Tank Cleaning

ExxonMobil JOLIET REFINERY safety procedures
Tank Entry/Cleaning Procedure August 2012
TANK ENTRY/CLEANING PROCEDURE
PURPOSE
To provide guidelines for the safe execution and preparation for maintenance activities involving storage
tanks and spheres. The overall aim is to ensure all jobs are performed safely and due consideration is
given to protecting employee health and property.
SCOPE
Any work activity, which involves the isolating, opening, cleaning and repairing of storage tanks and
spheres, must comply with this procedure. The tank cleaning process begins when the product is
removed from the tank by means other than normal fixed piping.
The Tank Entry/Cleaning Procedure is intended to be used in conjunction with established procedures
such as Hot Work/Entry, Equipment Lockout/Tag Out, Opening up Process Equipment, PPE Procedure,
Respiratory Protection Program, Welding on tank bottoms and Safe Blinding, and does not replace or
reduce the requirements of other procedures.
Revision & Review Record

Date of Review
Name of Reviewer Reviewer’s Position Comment(s)
&/or Revision
Phil Gildea SHE Advisor 8/99 General Review
Clarification of Procedures; Changed
“Production” to “Process”; “Facilities” to
Kim Brackett Field Safety Advisor 2/00
“Mechanical”; “Engineering” to “Technical”
and “EHS” to “SHE”.
John S. Trammel Field Safety Advisor 9/00 Annual review
Patrick Shelton Field Safety Advisor 5/02 Annual review
Van A. Holman Field Safety Advisor 4/03 Change under C. Tank Cleaning 2. 'a. from
50 ppm to 25 ppm.
Tom Ader Field Safety Advisor 1/04 Major additions/deletions to procedure.
Van A. Holman Field Safety Advisor 10/06 Annual review - formatting and minor
corrections.
Craig Skubic Field Safety Advisor 1/08 Annual Review – minor corrections.
Craig Skubic Field Safety Advisor 9/09 Annual Review – minor corrections.
Mike R. Smith Oil Movements PCS
Craig Skubic Emergency Response 1/11 Annual Review – Formatting and minor
Coordinator corrections.
Art Arias Oil Movements PCS 8/12 Incorporated Tier-1 BP procedures
Section 9 – Tank Entry Cleaning Procedure -1-

I. RESPONSIBILITIES
A. Process
1. Advises Mechanical and Contractors of the product stored in the tank and ensure
they are aware of the hazards. (This can be accomplished in the Pre-Cleaning
Conference see Appendix A.)
2. Prepares tank for maintenance activities by:
a. Closing valves.
b. Identify and tag blinding locations.
c. Inspect the floating roof.
d. Draining liquid product from the tank through fixed piping.
e. Lockout/tagout mixers, valves, level indicating devices, cathodic
protection and pumps and any other potential energy sources.
f. Lowering the roof long legs on external floating roofs.
g. Post or barricade the area to prevent entry of vehicles or unauthorized
personnel into the work area.
h. Communicate other activities to all personnel in area. ie; draining,
sampling, opening up process equipment.
NOTE: Often times, when an external floating roof is on its legs, the roof drain hose will
crimp and the roof will not drain. The roof should be monitored for water
accumulation. If necessary, the emergency roof drain plugs may be pulled to
remove the water.
B. Mechanical/Contractor
Mechanical is responsible for ensuring that the following is accomplished:
1. Train personnel on correct procedures, potential chemical exposures, and
personal protective equipment requirements.
2. Stop all other work inside the diked area and within a minimum of 50 feet (15
meters) upwind from the tank (longer distances may be required when there is
no wind, or because of other weather conditions or special circumstances, like
downwind location). During initial opening of the tank stop all work within a
minimum of 100 ft (30 m) from the tank or such greater distance as appropriate
considering site conditions.
3. Prior to residual product removal and tank ventilation, the Assigned Supervisor
must control ignition sources.
4. Blind and isolate all lines to the tank.
5. Notify Field Safety prior to opening tank manways.
6. Open, vapor free, clean, and repair storage tank.
7. Identify Hazards and minimize exposures.
8. Install barriers around, or over floor openings, overhead hazards and trip
hazards
9. Post Caution Hazard Signs at the entry point that identifies hazards and update
as necessary.
10. Review the Contractors JSA for accuracy prior to initiating work.
11. After Maintenance activities are completed, prepare the tank to return to service.
12. Any equipment inside the diked area must be bonded to the tank. It is imperative
to use only diesel powered equipment which has emergency engine air intake
shut-off devices in the event vapors reach the equipment.

