery and minimize hazardous waste disposal.
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As sludge material is removed from a tank, it can be processed through equipment

to separate the usable oil from the water and from the unusable solids. Several types
of equipment are available to do this work. Reputable companies furnishing the
equipment can test representative samples of the sediment removed from the tank
and determine the best system to use. They normally require a 1 to 5 gallon sample.
Care should be taken to obtain a true sample of the sediment and not the stock
above the sediment. Typical equipment used for separation includes: rockers,
centrifuges, chemical treating tanks, shakers, settling tanks, presses, filters, and
heavy metal extraction units.
Procedures and equipment for separation and for hazardous waste management are
continually being updated. Vendor claims must be backed by proven results. We
strongly recommend that you discuss your particular requirements with other tank
maintenance groups. Sometimes distant contractors with proven technology may be
more economical to use than local contractors. You can also consult ETCs tank
specialist for new technology on waste processing.
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1118 Final Cleaning
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After the sediment is removed, a final cleaning must often be performed before
maintenance work. The methods and equipment used in the final tank cleaning
process are determined by the type of contaminate and the degree of cleanliness
needed.
Non-oily Contaminate
This contaminate is primarily scale (corrosion product) with possibly some trapped
hydrocarbons, especially if the tank has had a change of service. Typical services
include gasoline, thinners, and some jet fuels. Usually the scale can be removed by
pressure washing (200 psi) or hydroblasting (6,000-10,000 psi). Very hard, tight and
active scale may require abrasive blasting or ultra high pressure (35,000-70,000 psi)
hydroblasting.
Oily Contaminate
This contaminate is primarily hydrocarbon and may be a tightly bonded asphalt-like
or greasy deposit. Typical services include crude oil, recovered oil, and gas oil.
Usually a pressure washer along with sprayed-on detergent will remove the contaminate. If scale is also present or the baked on material is too hard and well bonded,
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1100-11
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hydroblasting may be necessary. Oily surfaces should never be cleaned by abrasive blasting. Oil can be embedded in the metal surface by abrasive blasting thereby
causing major problems with future coating application.
1119 Levels of Cleaning Required

Figure 1100-5 gives required levels of cleaning.
Fig. 1100-5 Summary of Levels of Cleaning
Level of Cleaning
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Objectives
Change of service or remove sludge to

improve tank operation or product
quality.
Tank out-of-service well before its due
date. Quick visual inspection requested;

no repairs anticipated.
Remove sludge. Remove scale if it

impedes inspection.
Tank out-of-service on normal maintenance interval (10 years). Detailed

inspection needed.
Remove sludge. Remove scale for thorough inspection.
Welding required in the tank.
Remove sludge. Remove scale. Clean

oily film off of metal.
Coating required.
Remove sludge. Clean oily film off metal.

Abrasive blast surface to recommended
finish.
Remove sludge. No final cleaning

required.
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1120 Gas Freeing
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This section covers the general principles of vapor freeing and degassing. Vapor
freeing is the discharge of vapors in a tank to the atmosphere to allow maintenance
personnel to enter and service the tank safely. Vapor freeing is considered part of
normal tank operations. Degassing is usually performed in response to regulatory
requirements. When a tank is degassed, the fumes are treated or recovered before
being discharged to the atmosphere.
1121 Vapor Freeing Methods
Selecting an appropriate vapor freeing method is based on considerations such as

tank size, flammability, and toxicity. Vapor freeing can be accomplished by one of
the following methods:
1100-12
mechanical ventilation
natural ventilation
steam ventilation
displacement by water or inert gases
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These methods are described briefly below. Figure 1100-6 provides additional guidance in selecting an appropriate method of vapor freeing.
Fig. 1100-6 Selecting a Vapor Freeing Method From API 2015, Fig. 5.1. Courtesy of the
American Petroleum Institute.
Tank Size
Consider:
Mechanical Ventilation
Natural Ventilation
Steam Ventilation
Use Mechanical
Ventilation
Does Air Mover Have

Moving Parts?
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Yes
(e.g., Fan)
Large
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Small
No
Connect Suction or
Discharge to Tank
Will Vented Vapors Be

Flammable?
No
(e.g., Eductor)
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Yes
Connect Suction or
Discharge to Tank
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Connect Suction Side

Only to Tank
Mechanical Ventilation
July 2000
Mechanical ventilation is the preferred method of vapor freeing for Company tanks.
Refer to API 2015, Appendix B, for a detailed description of, and application guidelines for, mechanical ventilation.
Natural Ventilation
Natural ventilation is generally not applicable to tanks in flammable service because
rich fumes may be free to flow into a remote ignition source and flashback to the
tank. Natural ventilation has sometimes been used for small tanks when two conditions are met: there is a manway near the bottom and the top of the tank; and the
contents are sufficiently volatile to rapidly dissipate from the tank interior. For large
tanks, air movers such as fans or eductors are necessary to develop sufficient diluent
air to accomplish the required reductions in concentrations of hydrocarbons. Generally, use of natural ventilation for vapor freeing tanks is not recommended.
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Steam Ventilation
Steam nozzles produce significant potential for the generation of static charge,
which can be an ignition source. Also, because steam condenses it can cause the
pressure in the tank to drop enough to collapse if there is insufficient opening to
allow for make up air. Steam ventilation may be considered for very small tanks
storing materials in which the cleaning process is significantly facilitated by the
condensing steam. These would typically be small chemical tanks. Steam ventilation should generally be avoided.
Inerting
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Inert gases can displace hydrocarbon vapors and serve to vapor free or degas.
However, it creates new problems which are the disposal of the inert gas itself and
the high degree of health hazards associated with inert gases. Inerting has therefore
rarely been used and is not recommended.
1122 Vapor Freeing Equipment
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Vapor freeing is most often accomplished by ventilation equipment using air as a

diluent. Air movers used for tank ventilation with the potential for flammable
vapors are generally air or stream driven and are either the eductor type or an axial
fan. Figure 1100-7 shows both of these types of equipment.
Eductor
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Fig. 1100-7 Tank Air Movers for Flammable Atmospheres Courtesy of the Coppus Portable
Ventilation Division of the Tuthill Corp.
Fans
1100-14
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The eductor has no moving parts while the fans are driven by air motors which
reduce the chance of creating an ignition source. Electrically driven fans must be
suitable for NFPA 70 Class 1, Division 1 locations. When fan motors or eductors
use steam as the motive fluid, the steam discharge must be outside and away from
the tank because the static could serve as an ignition source. Fans or eductors driven
by compressed air are the recommended method for Company applications.
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Figure 1100-8 shows a method for vapor freeing a fixed roof tank. The tank vapors
are withdrawn from a low point in the tank which maximizes both mixing of the
hydrocarbon vapors with air and withdrawal rate. When the roof manway is used to
expel the vapor-laden air, a drop tube is required to pull the vapors off of the bottom
to prevent channeling of air through the upper portion of the tank. Discharging the
air high off the ground substantially reduces risk of the vapors coming in contact
with a remote ignition source, causing a flashback to the tank.
Air Eductor
(Electrically bonded
to tank)
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Fig. 1100-8 Vapor Freeing a Fixed Roof Tank From API 2015, Fig. 5.6. Courtesy of the
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Figure 1100-9 shows how to ventilate a floating roof tank.
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Fig. 1100-9 Vapor Freeing a Floating Roof Tank From API 2015, Fig. 5.5. Courtesy of the American Petroleum Institute.
Air eductor
Bonding cable
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Air mover
The main difference between this scheme and the vapor freeing of a fixed roof tank
(Figure 1100-8) is that there is cross flow through the tank so that discharging
through a shell manway becomes much more acceptable. Notice, however, that the
vapors should be routed upward and discharged near the top rim of the tank to
prevent flashback. When discharging out of a roof manway, the space above the
floating roof may be flammable. When the air speed is low and the humidity and
temperature are high, it is safer to discharge through a shell manway using flexible
ducting to route the vapors upward where they can be disbursed.
1100-16
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1123 Safe Vapor Freeing Operations