C. Assigned Supervisor
1. The Assigned Supervisor must ensure that tank cleaning is conducted safely and
efficiently according to the ExxonMobil Tank Cleaning Procedures and local
regulatory requirements. The Assigned Supervisor should be an ExxonMobil
qualified employee.
2. The Assigned Supervisor must:

a. Conduct the Pre-Cleaning Conference and site review with the appropriate
personnel involved with the project.
b. Ensure that all safety requirements are understood and followed by all personnel
involved.
c. Ensure strict conformance with Work Permit and Confined Space Entry
procedures.
d. Inspect equipment to be used to assure it complies with safety standards, is
calibrated, and in proper working order.
e. Be present at the work site during the execution of critical steps (i.e., opening
manway, tank entry, vapor freeing, beginning of ventilation, etc.).
f. Prepare all Confined Space Entry/Hot Work permits as required.
g. Witness all hydrocarbon vapor, oxygen, and toxic tests until the tank is declared
vapor/gas and/or lead free. Must personally certify, or endorse certification that
the tank is vapor/hazard free.
h. Ensure contractor’s adherence to safety standards and acceptable safe work
practices during operations.
i. Establish site-specific work plans and procedures which are consistent with the
procedures outlined in this document.
j. Ensure that a checklist similar to Appendix A is utilized and sign off on its proper
completion.
k. Have full authority to stop the work any time applicable safety requirements are
not complied with.
D. Field Safety
Field Safety is responsible for the following:
1. Assist Mechanical and Process with personal protective equipment selection and
requirements (see Appendix F).
2. Assist Mechanical and Process with hazard identification.
3. Conduct tank atmosphere tests for hydrocarbon vapors, benzene, oxygen, and other
chemicals as needed (see Appendix E).
4. Review posted Caution Hazard Sign and update as necessary.
5. Ensure proper barriers are in place such as sump holes.
6. Review tank for physical hazards
7. Issue Hot Work and Entry Permits.
8. Check for trapped hydrocarbons, e.g., in pontoons, floating roof legs, fixed roof
support columns, internal piping, seals, tank bottom lining/coating, pipe supports,
steam coils, etc. Foam log-type (also known as toroidal or tubular) seal materials
may be saturated with hydrocarbons
E. Technical
The Inspection Group is responsible for the following:
1. Review work permits, confined space entry permit and hazard recognition signs prior
to starting work activities.
2. Inspect external floating roof legs to ensure they are adequate to support roof.
3. Inspect roofs for thickness around vacuum vents and access ladders.
NOTE: Planks must be used to walk on roofs when thin areas are suspected.
4. Visually inspect internal floating roof legs for structural stability.
5. Visually inspect internal structural supports for structural stability (cone roof).
6. Perform Non-Destructive Testing procedures to qualify structural integrity of floor,

supports and tank shell as necessary.
II. PROCEDURE
A. Tank History Review
1. Prior to cleaning any tank, the following factors must be taken into account when
developing the cleaning plan:
a. The product(s) stored in the tank since the last cleaning [including Material
Safety Data Sheets (MSDSs)].
b. Potential contaminates or byproducts from upstream processes that were or may
be reactive in the presence of water, oxygen, detergents or solvents.
c. If leaded gasoline has been stored in the tank, and records do not indicate that it
has been declared lead-free, steps must be taken to test and control exposures
to organic lead.
d. Product removal considerations including potentially hazardous contaminates
(e.g. hydrogen sulfide).
e. Iron sulfide history of tanks storing sour materials (e.g., crude oil, sour naphtha,
slop).
f. Construction and physical condition of the tank.
g. Making required notifications and obtaining permits.
h. Consider potential community impacts.
i. Coordinating hazardous waste handling.
j. Previous mechanical work.
2. Appropriate personnel should ensure all required notifications are made and permits
obtained. Consideration should also be given to potential community impacts. There
may also be requirements to coordinate hazardous waste handling.
B. Pre-Cleaning Conference
1. Arrangements should be made to conduct a Pre-Cleaning Conference and site
review to ensure that tank-cleaning personnel are instructed concerning the
following:
a. Potential hazards specific to tank cleaning operations, as well as including facility
safety orientation, fire fighting, and emergency evacuation procedures.
b. Correct methods and sequence of operations.
c. Work permitting requirements. Cold or Hot work and confined space permitting.
d. Tank ventilation.
e. Atmosphere air sampling requirements.
f. Flammable vapor hazards.
g. MSDS's and toxic substance concerns, where applicable, e.g., hydrogen sulfide,
lead, hydrocarbon vapors, including benzene, MTBE;
h. Personal protective equipment (PPE).
i. Potential sources of ignition, including static electricity, and their control.
j. Safe use of potentially hazardous equipment such as electric motors and
gasoline or diesel fueled engines, vapor recovery unit.
k. Environmental requirements.
2. Prior to the Pre-Cleaning Conference, a survey of the surrounding area should be
conducted to determine necessary steps to mitigate or eliminate potential hazards
such as drifting vapors from other tanks, lines, or sewers, as well as interfaces with
other nearby work areas. If after the start of operations planned conditions change,
another pre-cleaning conference must take place. The Job Safety Analysis (JSA)
may be built/assembled in the Pre-Cleaning Conference. A checklist should be used
as a planning and execution resource to facilitate this activity (see Appendix A for an
example checklist, and Appendix B for additional resources and references).
C. Preliminary Precautions
1. Hazard Identification
Process will identify potential hazards associated with each tank, such as:
a. Explosion/Fire Hazard
1. Flammable Liquids
During tank vapor freeing and cleaning, the hydrocarbon vapor in air
concentration may be in the explosive range. To reduce the potential for a
fire, air driven mechanical air movers (fans, air horns, etc.) are used to
reduce the vapor in air concentration.
2. Pyrophoric Conditions
In vessels, which have contained sour hydrocarbon streams, there is a
potential for pyrophoric conditions. The iron sulfides, when exposed to air,
will ignite. Firewater hose lines should be used to minimize the potential for
ignition. The nozzle must be bonded or grounded to the tank before using
hose lines.
b. Toxic Liquids and Vapors
1. Hydrogen Sulfide
The atmosphere in all tanks that have contained sour crudes and stocks
(high sulfur content) should be considered toxic until tests prove otherwise.
2. Lead Antiknock Compounds
A tank that has contained leaded gasoline or lead slop and has been used to
store other products without prior cleaning should always be considered lead
hazardous. All tanks will be tested before being considered lead free.
Contact Industrial Hygiene for appropriate testing.
3. Petroleum Substance
Exposure to hydrocarbon liquid and vapor should be avoided. Health

information with respect to particular materials may be obtained from PSIMS
on the refinery computer network (or the Industrial Hygienist).
4. Benzene
Benzene is a component found in some hydrocarbon streams such as
gasoline and naphtha. Exposure to benzene must be avoided. Refer to the
Benzene Safety Procedure, Section 35, of the SPPM for information on
protective equipment and safe work practices while draining, isolating, vapor
freeing, cleaning and entering storage tanks.
c. Oxygen Deficient Atmospheres
Any confined space where the percent of oxygen in the air is less than 20%
requires the use of air supplied respiratory equipment. No entry is permitted
when the oxygen content is less than 16%.
b. Physical Hazards
Additional problems may be identified, such as:
1. Structural failure of the tank shell, floor, roof, or supports.
2. Energy Sources and the control of them, including cathodic protection, static
electricity, valves and level reading devices.
3. Falling objects, debris or tools from overhead.
4. Falls through corroded tank roofs.
5. Tripping over hoses, piping, or equipment.
6. Floor openings such as sumps.
7. Slipping on wet or oily surfaces.
8. Inadequate personal protective equipment (PPE).
9. Improper use of tools.