Once air moving equipment is shut down, several factors may allow toxic or flammable vapors to quickly re-establish themselves in tank interiors. These factors
include, but are not limited to, the existence of sludge, pipe columns that retain
liquids, cracks in bottom plates that allow liquids or fumes from under the tank to
enter, foam log seals that are product-soaked and leaking pontoons. Ventilation
equipment and gas testing should be operating the entire time work is performed if
there is any doubt as to the ingress of hazardous fumes.
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Whenever a tank is vapor freed and sealed up for any period of time, assume that its
atmosphere has become hazardous again unless testing shows otherwise.
1124 API 2015
Everyone responsible for tank cleaning, degassing or vapor freeing operations

should be thoroughly familiar with the requirements of API Standard 2015, 5th
edition, Safe Entry and Cleaning of Petroleum Storage Tanks. The principles
covered by API 2015 are outlined below.
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Basic Requirements of API 2015
The standard provides useful guidance and requirements such as:

references from federal regulations that require personnel have specific training
how to work with contractors
what the nature of the qualifications should be for various job functions
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Figure 1100-10 is a flowchart covering the basic requirements of API 2015. The
flowchart follows the typical sequence of events for tank maintenance.
Administrative Controls
The most important aspects of tank entry are the up-front, pre-planning and scoping
study processes. During these phases, consider the following administrative
controls:
written procedures
permitting systems
checklist development
pre-job discussions with employees and contractors
qualification standards for various key personnel
training
hazardous substance testing equipment methods and frequency requirement
the use of personal protective equipment and training
hazards assessment
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Fig. 1100-10 API 2015 Flowchart Derived from API 2015. Courtesy of the American Petroleum Institute.
Preplanning Tank
Work
Empty Tank
Isolate Tank
Vapor Free Tank
Note 1
Test Atmosphere
Note 2
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Notes:
1. Continuous ventilation may be
required.
2. Testing required in several places
throughout this flowchart.
Determine Hazards:
Entry without
Restrictions:
O2 = 20.9%
No Flammable Vapors
Toxics < PEL/TLV
No Lead
Entry with
Restrictions:
19.5% < O 2 < 23.5%
PEL/TLV < Toxicity
Entry Prohibited
if Flammable Vapors
> 10% LEL
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Entry with
Special Precautions:
O2 19.5% or O 2 23.5%
Toxicity > Level that allows
self-rescue
engulfment
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Oxygen Concentration
Flammability
Toxicity
Physical
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Determine Personal
Protective Equipment (PPE)
1100-18
Entry Permit System

Hot Work Permit System
Tank Entry for

Repairs/Inspection
Recommission Tank
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Classification of Hazards
There are numerous combinations of hazard conditions encountered in tank entry
work. API 2015 categorizes these hazards to simplify the task of planning.
The standard recognizes four hazards when entering petroleum tanks:
fires and explosions
2.
oxygen deficiency or enrichment
3.
toxic substances
4.
physical hazards
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1.
The hazards which are most difficult to assess deal with the nature of the vapors and
fumes in the tank. These particular hazards cannot be assessed without the use of
instrumentation. Therefore, the standard relies heavily on atmospheric testing.
To classify these hazards, the standard provides three degrees of entry conditions:
Entry with Special Precautions
2.
Entry with Restriction
3.
Entry without Restrictions
4.
Prohibited Entry
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1.
The oxygen concentration outside is of the limits 19.5% to 23.5%.

The toxicity level is greater than a level that would allow for self rescue.
An engulfment or physical entrapment hazard exists.
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Entry with Special Precautions. This is the most hazardous condition found inside
storage tanks and corresponds to OSHAs Permit Required Confined Space Entry
Rules. This entry condition applies in any one of the following circumstances:
Entry With Restrictions. This intermediate entry condition applies if any of the
following conditions are met:
The oxygen concentration is 19.5% or 23.5%.
The toxic substance concentrations are above the PEL/TLV, but not so high as
to inhibit self rescue efforts.
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Entry Without Restrictions. This condition allows tank entry without personal
protective equipment or other restrictions. A permit must still be issued. The conditions allowing this classification are the simultaneous presence of:
Oxygen concentration at 20.9%.

Flammable vapors at 0% LEL.
Toxic substances at or below PEL/TLV.
Prohibited Entry. Entry is prohibited if flammable vapors are greater than

10% LEL.
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1100-19
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Note The most stringent hazard entry condition (Entry with Special Precautions)
applies to all tank entries unless it is proven otherwise by atmospheric testing. Any
tank that has been cleaned, reclosed and inactivated for any period of time must be
treated as though it requires Entry with Special Precautions, until retested.
Determining the Level of Hazard

The standard relies on atmospheric testing to assess the actual hazard and entry
conditions. To ensure that correct data are gathered on the hazardous nature of the
atmosphere the standard requires that:
intrinsically safe equipment be used (good for class I, division I, Group D)

each instrument must be calibrated and its calibration documented
the user must understand the limitations and behavior of all the instruments
the user must be qualified and trained in the proper use of the equipment
the tests must be run in the following sequence: oxygen, flammable, and then
toxic
redundant testing when ventilation equipment is stopped
redundant monitoring of the atmosphere inside the tank
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A qualified person should determine the appropriate type of atmospheric testing and
how often the tests should be performed.
Preparing The Tank For Entry
In addition to hazard assessment and testing requirements, the standard specifies

conditions for performing the actual work itself including:
Emptying the tank
Isolation: all lines must be blinded off or separated from the tank so that there is
no possibility of leakage into the tank. Cathodic protection systems should be
turned off, electrical systems locked/tagged out and all cleaning equipment
grounded to the tank. Specifications for electrically bonding the tank are given.
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Control of Ignition Sources: specifications for electrical equipment used in the

work are given in addition to grounding and bonding requirements. The
standard requires that all work cease if an electrical storm is in progress or
imminent.
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1125 Degassing Operations

Degassing requirements apply to most crude oil storage tanks and to tanks that have
been used to store motor fuels, aviation gasoline or other stocks (such as naphthas)
that meet certain vapor pressure qualification rules. Degassing is not required for
stocks such as lube oils, diesels and jet fuels because their vapor pressures are too
low. Other stocks that usually require degassing are alcohols, oxygenates, alcholates
and reformate streams. Spheres used to store propane also need to be degassed.
Although degassing may be required by regulations it is sometimes used voluntarily. Examples of voluntary degassing include: venting or blowing down pipelines; venting tanks which have odors in a residentially sensitive area; and when
1100-20
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1100 Maintenance
toxic or harmful fumes might otherwise be released. Degassing is used frequently

on underground storage tanks and sometimes on the treatment of vapors removed
from contaminated ground/groundwater media under remediation.
Degassing, if required, should be the first task performed, followed by continuous
ventilation or vapor freeing. Degassing may be accomplished by one of the
following methods:
Air or steam ventilation
Thermal oxidation of the fumes
Recovery of vapors by refrigeration
Removal of fumes by carbon adsorption
1126 Degassing Regulations
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The aim of degassing regulations is to prohibit the release of hydrocarbon vapors to

the atmosphere from aboveground tanks being taken out of service. Since it is
generally recognized that API 653 requires periodic out-of-service tank inspections,
new regulations will likely seek to reduce the emissions associated with tank shut
downs.
Although the rules have general principles and requirements, a technology specific
permit is assigned to contractors/vendors whose equipment is required to perform
under the provisions of the permit. In many cases the permit requirements are more
stringent than in the legislated rules.
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Many states and local jurisdictions have enacted degassing regulations. The South
Coast Air Quality Management District (SCAQMD) and Bay Area Air Quality
Management District (BAAQMD) have enacted degassing regulations. Other
authorities have either enacted or are considering enacting degassing regulations.
Refer to your local air quality regulations.
Comparison of AQMD Regulations
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Various districts degassing rules are generally similar, however, they may vary in
the following key requirements parameters. Examples of how they may differ
include:
Exemptions - Tank Size and Vapor Pressure. Tanks below a certain size are
exempted from the rules. The range of the size for tanks which contain hydrocarbons but that are not regulated varies from about 5,000 to 40,000 gallons. The rules
also do not apply if the vapor pressure of the organic liquid is sufficiently low
(e.g., diesel).
Hydrocarbon endpoint concentration. Degassing must continue until some

concentration (e.g., 10000 ppmv) is reached. However, the SCAQMD uses an
endpoint that depends on the volume of displaced vapor being equal to 2.3 times the
volume of the tank. This requirement would normally be very easy to meet and be
one of the most lax degassing standards. However, in permit applications, the
SCAQMD generally includes a permit provision requiring degassing to levels with
an endpoint concentration of 700 ppmv. This provisions is one of the most stringent
in the state.
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1127 Degassing Technologies