10. Excessive noise.
11. Inadequate lighting.
12. Inadequate work space.
13. Limited access/egress.
14. Limited head room.
15. Swing lines or floating suctions should be lowered to the tank bottom or
properly supported by angle frames.
Note: This list is not all-inclusive.

2. Personal Protective Equipment (PPE) (see Appendix F)
Personal protective equipment for tank cleaning is as follows:
a. Boots and gloves impervious to petroleum products.
b. Disposable coveralls for dry material and impervious coveralls for liquids.
Coveralls should be light colored to detect any splash.
c. Chemical goggles to protect eyes from liquid splash.

d. Respiratory protective equipment as required by the Respiratory Protection

Program.
e. During scaling or activities, which generate dust, goggles are required unless full-
face respiratory equipment is worn.
f. Anti-static coveralls.
NOTE: Reference the PPE Procedure for further guidance on the selection and use
of PPE.
3. Training
The Mechanical Supervisor or Contractor Supervision in charge of personnel
executing the work should conduct training covering the following areas:
a. Potential hazards such as fires, flammable vapors, ignition sources, limited
access/egress, working in confined spaces, chemical exposure, health hazards,
oxygen deficient atmospheres, and physical hazards.
b. PPE requirements (clothing, respiratory, decontamination, etc.).
c. Safe use of tools and equipment (engine placement and air driven motors).
d. Procedures for cleaning up the work area and for decontamination of tools.
e. Correct order of tank cleaning steps as described in this procedure.
4. Tank Inspection
The Inspection Group will inspect the roof's condition as follows:
a. Cone Roof Tanks - Inspection Group will inspect the roof for thinning plates and
deterioration. If a thin roof is suspected, planking shall be used to distribute
weight.
b. External Floating Roof Tanks - Inspection will inspect roof legs for corrosion.
NOTE: Descending onto and working on floating roof tanks require adherence to the Hot
Work / Confined Space Entry Procedure.
c. Internal Floating Roofs - Inspection Group will conduct a visual inspection from
the manway to see if the legs are vertical and not buckled.
D. Tank Preparation
NOTE: All personnel working in the tank area must work to control sources of ignition.
1. Product Removal
a. Process will pump product out and drain the tank to the lowest possible level.
This is usually accomplished by connecting a stripping pump to the water drain
or pump out connection. Process will add water through existing pipe
connections to float and strip additional hydrocarbon and water.
b. The tank must first be emptied of all recoverable product through the tank
discharge nozzle, sample line, water draw-off, or other suitable fixed connections
without opening the tank manways. Before product transfer from a floating roof
tank, the legs of the floating roof should be adjusted to the high position to allow
room for entrants to work underneath the roof after the tank is emptied. This
assumes that confined space entry requirements can be satisfied, especially in
the case of internal floating roofs.
NOTE: Internal floating roof tanks may have to emptied, stripped and refloated with
water to help satisfy entry requirements.