Degassing regulations provide two methods for removing the hydrocarbon vapors
from a tank:
Liquid or Water Balancing: either water or a relatively non volatile stock, such
as diesel, is used to displace the hydrocarbon vapors. This technique can be
used to displace vapors prior to opening a tank or when a tank floating roof is
landed.
Emission Control Devices: the basic degassing requirements as applied to

devices which either destroy or recover vapors are specified in terms of efficiency of vapor removal or destruction. Technologies such as thermal oxidation, activated carbon, refrigeration and condensation, scrubbing, etc. can be
used to meet these specifications.
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Figure 1100-11 provides a general comparison of the various degassing technologies.
Thermal Oxidation Methods
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This section covers basic thermal oxidation degassing methods.
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Flame Oxidation Method. This process uses a flame to oxidize the hydrocarbon
fumes in a tank and is typically a contracted specialty service provided by tank
degassing contractors. Since vacuum trucks are usually operating at the same time
as degassing units, the vapors from the vacuum truck can be discharged back to the
tank space or into the degassing unit. A portable trailer unit that contains the
oxidizing furnace, blowers, piping and controls, and a portable propane fuel supply
are brought to the site and connected to the tank. Figure 1100-12 shows a typical
flame degassing operation schematic flow diagram.
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A flexible line made of plastic pipe or flexible ducting is connected from a tank
manway to the thermal oxidizer. It is important for other manways on the tank to be
open to allow airflow into the tank or the blower that draws tank fumes into the
oxidizer. Without sufficient airflow, vacuum could result and collapse the tank.
Some tank degassing contractors use a vacuum breaker which allows air to flow into
the degassing unit suction line should the pressure drop too low. The tank fumes
pass through a flame and detonation arresting device so that a flame cannot propagate from the oxidizer through the ducting and into the tank.
Sufficient volume (residence time) must be provided to allow oxidation of the

fumes to meet required regulations. Some regulations require at least 0.5 seconds of
residence time. In addition the temperature must also be high enough, usually
1400F to 1500F. Degassing tanks over 150 feet in diameter can take anywhere
from 8 to 36 hours, or more, depending on the product and amount of solids. The
typical flow rate for currently available degassing services is from 1000 to 3000
scfm. The process should not be stopped until the vapor space of the tank drops well
below 10 percent of the LEL. The tank may then be ventilated by forcing air
through the tank unless the local regulations prohibit this.
1100-22
July 2000
Flame Units
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Thermal
Applicability and Characteristics
Performance
Large or small tanks primarily hydro- Quick and efficient.

carbon.
Meets all of the most stringent air
Relatively simple operation.
district requirements.
Safety Considerations
Can be ignition source.
Safety of oxidizer design is critical.
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Degassing Method
Tank Manual
July 2000
Fig. 1100-11 Comparison of Degassing Methods From API 2015, Fig. 5.13. Courtesy of the American Petroleum Institute.
Burner controls interlocked for safety,

but can be overridden by operator.
Large or small tanks.
Complex unit, subject to meticulous

maintenance and operation requirements.
Water Balancing
Slower than thermal, may not meet

most stringent requirements.
Small tanks or as air cleaning unit on Excellent.

tank breathing and displacement air. Spent carbon must be disposed of or
regenerated making this impractical
for large tanks
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Activated Carbon
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Refrigeration
Lower flow rate causes longer down- Not as efficient as flame unit.
time.
Engine Units
Useful primarily for stock changes in

tanks or when liquid level brought
below landed roof position and to
meet air jurisdiction requirements.
Unit depends on flame arrestor to

prevent a flashback to tank; the
design of the flame arrestor and
piping must be exacting to prevent
incident.
Can be an ignition source, especially

when flow through unit is variable or
stops.
Probability of hot spots greatest when
chemically activated carbons are
used.
Variable results, depends on contents Relatively safe.

of tank, sludge contents and the
displacement liquid used.
1100-23
1100 Maintenance
Not applicable for general tank entry

or cleaning operations.
Same hazards as flame unit except

that an engine backfire is possible.
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Fig. 1100-12 Thermal Oxidation Degassing - Flame Oxidation Method From API 2015, Fig. 5.8.
Courtesy of the American Petroleum Institute.
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Internal Combustion (IC) Engine Method. Instead of using a flame to oxidize

the hydrocarbon fumes, an internal combustion engine can be used as shown in
Figure 1100-13. Application of this technology was originally started for degassing
of small underground storage tanks (less than about 5000 gallons) in the Los
Angeles basin. The following description of an internal combustion engine degassing method is generic.
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Fig. 1100-13 Thermal Oxidation Degassing - Internal Combustion Engine Method From API
2015, Fig. 5.9. Courtesy of the American Petroleum Institute.
1. Vapor Inlet
2. Separator Drum
3. Mixing Valve
1100-24
4. Filter
5. Flame Arrestor
6. Engine
7. Silencer
8. Load Blower
9. Vapor Blower
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1100 Maintenance
A typical aboveground degassing setup includes at least one trailer unit containing
two 460 cubic inch V-8 Ford engines operating at about 150 horsepower each on a
continuous basis.
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The vapors pass through a knock-out pot to drop liquids and water out. A system of
mixing valves is used to obtain the proper air-fuel ratio by introducing make up air
when the tank vapors are rich. Just prior to entering the engine, propane may be
introduced to maintain the proper air fuel ratio when the tank vapors are below the
LEL. A filter removes particulates and dust. Then the clean, ready-to-burn air-vapor
mixture is passed through an isolating flame arrestor and into one or more internal
combustion engines.
Although the blowers that draw air from the tanks are powered by the engines to
conserve energy, there is a net excess of energy created by this process. The engines
must deal with this extra energy. Most often, the engines are connected to a blower
which has no function other than to consume energy by taking atmospheric air,
compressing it in a lobbed vane blower and expanding it back to atmosphere. The
amount of vapors processed is proportional to the amount of energy consumed by
the engines.
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Typical vapor processing rates are less than the flame oxidation units as they can
only process about 400 cfm per engine. Two to five trailers with two or more
engines can be manifolded together to develop adequate flow for degassing large
tanks.
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The IC engine method, unlike the flame thermal oxidation method, requires precautions to protect the equipment are required if the tank vapors are laden with H2S or
thiols (mercaptans). These vapors will quickly corrode the engines and the instrumentation causing it to break down while in operation or to shorten its useful life.
Most suppliers of IC degassing technologies require that the sulfur compounds be
reduced to less than 10 ppm by placement of a wet caustic scrubber or activated
carbon upstream of the unit. Review the local AQMDs rules regarding NOx and SOx
when degassing tank vapors with significant levels of ammonia, H2S or mercaptans.
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Refrigeration. Just as in thermal oxidation, the refrigeration method requires that

vapors are withdrawn from the tank. The refrigeration lowers the vapor stream sufficiently to drop out a significant amount of volatile organic compounds by condensation. The remaining air and vapors are recirculated to the tank.
July 2000
The refrigeration system recovers the liquid in the vapor. Usually, several stages of
cooling are required. The water vapor must first be removed by cooling the vapor
stream to about 35F so that additional stages of cooling do not cause it to freeze.
Once the water is removed, the temperature may be further dropped to about -40F
to -100F. The cooling is achieved by using either special low temperature refrigeration units or by liquid nitrogen. Figure 1100-14 shows an example of a refrigeration
system (which is characterized by its complexity).
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Fig. 1100-14 Thermal Oxidation Degassing - Refrigeration Method From API 2015, Fig. 5.11. Courtesy of the American
Petroleum Institute.
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Carbon Adsorption. In this method, the vapor stream is fed into an activated
carbon unit as shown in Figure 1100-15. While activated carbon does an excellent
job in reducing the levels of hydrocarbon vapors, the activated carbon is consumed
in the process. Typically, portable canisters are valved in parallel and switched to
fresh sources as they are used. Once spent, the carbon must either be regenerated or
disposed of. In either case, the cost is too high for practical applications.
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Balancing Methods
This section covers balancing methods for degassing.
Water Balancing. In this method, either water or a relatively non-volatile stock

such as diesel is used to displace the vapors that would otherwise accumulate when
a floating roof tank is landed. This method is not useful for emptying tanks for
personnel entry for inspection or repairs of the tank. Figure 1100-16 depicts the
water balancing method.
1100-26
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Fig. 1100-15 Thermal Oxidation Degassing - Carbon Adsorption Method From API 2015, Fig. 5.12. Courtesy of the
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Fig. 1100-16 Water Balancing Method From API 2015, Fig. 6.2. Courtesy of the American
Petroleum Institute.
Product out to
temporary
storage or
treatment
facilities
Hot Tap
Above Ground
Internal Floating Roof
Storage tank
being degassed
Clean water supply
Inert Gas Balancing. The specific gravity of a gas is proportional to its molecular
weight. Most light hydrocarbons filling the vapor space of tanks, vessels and barges
have a specific gravity that is less than carbon dioxide (molecular weight 44). This
means that carbon dioxide may be used to displace the hydrocarbon fumes from
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1100-27
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Tank Manual
enclosed spaces. This method has not been proven for practical use on aboveground
storage tanks. It may have good potential for tanks with very specific conditions and
requirements.
1128 Factors Affecting Degassing Time
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One of the most important considerations in selecting potential contractors is the

time required for degassing. The concentration of the tank vapors decays in a logarithmic mode. The rate of decay is proportional to the ratio of the flow rate of
exiting vapors divided by the volume of the tank. The higher the ventilation rate the
quicker the concentration of fumes decays.
Other important considerations include:
The initial cleanliness of the tank being degassed. If there are large amounts of
liquid/sludge left in the tank then the degassing time (and costs) increases
dramatically.
Vaporization rates of hydrocarbons from both remaining sludge or liquids in the

tank as well as the gross volumetric thermal expansion. Heat from solar radiation can cause significant amounts of vapor and air expansion, as well as
increased evaporation. If the withdrawal rate of the vapor freeing or degassing
operation is too low, the net expansion of the air inside the tank combined with
the increased evaporation can exceed the flow rate of the vapors being withdrawn to the degassing unit.
The heat flux into a tank is a diurnal phenomenon; therefore, the starting and
ending time of the degassing operation can have a significant effect on the total
degassing time required. If the degassing is started in the morning, the operation will have to fight the thermal effects of expansion and evaporation. If it is
started in the evening when solar radiation becomes insignificant, it is likely the
degassing will be complete sometime during the night.
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A reduction in barometric pressure can cause the tank vapors to expand,

causing increased loading on the degassing unit. As with thermal effects, this
increased loading will tend to reduce the effectiveness of the degassing operation. Degassing conducted during cold weather usually proceeds quickly and
efficiently. On very hot days, however, it may not be possible to degas a tank to
within requirements.
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A simple rule of thumb for sizing a degassing unit holds that the minimum rated
flow of the degassing unit, after stoichiometric conditions are reached, should not be
less than the tank volume divided by 600.
Recommendations for Degassing Technologies
1100-28
Only the flame and IC thermal degassing processes be used on Chevron facilities. Not only are these the lowest cost and quickest tank degassing processes
but the hazards are understood.
Schedule most degassing to be done during cold weather if possible, as this will
reduce degassing time and costs.
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Tank Manual
1100 Maintenance
Initiate degassing operations in the evening and attempt to complete prior to

sunrise the next morning.
Do not remove PV valves prior to or during degassing. Instead, ensure they are
working properly prior to degassing.
Ensure that vendors bid proposals consider a degassing unit sized to flow
at least at the tank volume divided by 600 in standard cubic feet per minute
of flow.
1129 Degassing Safety

General Precautions
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All of the safety principles discussed above under the sections on vapor freeing,
including the provisions of API 2015, are applicable to degassing. However,
because degassing connects a process to the exiting tank vapors instead of
discharging them directly to the atmosphere, there are additional process-related
hazards. These hazards are discussed in this section. Only the safety hazards associated with thermal oxidation processes are covered.
Although hazards exist throughout the degassing operation it is important to understand where the risks are highest and during what phases they pose the greatest
threat. These hazards may be broken into three phases. Figure 1100-17 describes
each of these phases.
Fig. 1100-17 3 Phases of Degassing Hazards
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Concentration
UFL
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100% LFL
0% LFL
July 2000
Phase 1
Hazard
Phase 2
Hazard
Phase 3
Hazard
Phase 1 Hazards
Rich hydrocarbon vapors released when

opening manways, from leaks in temporary
manway covers, phyrophonic deposits.
Phase 2 Hazards
Tank interior within explosive regime, potential

flashback from degassing unit, static electricity, severity of incident during this phase is
very high, risk of phyrophonic ignition.
Phase 3 Hazards
Tank can move back into flammable range with

changes in ambient condition, hazards to
personnel entering tank.
1100-29
1100 Maintenance
Tank Manual
Recommendations to Avoid Phase 1, 2 and 3 Hazards

All temporary manway covers should be gasketed or caulked against the
manway flange and checked for hydrocarbon leakage using atmospheric monitoring equipment.
Treat the area in front of any working or serviced manways as though flammable vapors are present. Under no circumstances should the degassing unit be
set up within the secondary containment area in front of these manways.
Review the contractors procedure to check continuity of bonding wires and

grounding. Ensure that each connection has little or no resistance.
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1130 In-Service Repairs
Because it is costly to remove tanks from service and clean them for entry, it is often
necessary to work on tanks while they are in service. This section discusses inservice repairs and the safety guidelines for completing these repairs.
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1131 Safety Guidelines for In-service Work on Tanks
All work should be in accordance with the latest edition of API Standard 2015.
Gas Testing
Before the start of repair work, test the vapor space in the tank and the surrounding
area for combustible gases, aromatics, hydrogen sulfide, and any other anticipated
hazardous gases. A tag which shows the date, time, gas concentrations, and other
pertinent information must be attached to the tank.
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Gas tests must be taken at intervals as required to ensure safety during progress of
the work, and as a minimum should be taken at the following times:
Before work is started each day
At least hourly or when conditions change
Just before work is resumed, if work has been interrupted for a period of
1 hour or more
Just before work is resumed after any stock movements in or out of the tank
After removal of a portion of the seal assembly and injection of inert gas and
before work on the seal system begins
At any other time when, in the opinion of the Company or Contractor, it is

necessary to ensure safety
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No work will be permitted without fresh air breathing equipment in areas where the
hydrogen sulfide concentration exceeds ten (10) parts per million or the aromatics
concentration exceeds one (1) part per million.
1100-30
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1100 Maintenance
Hot Work Precautions