2. Tank Isolation
a. Mechanical or Contractor will isolate all lines (including steam coils) following
the Safe Blinding Procedure.
b. Process, Mechanical, and/or Contractors will lockout and tag out all mechanical
or electrical equipment (e.g., mixers) following the Equipment Lockout/Tag Out
Procedure.
c. The assigned supervisor along with process should review the thermal relief
requirements for piping to prevent over-pressuring any associated piping.
e. Once the tank has been pumped out to its lowest possible level, and other
appropriate external product removal methods have been taken, prepare the
tank to be opened to complete emptying. Where pyrophorics are expected in
floating roof tanks, consider introducing water after the roof has landed to
maintain underside of roof wet. At this point, all electrical equipment (e.g.,
hydrostatic tank gauges, high level alarms, mixers, cathodic protection, sump
pumps, etc.) must be isolated and locked-out prior to other tank isolation
activities. Steam coils or electric heaters inside the tank, if present, should be
isolated and blanked-off/locked-out and allowed to cool prior to exposing the
heater above the tank liquid level.
f. A bonding wire must be connected across the flanges before the first valve is
removed. The wire must remain until one or more valves have been reinstalled.
This practice avoids sparking when the lines are disconnected due to
differences in electrical potential between tank and piping.
g. The tank must be isolated from active service by blinding, or by the removal of
valves and spool pieces, between the flanges closest to the tank. If blinding is
not possible due to welded flanges and we are going to use double block
and bleed this will require the approval of the SOC. Be sure to blind any
resulting exposed piping, valves or flanges. The tank bottom drain valve should
remain open if it will be needed for cleaning the tank. Pressure relief valves
bypassed around a blinded flange must be disconnected and capped. The
supervisor should review the thermal relief requirements for isolated piping to
prevent over-pressuring the line.
h. Close and tag out all dike/firewall drain valves and lines into adjacent areas.
i. Check to ensure the tank is adequately grounded.
j. Tank Fire Fighting foam systems must remain connected until the tank is
certified vapor/gas free.
3. Opening Manways
a. Opening the tank manways is a critical part of the tank cleaning process.
Personnel must be cautious of flammable and toxic vapors, which may be
released from the tank when the manways are removed. Personnel will adhere to
the following steps to reduce the potential for exposure:
NOTE: All unnecessary personnel shall be restricted from inside the tank dike area
during the removal of the manways and no work is allowed within the tanks dike /
restricted area, until vapor concentrations in the tank are reduced to below 50%
lower flammable limit.
b. Remove all potential sources of ignition from inside the tank dike. Hot Work
(welding, etc.), is not allowed in the dike area until the tank is declared
hydrocarbon free.
c. Remove non-intrinsically safe communication equipment (e.g. cell phones,
walkie-talkies, pagers) from the work area.

d. Remove non-intrinsically safe electrical equipment (e.g. alarms, transformers)

from the work area.
e. Remove non-intrinsic battery operated equipment (e.g. cameras, radios,
flashlights, meters, etc.) from the work area.
f. Install barricades on the road a minimum of 75 yards downwind of the tank to
restrict motor vehicle traffic.
g. Follow handling procedures as required for other potential exposures (H2S,
Caustics, Benzene).
h. Select method of vapor freeing.
i. If tank has open vent at roof (e.g. a gooseneck) then a small air-driven eductor
should be placed at the open vent and a slight draft pulled shortly before
opening the bottom manway. The draft is only enough to draw fresh air in, not
allowing vapors to come out of the bottom manway. Caution should be used to
not pull a vacuum and damage the tank. Remove only one bottom manway
cover, and do not open roof manway covers. Ensure proper bonding of the
manway cover prior to removal, if the cover is to be removed by mechanical
means. Caution: Opening roof manways in addition to opening a tank shell
manway can cause a large vapor release. This configuration should be avoided.
j. Open shell manway and start to ventilate the tank with the air mover.
k. Appropriate breathing air equipment shall be worn by personnel removing a shell
manway cover from a storage tank if there is potential for hydrocarbon vapor,
benzene, H2S, or other toxic exposure
l. All hoses to be used in the cleaning process shall be properly grounded. If
unsure on proper grounding technique, contact F/S.
NOTE: A charged 1-1/2" water hose must be standing by for tanks containing products,
which may cause pyrophoric conditions (iron sulfides) a maximum of three 1-1/2"
hoses can be used. Fire hoses must have nozzles grounded to tank.
m. Electrical extension cords are not permitted in the tank dike area during vapor
removal.
n. If lifting equipment is necessary for the removal of valves, manway covers, etc.,
or for the installation of washing equipment (e.g., "Butterworths"), it is
recommended that cranes operating outside the diked area be utilized. If this is
not feasible, and it is necessary to take lifting equipment and/or tank washing
equipment into the diked area, it is imperative to use only diesel powered
equipment which has emergency engine air intake shut-off devices in the event
vapors reach the equipment. A fire-watch must be provided. Equipment should
be placed upwind and continuous air monitoring conducted to ensure <10% LEL
levels are maintained in the work area. Any equipment inside the diked area
must be bonded to the tank. Extreme care must be exercised when first opening
the tank to avoid ignition sources. Before tank ventilation can begin, this
equipment must be removed from the diked area until the tank is below 50%
LEL.
o. Install a windsock if needed and frequently monitor wind direction and potential
downwind ignition sources, windsock needs to adequately grounded.
4. Vapor Freeing
a. Mechanical should consider the following in vapor freeing a storage tank:
1. Tank size, configuration and physical condition.
2. Weather conditions.
3. Equipment available.
4. Characteristics and amount of residual sludge on the tank bottom.