No work will be permitted in areas where the concentration of combustible gases
exceeds 0.05 on the J-W (or other approved) combustible gas indicator. Hot work
must be immediately stopped and all personnel must immediately leave the tank
when the combustible gas concentration exceeds this limit.
Stock must not be transferred to or from the tank while work is being performed. To
avoid accidental pumping into or out of the tank, valves must be closed and locked
out/tagged out by the operator. These valves must not be touched during the repair
work.
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No hot work is allowed on any roof in service. Hot work on the shell, such as hot
tapping nozzles, clips, brackets, attachments, etc., requires that the liquid level be a
minimum of 3 feet above the highest weld point. A liquid level is necessary to keep
the shell cool and to prevent possible hot surface ignition of the tank vapor space.
Work above this level on the shell must be performed cold. Hot work on shell
spiral stairways (but not on the shell) must be enclosed with a non-porous material
and continuously tested for concentrations of combustible gases. Section 1133
contains a detailed hot tap procedure.
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Floating Roof Entry Precautions
In all cases when it is necessary for personnel to go onto the roof, a safety watch
must stand by at the top of the stairway. If the person on the roof is overcome with
gas, the safety watch must immediately summon help.
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When the top of the floating roof is more than 4 feet below the top of the shell, the
top of the roof is defined as an enclosed space. Two (2) safety watches must be
present, one at the top of the stairway to the tank and the other on the floating roof,
and they must continuously test for combustible and hazardous gases. The safety
watch at the top of the stairway must not descend into the tank but will summon
help by radio if necessary.
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When workers are using fresh air breathing equipment, there must be a safety watch
with a Scott Air Pack on the gaugers platform. A second safety watch must be on
the ground monitoring the breathing air (compressor or air bottles). Tank emergency egress must be provided. This can be a crane or a portable hoist mounted on
the rim.
When working on the floating roof seal assembly, no more than 25% of the vapor
space must be exposed at any one time.
1132 In-service Shell Repairs

Leaks in in-service shells can be repaired in the following ways.
July 2000
Single holes can be temporarily repaired by inserting a screwed plug and

applying epoxy around the plug to seal and hold it. The tank should be taken
out of service immediately to complete a permanent repair.
Rivet and seam leaks can be repaired by peening the metal around a leak to seal
off the leaking area. Care must be taken to avoid applying too much force.
1100-31
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Epoxy seam sealers also can be used, but the tank level must be lower than
the leak during application of the seam sealer.
1133 Hot Tapping of Tanks in Service

General
Occasionally there is a need to install a new nozzle or other appurtenance on a tank
shell without taking the tank out of service. This work can be accomplished safely
by hot tapping, if proper procedures and precautions are used.
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An alternative which should not be overlooked is the possibility of installing the

required new nozzle on a manway cover. The advantages, if operationally feasible,
are the ability to remove the manway cover to the shop where the quality of the
alteration work can be tested, and the elimination of hazardous work in the tank
area. This, however, requires taking the tank out of service.
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API 653 section 7 lists requirements to be followed when performing installation of

radial hot tap connections. The shell material must not have been required to be
postweld head treated when originally constructed. The size of connection that may
be installed is limited by the minimum shell thickness at the connection weld location and shell material toughness. See API 653 latest edition and addenda for the
limitations and requirements. Hot tap procedures must include API 2201 practices.
See API 2201.
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Consideration should be given to the effects of welding on shells less than " thick
when the heat of welding can potentially decompose the liquid in the tank. Some
fluids, such as caustic solutions, may cause stress corrosion cracking. Other fluids
become very aggressive when heated above a certain temperature and can cause
localized corrosion of the tank shell.
Safety Precautions
Hot tapping is a useful method of making in-service repairs, but it involves hazards
which must be recognized and weighed against alternative solutions.
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Since welding done on a hot tapping job cannot be inspected or tested thoroughly,
this work should be done only by skilled welders under competent supervision.
Welding requires that the area be completely gas free and that J-W readings be taken
continuously during the welding process to assure no vapor accumulates. All
sources of vapor in and adjoining the area should be properly controlled, and the
timing of the work should correspond to the in-breathing (emptying) of tanks which
might contribute vapor to the area.
The liquid level should be at least 3 feet above the level where welding work is
being done. Consult the local operating management for any requirements
specific to your plant.
The gas testing and hot work precautions listed in Section 1131 should be used
during a hot tap.
1100-32
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1100 Maintenance
Equipment
Pre-work Inspection
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Several makes of hot tap machines can be purchased or rented. Although they were
developed primarily for use on pipe lines, they are also suitable for use on tank
shells. The size of the machine needed depends on the size of hole. Some machines
can make cuts up to 18 inches in diameter. Note that hot tap cutters usually cut a
hole somewhat smaller than the nozzle inside diameter. This must be considered
if appurtenances are to go through the hole. Maximum nozzle size allowed by
API 653 is 18-inch diameter. Chevron limit is 12 inches. See Limitations in this
section.
Before a hot tap is made, UT scan the tank shell at the location of the hot tap for any
possible deficiencies and review recent records of interior inspection of the tank.
Every effort should be made to determine the soundness of the shell plate. If there is
reason to suspect shell plate deficiencies, hot tapping should be avoided.
Nozzle Location and Hot Tapping Procedure
at
The new nozzle should be kept clear of existing seams and other nearby nozzles.
API 653 Section 7.14 requires certain minimum weld spacing (Toe-to-Toe) from the
hot tap nozzle and reinforcing plate (if any) and existing tank shell welds. All
welding to the tank shell must be done with low hydrogen electrodes. Pipe, flanges,
reinforcing plate and details should conform to API 650 (Section 3.7.6) nozzle
details. Only the method of welding the nozzle to the tank should differ from
API 650. Since the interior backup weld for the nozzle obviously cannot be made
with the tank in service, it must be altered as indicated in the following procedure for
pipe connections over 2 inches. All other welds should follow API 650 requirements.
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Small connections up to 2 inches. Install a weld boss per Standard Drawing

GC-C1043 Rev. 2 (see Pressure Vessel Manual).
Pipe connections over 2 inches. These nozzles require a reinforcing plate. Install
nozzle and reinforcing plate in accordance with Figures 1100-18 and 1100-19 and
the following procedure:
Bevel nozzle end 37 degrees with 1/16-inch lip edge.
2.
Tack to shell with 1/16-inch lip edge spacing.
3.
Apply full penetration weld with full fusion to pipe and shell. Leave no
undercut on pipe and remove all slag and weld splatter from shell and pipe. See
Figure 1100-18.
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1.
July 2000
If pipe connection is 10" or larger, back grind the nozzle-to-shell weld if the
shell thickness is 3/8 inch or less. Back gouging may be used on shells having
thickness greater than 3/8 inch. Clean metal and back weld to assure full penetration and fusion throughout thickness of nozzle-to-shell weld.
1100-33
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Fig. 1100-18 Hot-tap Welding DetailsNozzle-to-Shell From API 653, Fig. 7.7. Courtesy of the
Hydrostatic test the nozzle to 1.5 times the hydrostatic head pressure of the
tank.
5.
Roll reinforcing plate to fit snugly to shell. Trim inside diameter of opening to
fit toe of pipe weld leaving appropriate lip edge space and groove dimensions
for the diameter of hole and thickness to be welded. See Figure 1100-19.
at
4.
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Fig. 1100-19 Hot-tap Welding DetailsReinforcing Plates From API 653, Fig. 7.7. Courtesy of
the American Petroleum Institute
1100-34
6.
Press pad firmly against shell and tack outside diameter of pad.
7.
Weld inside diameter of pad being sure to get good fusion to shell.
8.
Finish weld with smooth fillet from top of pad to nozzle surface. Leave no
porosity or undercuts.
9.
Complete the weld on the periphery of the pad per API 650.
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1100 Maintenance
10. Test reinforcing plate with air pressure between 5-15 psi.
11. Prior to cutting a hole in the shell, test the completed nozzle assembly to
1.5 times the static head pressure at the nozzle location.
Limitations
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Hot tapping of tanks should not be done if the nozzle diameter is over 12 inches. If a
larger nozzle is necessary, the tank should be taken out of service and the nozzle
assembly shop-welded and stress-relieved. See section on shells in Specification
TAM-EG-967.
1134 Fixed Roof Repairs
Fixed roof repairs can be made in the following ways.
Deck plate holes. Holes in the deck plate can be cold patched. A patch plate to
cover the area is prepared with holes drilled along the edge. After applying a
sealant/adhesive to the deck plate where the edge of the patch plate will be, the
patch plate is then set in place and fastened with sheet metal screws.
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Thin roof deck. The thin roof deck can be repaired by applying a laminate coating.
Holes are first covered with light sheet metal patches held in place with sealant/
adhesive or sheet metal screws. See the Coatings Manual for more details on laminate coatings. The deck must be marked to prevent access after the repairs are
performed.
Appurtenances. You can install appurtances using the following methods:
Existing pipes can be cut off, threaded, and a threaded flange installed with the
new appurtenance bolted on. If no lifting force will be applied when the appurtenance is used (such as the funnel on a sample hatch), the attachment can also
be made by gluing the flange to the pipe. In this case, tack welds on the inside
of the slip-on flange made in the shop can hold it in place before gluing.
ed
1.
A surface-mounted appurtenance can be installed on the roof deck by welding a

reinforcing pad on the appurtenance in the shop, cutting an opening in the roof
deck, and then attaching the appurtenance to the roof deck in the same manner
as a large patch.
at
2.
1135 Floating Roof Repairs
July 2000
Floating roof repairs can be made in the following ways.

Temporary hole repair. Temporary repairs of holes in the deck plate can made with
steel plugs and sealant as done with shells.
1100-35
1100 Maintenance
Tank Manual
Cold patches. Cold patches can be made in the same manner as with a fixed roof,
with the following additional steps:
1.
The leak must be momentarily plugged using a plug and sealant.
2.
The patch should be conical shaped so as not to displace the temporary plug
while the patch is being installed.
3.
After installation of the patch, the area should be thoroughly cleaned of all oily
contaminate and an epoxy sealant installed over the patch after adequate
surface preparation.
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A thin upper deck of pontoons can be repaired in the same manner as a fixed roof:
by sheet metal patching and laminate coating. The area must be marked to prevent
access.
Rolled or bent floating roof fixed low legs can be cut off internally (below the lower
roof deck) by use of an ultra-high pressure hydrocutter. The remainder of the roof leg
through the roof then becomes the guide sleeve for a temporary two-position leg.
at
1136 Floating Roof Seal Systems
Rim-mounted primary shoe and toroidal seal systems can be removed, repaired, or
replaced. To minimize evaporation and potential hazard to the workers, no more
than one-fourth of the roof seal system should be out of the tank at one time.
Temporary spacers to keep the roof centered should be used during the repairs.
Primary seal systems mounted partly or fully below the bolting bar or top of the rim
usually cannot be reached to allow removal in service. In this case, in-service
repairs are restricted to replacement of the primary seal fabric.
ed
Rim-mounted secondary seals are readily installed, repaired, or replaced with the
tank in service, as are shoe-mounted secondaries.
1137 Insulation
at
In-service repairs to insulation on the shell and fixed roof can be made by the
following methods.
Shell. Shell insulation can be installed, repaired, or replaced in service. A special

bar with studs for the laybar installation will be required to provide studs above a
level 3 feet below the stock level of the tank. Below that level, the bar will be
welded to the tank using the hot tap procedure described in Section 1133. (See
Figure 1100-20.)
1100-36
July 2000
Tank Manual
1100 Maintenance
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Fig. 1100-20 Laybar InstallationIn-service Tank
Caution The roof should be inspected to ensure it has adequate thickness in the
at
area of the required repairs.
Fixed Roof. Roof insulation is normally impaled on studs welded to the roof. Inservice replacement of insulation is feasible as long as the impaling studs are not
damaged.
Where in-service installation is required without studs, one company, Thermacon,
has a design consisting of cables in tension across the roof which are attached cold
to the top angle. These cables hold the roof insulation in place.
ed
1138 Appurtenances
Caution When an appurtenance is to be removed from a tank that is in service,

precautions may be required to prevent the uncontrolled release of
vapor from the tank.
at
Bolted-on appurtenances, such as valves, breathers, hatch covers, manway-mounted

mixers, and heaters, etc., and threaded appurtenances, such as hatch covers,
autogauge guides, etc., can be replaced in service. To install some appurtenances
will require that the tank level be pumped down. Some appurtenances which are
above the liquid level, such as sample hatch funnels on existing sample hatches of
floating roofs, and those fixed roof appurtenances mounted directly to the roof, can
be replaced in service.
In-service repairs can be made on stairways, platforms, and wind girders by bolting
instead of welding. Such attachments must be well sealed to prevent corrosion
product between the surfaces from breaking the bolts.
Rolling ladders can be removed from the tank and repaired, rebuilt, or replaced in
service.
July 2000
1100-37
1100 Maintenance
Tank Manual
1140 Resources
DeBeer, E. E., Foundation Problems of Petroleum Tanks, Annales de LInstitut
Belge du Petrole, No. 6, 1969, pp. 25-40
Malik, Z. Morton, J., and Ruiz, C., Ovalization of Cylindrical Tanks as a Result
of Foundation Settlement, Journal of Strain Analysis, Vol. 12, No. 4, 1977
pp. 339-348.
Timoshenko, S., Theory of Plates and Shells, McGraw-Hill Book Co., Inc.,
New York, N.Y., 1955
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Sullivan, R. A., Nowicki, J. F., Settlement of Structures, Conference organized by

the British Geotechnical Society at The Lady Mitchell Hall, Cambridge held in
April 1974
Duncan, J.M., DOrazio, T. B., Stability of Steel oil Storage Tanks, Journal of
Geotechnical Engineering, Vol 110, No. 9, September, 1984
API 653, Appendix B.
at
Duncan, J.M., DOrazio, T. B., Distortion of Steel Tanks Due to Settlement of their
Walls, Journal of Geotechnical Engineering, Vol 115, No. 6, June, 1989
Sullivan, R. A., and Nowicki, J. F. 1974, Differential Settlements of Cylindrical Oil

Tanks. Proceedings, Conference on Settlement of Structures, British
Geotechnical Society, Cambridge, pp402-424.
Marr, W. A., Ramos, J. A., and Lambe, T. W. Criteria For Settlement of Tanks,
Journal of the Geotechnical Engineering Division Proceedings of the American
Society of Civil Engineers, Vol. 108, No GT8, August, 1982.
ed
DOrazio, T. B., Duncan, J. M. Differential Settlements in Steel Tanks, Journal of

Geotechnical Engineering, Vol. 113, No. 9, September, 1987.
Koczwara, F. A. Simple Method Calculates Tank Shell Distortion, Hydrocarbon

Processing, August 1980
at
EEMUA (The Engineering Equipment and Materials Users Association) Document

No 159 (Draft)
Duncan, J. M., DOrazio, T. B., and Myers, P. E., Settlement of Tanks on Clay,
presented at ASCE Settlement 94
1150 Tank Shutdown Checklist