b. Frequent gas checks, a minimum of 2 per shift, of the tank's atmosphere and
surrounding area with a hydrocarbon detector are needed to determine vapor
concentrations.
c. Vapor freeing may be accomplished by two different methods:
1. Mechanical ventilation is the most commonly used method of vapor freeing a
tank. An air driven, properly grounded mechanical device is used to either:
2. Draw vapors from the top of a cone or internal floating roof tank, or;
3. Force air in through a bottom shell manway of a floating roof tank,
exhausting into a bonded chimney/duct over the top of the tank shell
NOTE: The engine driven compressor used for the mechanical air movers must be
located 75 ft. upwind of the tank and outside of the tank dike.
4. The discharges of vapors at the top of any tank allow maximum mixing with
outside air and reduce the chances of a flammable mixture reaching a
source of ignition. When using a shell (bottom) manway to discharge vapors,
it is necessary to exhaust vapors twelve feet above grade by way of a
bonded chimney or a duct. Personnel are restricted from external floating
roofs until the tank is vapor free because a potential problem exists with the
dissipation of vapor, especially during days of high humidity. Before
personnel are allowed on the floating roof or entry into the tank, vapor tests
must be conducted to ensure hydrocarbon vapors are not trapped on the
roof.
NOTE: Air movers are to be electrically bonded to the tank to prevent a potential source
of ignition.
NOTE: The use of steam to vapor free tanks is not permitted.
NOTE: Electric driven air movers are not acceptable to use for vapor removal.
5. Gas Checks
a. Frequent air tests of the tank and surrounding atmosphere are conducted to
monitor effectiveness of the vapor freeing process.
b. A Field Safety Advisor will conduct these tests upon the request of the
Mechanical or Process Supervisor (minimum 2 per shift).
NOTE: Tank atmosphere checks should be taken at the exhaust outlet and in the tank
dike area. If it is decided that gas checks will also be performed of the interior of
the tank (frequent or continuous monitoring), assure that the point from which the
sample is being taken is well inside the tank. Interior gas checks/monitoring
should be performed well away from the manway where fresh air is being pulled
due to mechanical ventilation.
c. Personnel and work activity must be restricted from the area inside of the tank
dike until the vapors in the tank are below 50% LEL. After the vapors are below
50% LEL, work activity outside the tank may resume, but hot work must still be
restricted.
d. When the vapor concentration is reduced to 20% LEL, the first objective of
removing flammable vapors is essentially accomplished. Tank cleaning, as
described in Section C, may commence (from outside of the shell manway).
Entry into the tank is NOT permitted when LEL levels > 20% or other gas check
readings above IDLH.
6. Hydrocarbon / Toxic Vapor Action Levels
Section 9 – Tank Entry Cleaning Procedure - 10 -