Included in this section are examples of Tank Shutdown Checklists that have been
developed at various facilities. They each list the typical work done during a tank
shutdown and can be utilized by the engineer or Company Representative to help
plan work for each tank. For questions concerning the checklists, please contact a
representative from that particular facility. The checklist, which starts on the next
page, is a sample tank shutdown checklist from the Richmond Refinery. Other
samples follow.
1100-38
July 2000
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1100 Maintenance
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CLEAN START DATE:

____TANK CHECKLIST
CHECK. MEETING:
WORK START DATE:

CLEAN CHG. # :
WORK END DATE:

SERVICE:
LOCATION:
REPAIR CHG. # :
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
TECH REP:
MAINT REP:
OPR REP:
ENGR REP:
INSP REP:
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
MOAN LIST: YES NO
BLIND LIST:
YES NO
VALVE REPAIR LIST: YES NO
EVACUATION PLAN: YES NO
----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
INSP. RPT.: YES NO
ER COPY: YES NO
ENGR. BM'S/MTL. LIST: YES NO
TANK CLEANED: YES NO
======================================================================================================================
EWO/
WORK COMPLETED
EXECUTION REF
620#
ITEM DESCRIPTION
OPER. MAINT. INSPECT. RESPONSIBIL. LOC

====== ============================================================= ========= ========= ========= ============= =====
I.
PRELIMINARY ITEMS
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL BLINDS PER OPERATOR BLIND LIST
XXXXXX
PLAN
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
PULL TANK LEGS
XXXXXX
PLAN
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
OPEN ALL TANK MANWAYS

XXXXXX
XXXXXX
PLAN
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
CLEAN TANK FOR INSPECTION

XXXXXX
PLAN
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
REMOVE FOAM LOG SEAL BEFORE REPAIR WORK BEGINS

XXXXXX
PLAN
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====
II.
TANK INTERNALS
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT BOTTOM & PULL __ COUPONS

XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
REPAIR/INSTALL NEW API BOTTOM W/ 3/8" ANNULAR RING

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
1) CK QUALITY OF MEMBRANE
XXXXXX XXXXXX
INSPECTION
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
2) VAC. TEST MEMBRANE

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
3) CUT GROOVES IN FIBERCRETE CONCRETE

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
4) SEND CONCRETE SAMPLE OUT TO LAB

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
5) INSTALL BACK-UP STRIP FOR ANNULAR RING

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR INTERNAL SHELL

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
MODIFY/REPAIR TANK NOZZLES & MANWAYS FOR NEW BOTTOM

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT,SLOT,REAM & REPAIR GAUGE WELL

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL/REPLACE GAUGE WELL SS STRICKER PLATE

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
CHECK TANK GAUGE WELL CLEARANCE - 12"

XXXXXX
INSP/CONT
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & INSTALL/REPAIR VORTEX BREAKER

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT,REPAIR/REPLACE & LUBE SWING LINE WINCH & SHEAVE

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSP,REPAIR/REPLACE SWING LINE: CABLE,PONTOONS & PIPE

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
July 2000
1100-39
1100 Maintenance
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=======================================================================================================================
EWO/
WORK COMPLETED
EXECUTION REF
620#
ITEM DESCRIPTION
OPER.
MAINT. INSPECT. RESPONSIBIL. LOC
====== ============================================================= ========= ========= ========= ============= =====
INSPECT,REPAIR/REPLACE&HYDRO @ 45psi_SWING LINE PONTOON

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT,REPLACE & HYDRO @ 45psi _ SWING LINE STAY-TITES

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR FILL LINE DISPERSER

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
CHECK/ADD BALLAST (450 THINNER) ON PONTOONS

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR ROOF LEGS

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL MOUSE HOLES ON ROOF LEGS

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL NEW COFLEXIP ROOF DRAIN

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
HYDRO ROOF DRAIN @ 45psi

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL CATHODIC PROTECTION

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
POWERWASH & SANDBLAST RIVET TANK FOR SEAM FIX

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SEAM FIX & COAT INTERNAL RIVETED SEAM AREA

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SANDBLAST & COAT INTERNAL SHELL & ROOF

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SANDBLAST & COAT BOTTOM

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SANDBLAST & COAT 100% TANK INTERNAL

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL ROOF LEG WEAR PLATES

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====
III
TANK ROOF
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT TANK ROOF

XXXXXX
INSPECTION
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL/REPAIR NEW API CONE/FLOATING ROOF & APPURTANCES

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SERVICE/REPLACE/INST. _ SHAND&JURS ROOF BREATHER VALVES

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & SERVICE/REPLACE ROOF VENTS & VACUUM BREAKERS

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & SERVICE/REPLACE GAUGE HATCH

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & SERVICE ALL ROOF HATCHES

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
CLEAN-OUT ROOF DRAIN

XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
MODIFY ROOF DRAIN ON CONE ROOF TKS.

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR/REPLACE ROOF RIM ANGLE

XXXXXX
XXXXXX CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
REMOVE OLD PRIMARY & SECONDARY ROOF SEAL

XXXXXX
CONTRACTOR PLAN
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR/REPLACE PRIMARY ROOF SEAL

XXXXXX
SEAL/CONT/TK
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
1100-40
July 2000
Tank Manual
1100 Maintenance
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=======================================================================================================================
EWO/
WORK COMPLETED
EXECUTION REF
620#
ITEM DESCRIPTION
OPER. MAINT. INSPECT. RESPONSIBIL. LOC
====== ============================================================= ========= ========= ========= ============= =====
INSPECT & REPAIR/REPLACE SECONDARY ROOF SEAL WIPER

XXXXXX
SEAL/CONT/TK
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
DIESEL/FLOURESCENT DYE CHECK ROOF PONTOONS

XXXXXX
CONTRACTOR PLAN
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
REPAIR ROOF PONTOONS

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
REPLACE/INSTALL 1/2" BRASS GAUGE WELL GUIDE PLATE

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
WELD REPAIR ON GAUGERS PLATFORM

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR/REPLACE ROLLING ROOF LADDER & SS PIN

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL LIGHTNING SHUNTS

XXXXXX
SEAL/CONT/TK
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR FIRE FOAM SYSTEM

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SANDBLAST & SPOT PAINT/COAT TANK ROOF

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSULATE TANK ROOF

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====
IV
TANK EXTERNAL SHELL
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR TANK SHELL

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
REPAIR TANK INSULATION & WEATHER JACKET AS NECESSARY

XXXXXX
INSUL/CONT
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
REPAIR TANK INSULATION BANDS AS NECESSARY

XXXXXX
INSUL/CONT
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL RE-INFORCING PLATE WEEP HOLES

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR TANK STAIRWAY

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SANDBLAST & SPOT PAINT/COAT TANK SHELL AND NUMBER TANK

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SANDBLAST & SPOT PAINT/COAT TANK STAIRWAY

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SANDBLAST & COAT TANK ACCESS PLATFORMS

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SANDBLAST & SPOT PAINT/COAT WINDGIRDER

XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====
July 2000
1100-41
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=======================================================================================================================
EWO/
WORK COMPLETED
EXECUTION
REF
620#
ITEM DESCRIPTION
OPER.
====== ============================================================= ========= ========= ========= ============= =====
V
INSTRUMENTATION
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

INSPECT & REPAIR ALL THERMOWELLS(TACK WELD IN PLACE)
XXXXXX
CONT/TK
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

DISCONNECT,INSPECT,RECALIBRATE,REINSTALL TANK AUTO GAGE
XXXXXX
XXXXXX
B&S I&E
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

CALIBRATE & REPAIR/REPLACE/INSTALL TEMPERATURE SENSOR
XXXXXX
XXXXXX
TK/I&E
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT GAGING DATUM PLATE
XXXXXX
TK/I&E
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====
VI
MIXERS & PUMPS
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

OVERHAUL/REMOVE/INSTALL _ TANK MIXERS
XXXXXX
XXXXXX MACH. SHOP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

OVERHAUL/REMOVE/INSTALL _ TANK MIXER MOTORS
XXXXXX
XXXXXX MACH. SHOP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

CONVERT/REPLACE _ PACKING SEAL MIXERS W/MECH. SEAL TYPE
XXXXXX
XXXXXX MACH. SHOP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REPLACE SIDE SAMPLE PUMP & MOTOR
XXXXXX
XXXXXX MACH. SHOP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====
VII
TANK HEATER
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

CLEAN,INSPECT & HYDRO _ HEATER COIL/BUNDLE
XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REPLACE/INSTALL _ HEATER COIL/BUNDLE
XXXXXX
BOIL. SHOP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REPAIR HEATER PIPING
XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REPAIR/REPLACE/INSTALL HEATER PUMP
XXXXXX
XXXXXX CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

ATTACH HEATER SUPPORT RAIL TO SHELL
XXXXXX
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====
VIII
TANK VALVES
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REMOVE & REPAIR/REPLACE _ VALVES PER OPR.
XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REPAIR/REPLACE _ VALVES PER INSP.
XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REMOVE,POP & RESET _ PSV'S PER OPR.
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REPLACE/UPGRADE SAMPLE SYSTEM VALVES TO E-1 SPECS.
XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====
Tank Manual
1100-42
July 2000
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=======================================================================================================================
EWO/
WORK COMPLETED
EXECUTION REF
620#
ITEM DESCRIPTION
OPER.
====== ============================================================= ========= ========= ========= ============= =====
IX
PIPING
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

INSPECT & REPAIR TANK PIPING
XXXXXX
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

UPGRADE/INSTALL SUN RELIEF PIPING & VALVES
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

UPGRADE PIPING & VALVES TO E-1 PIPE SPECS. AS NECESSARY
XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
UPGRADE/INSTALL SIDE SAMPLE SYSTEM TO E-1 PIPE SPECS.
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

MODIFY PIPING FOR NEW BOTTOM
CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REPAIR/REPLACE/UPGRADE STEAM TRACE TUBING AS NECESSARY
XXXXXX CONTRACTOR
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

REPAIR/REPLACE PIPE INSULATION AS NECESSARY
XXXXXX CONT/ISULAT
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

INSPECT & REPAIR WATER DRAW
XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====

X
MISC.
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

CLEAN TANK BASIN AREA
XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

CLEAN-OUT WATER DRAW BASIN AREA
XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSPECT & REPAIR/REPLACE ACCESS PLATFORM
XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

INSTALL/REPAIR/REPLACE WALKWAYS
XXXXXX CARP. ZONE
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

CLEAN & REPAIR GUNITE DRAIN GUTTER
XXXXXX
ZONE/2-DIT
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

DAYLIGHT PIPING
XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ============================================================= ========= ========= ========= ============= =====
XI
OPERATIONS
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------

STENCIL SOH , HOD & LPO
XXXXXX XXXXXX OPERATIONS PLAN

------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
STENCIL TANK & THERMOWELL NUMBERS

------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
STENCIL SWING LINE DIAGRAM ON TANK

------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
PROVIDE EVACUATION PLANS
XXXXXX OPERATIONS PLAN

------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
CLEAN-OUT TANK PIPE LINES
XXXXXX OPERATIONS PLAN

------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
ENGR. MEASURE & CALC. NEW STRAPPING CHART & SAFE OIL HEIGHT
XXXXXX XXXXXX
ENGR.
PLAN
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ===========================================================
========= ========= ========= ============= =====
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=======================================================================================================================
EWO/
WORK COMPLETED
EXECUTION REF
ITEM DESCRIPTION
620#
OPER.
====== ============================================================= ========= ========= ========= ============= =====
XII
TANK HEAD-UP
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL/REPAIR/REPLACE WALKWAYS
XXXXXX
TK/ZONE
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
RAISE FLOATING ROOF LEGS AFTER TANK FIRST FILL
XXXXXX
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
CONT/TK
PLAN
HYDO TANK SHELL & ROOF
XXXXXX XXXXXX
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ===========================================================
========= ========= ========= ============= =====
XIII
POST TANK WORK
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL RETAINING WALL AROUND TANK
XXXXXX
ZONE/2-DIST
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
GUNITE AREA AROUND TANK
XXXXXX XXXXXX
2-DIST
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
GUNITE AREA UNDER PIPING
XXXXXX XXXXXX
2-DIST
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
2-DIST
INSTALL GUNITE DRAIN GUTTER
XXXXXX
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
SEAL TANK SKETCH PLATE AREA
TK GROUP
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
INSTALL LIGHTING PER ENGR.
XXXXXX XXXXXX
I&E ZONE
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
CHECK SEAL FIT & COMPLIANCE
XXXXXX
INSPECTION PLAN
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
====== ===========================================================
========= ========= ========= ============= =====
XIV
EXTRA TANK WORK
---------- ------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
------------------------------------------------------------------------------------------------------------ --------------- --------------- ---------------- -------------------------- ---------
Tank Manual
1100-44
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Tank Manual
1100 Maintenance
Revision History
Date
General revision
Author
Sponsor
JWIJ
JWIJ
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July 2000
Description
July 2000
1100-45
Tank Manual
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1100 Maintenance
1100-46
July 2000

TAM-EN-1100 Tank Maintenance

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CAUTION: Based upon the publication date, this document may not contain the latest

Tank Entry Precautions

Company and Industry Documents

Operating Methods to Minimize Sediment

Sediment Types and Removal Procedures

Separating Salvable from Non-salvable Material in Sludge

Levels of Cleaning Required

Vapor Freeing Methods

Vapor Freeing Equipment

Safe Vapor Freeing Operations

Factors Affecting Degassing Time

2000 Chevron USA Inc. All rights reserved.

Safety Guidelines for In-service Work on Tanks

In-service Shell Repairs

Hot Tapping of Tanks in Service

Fixed Roof Repairs

Floating Roof Repairs

Floating Roof Seal Systems

Tank Shutdown Checklist

2000 Chevron USA Inc. All rights reserved.

1110 Tank Cleaning

To change to a cleaner or non-compatible service

1111 Tank Entry Precautions

1112 Company and Industry Documents

Fire Prevention Manual, Fire Protection Through Inspection and

Manufacturing Department, Chevron U.S.A.

ES-666, Cleaning and Repair of Tanks (El Segundo Refinery)

Operating Standard AR-9240, Cleaning Tanks (Richmond Refinery)

Operating Standard AR-9241, Cleaning and Repairing Leaded Gasoline

Marketing Department, Chevron U.S.A., Operations Standard, Section IX,

Pipe Line Department, Chevron U.S.A., Safe Practice Regulations, 5.011.2

1113 Operating Methods to Minimize Sediment

Variable Angle Mixers

Tank downtime is reduced.

Very little solid waste must be disposed of.

2000 Chevron USA Inc. All rights reserved.

Area of Severe Sludge Buildup

Fixed Angle Mixer

Variable Angle Mixer

Overall cleaning costs are reduced.

Cleaning operation is essentially all done from outside the tank.

Exposure of people to the tanks atmosphere can be minimized or eliminated.

Procedure for Using a Variable Angle Mixer to Clean a Tank

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Hydraulic Jet Nozzles

1114 Estimating Sludge Quantity

Sludge removal procedures

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Gauging Sludge Depth

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Visual Survey Through Open Shell Manway

Caution Sludge rarely builds up evenly over the entire bottom.

1115 Determining Sludge Content

Tanks Unsafe to Enter

Tanks Safe To Enter

Collect a sample of each liquid layer as outlined in Step 1 above.

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Barrels left = 0.14 d2 h

Determine the number of sample points to be included in the composite sample

No. of Sample Points

Fig. 1100-4 Sludge Sampling Locations

Testing Sludge Content

1116 Sediment Types and Removal Procedures

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