a. Samples of vapors in the tank must be taken, preferably at the exhaust outlet
and the bottom manway, to determine the concentration of vapors and
effectiveness of the ventilation. Continuous monitoring of hydrocarbon vapors
and oxygen content is required from the time a 10% LEL concentration has
been reached and until the tank is certified vapor/gas free.
b. 11% - 20% LEL - Tank entry when hydrocarbon vapor concentrations exceed
10% is generally prohibited. Entry at concentrations above 10%, up to a
maximum of 20% or gas readings above IDLH, should only be permitted under
exceptional circumstances, and require approval by the refinery manager, (a
manager two levels above the site manager for other organizations) and SOC
approval. Entry at concentrations above 10% requires special precautions,
and should be addressed on a case-by-case basis.
c. The Assigned Supervisor will be present at the tank when entry at these vapor
levels occurs. Personnel wearing supplied pressurized breathing air (airline
equipped with hose quick disconnects and egress bottles) or self-contained
breathing apparatuses and personal protective clothing may enter the tank for
inspection purposes only when the vapor concentrations leaving the tank are
20% LEL or less. All personnel entering the tank should be equipped with
individual exposure monitors that will alarm above 20% LEL.
d. If during entry or inspection activities, the disturbance of residue or some other
action causes the vapor concentrations to exceed 20% LEL, personnel must
cease activities and vacate the tank. They may re-enter the tank, for
inspection purposes only, when the vapor concentrations are again reduced to
20% LEL or less.
e. Personnel entering a tank containing this range of hydrocarbon levels must
wear a full body harness with a life-line. Strict conformance with Confined
Space Entry procedures is paramount during this operation.
f. 10% - 0% LEL - Personnel wearing pressurized breathing airline or self-
contained breathing apparatuses and personal protective clothing may enter
the tank to continue the cleaning process if the atmosphere inside the tank is
10% LEL or less.
g. Mechanical ventilation must be continued during this phase of the operation. If
during the cleaning activity the vapor concentration inside the tank rises above
10% LEL, work inside the tank must cease and personnel shall be required to
vacate the tank. Mechanical ventilation shall be continued until a reading of
10% LEL or less is obtained from sampling the vapors leaving the tank, before
personnel are permitted to re-enter and continue the cleaning activity. See
Appendix D for safe entry concentration limits of oxygen and toxic materials.
h. Larger capacity blowers may be used at this time to educt air from the tank roof
vent in order to speed up the ventilation time. But they must be shut down
immediately if the hydrocarbon concentration through them exceeds 10% LEL.
E. Tank Entry
1. The Assigned Supervisor must restrict personnel from working within the diked area
around the outside of the tank during vapor/gas freeing operations until the level of
flammable vapors leaving the tank is 50% LEL or lower and the atmosphere in the
diked area is within acceptable permit limits. When the concentration level leaving
the tank is below 50% only cold work is permitted inside the restricted area. When
vapor concentrations inside the tank reach 10% LEL or lower, final entry and
cleaning of the tank can commence.
a. Workers may not enter the tank without first obtaining a Confined Space
Entry Permit. Strict conformance with confined space entry procedures is an
essential component of tank cleaning operations.
2. When the tank is initially entered:

a. The interior should be inspected for any materials, which might fall.
b. Swing lines or floating suctions should be lowered to the tank bottom or
properly supported by angle frames.
c. The roof legs and striker pads should be inspected for mechanical integrity.
Auxiliary supports should be provided if integrity is in doubt.
d. Check for trapped hydrocarbons, e.g., in pontoons, floating roof legs, fixed roof
support columns, internal piping, seals, tank bottom lining/coating, pipe
supports, steam coils, etc.
e. The number of personnel in the tank should be minimized while these steps
completed due to the potential for free product to be released.
F. Tank Cleaning
1. Initial cleaning of the tank is conducted by Mechanical or Contractor personnel from
outside the tank.
a. Cleaning involves using a high-pressure water hose to dislodge and float sludge
to the water draw or pump out connection.
b. Water nozzles must be bonded to the tank to avoid static electricity discharge. If
a different mechanical and/or chemical cleaning method is used, the special
safety precautions provided by the equipment manufacturer and/or the qualified
contractor must be followed. A number of different cleaning methods are
described in the EMRE Tank Maintenance Guide (EETD050).
c. Dislodging product residue with water streams may release hydrocarbon vapors.
If samples taken of the exhausted vapors exceed 10% LEL, the following shall
be implemented:
1. Personnel in the surrounding area are to cease work and leave the restricted
area if the LEL of the vapors leaving the tank exceed 50%.
2. Ventilation should continue until a safe concentration of 10% LEL or less is
achieved from readings taken of the exhausted atmosphere before tank
cleanup work commences.
d. Access to storage tanks being cleaned should be secured at the close of the
cleaning crew’s workday (i.e., restrict access to manway).
e. If a washing machine is used in a flammable gas atmosphere (above 10%LEL),
throughput must be limited to 60 cubic meters per hour (265 gpm) per single
spray nozzle and the total from all nozzles used inside a tank must not exceed
180 cubic meters per hour (795 gpm) to avoid the generation of static electricity.
NOTE: Ensure that personnel working at the manway have grounded themselves by
touching, with bare hands, the shell of the tank away from sources of ignition,
and that they wear anti-static clothing.
f. Agitation of the sludge will cause a release of vapors. Therefore, frequent air
tests must be conducted to monitor vapor concentrations level. If vapor
concentrations increase to 50% LEL, cease cleaning operations and continue to
ventilate until the concentration level is below 10% LEL.
g. Additional precautions which must be taken during initial tank cleaning are:
1. Prevent the ignition of sludge-ladened water draining to the sewer.
2. Locate spark or heat producing equipment 75 ft. on the upwind side of the
tank and obtain Hot Work Permit or Low Energy Permit before starting any
equipment.

3. Continuous mechanical airflow is required through the tank during entry.

4. It may be necessary to enter the tank to complete the removal of sludge and liquid.
An Entry Permit is required whenever entering a storage tank or sphere in
accordance with the Hot Work/Entry Permit Procedure.
a. Entry into the tank for cleaning with SCBA or airline with escape pack, and
lifeline, along with appropriate PPE, is required when:
1. Benzene greater than 25 ppm; and/or
2. Sludge is being disturbed where there is a potential for vapor release.
NOTE: When the vapor concentration goes above 10% LEL, cleaning operations from
inside must cease until the concentration is less than 10%. The first activity after
entering the tank will be to check vapor concentrations in the tank to ensure they
are below 10% LEL throughout the tank.
b. Entry into the tank without respiratory protection requires the following criteria in
Appendix D to be met:
c. Mechanical or Contractor personnel should inspect the inside of the tank for
physical hazards. Floor openings will be barricaded or covered and tripping
hazards flagged.
d. Sludge removal may be accomplished by:
1. Washing, brushing, and squeegee the sludge into piles.
2. Shoveling (aluminum or spark proof shovels) the sludge into steel barrels or
buckets and remove from the tank or vacuum the sludge with a properly
grounded vacuum truck and hoses.
3. After sludge is removed, sweep and wash down the tank into the water draw
to be drained.
4. Cleaning up any remaining moisture with rags or absorbent materials and
dispose of properly.
5. The refinery has established guidelines for the disposal of sludge in accordance with
applicable regulations. Questions concerning sludge disposal should be directed to
the Refinery Waste Coordinator.
G. Vapor / Gas Free Tank Certification
1. Once the tank has been cleaned, the atmosphere inside the tank must be tested for
oxygen, flammable vapors, and other toxics (e.g., benzene, lead). Tank ventilation
must be stopped for at least 15 minutes prior to gas testing. Tests shall also be
made of steel roof pontoon chambers with the covers removed, floating roof legs,
columns, internal piping and supports, foam seals, and other parts that may contain
residual hydrocarbons. For the tank to be confirmed vapor / gas free the tank has to
have 3 consecutive shifts of gas tests with acceptable readings. Additional cleaning
and testing may be required before the tank is considered vapor and toxic free.
Note: High benzene concentrations (over 6 ppm) have recently been
observed while cleaning heavy scale from the walls of a tank even though the LEL
readings inside the tank were 0%.
2. The assigned supervisor will either personally certify, or endorse certification that the
tank is vapor/toxic free. The Joliet Refinery Confined Space Entry Permit will
document these vapor readings and signatures.
a. Approved respiratory protection will be used for dust and sandblasting.
b. Approved respiratory protection will be used for application of internal coatings
after all hot work is completed.
3. Upon Vapor / Gas free certification, and before further work continues,
disconnect/blind the tank fire fighting foam piping system.
H. Tank Repair
After cleaning activities have been completed, maintenance activities may be required to
repair/replace materials or equipment. These activities may be classified into three
groups:
1. Cold Work - These activities may present potential exposures to physical (e.g., dust)
or chemical substances. Personal Protective Equipment, along with correct safe
handling procedures, will minimize potential exposures.
2. Low Energy Work - These activities may involve the use of electric or battery
operated tools, AC electronic equipment, or test instruments. Low Energy Permits
are issued by the Process Department.
3. Hot Work - The majority of tank repairs will include hot work activities such as cutting,
welding, and grinding:
a. A Hot Work Permit is required in compliance with the Hot Work / Confined Space
Entry Permit Procedure.
b. Surface areas need to be prepared where hot work will be performed (heated
area) so that no hydrocarbons or ignitable scale is present. Painted surfaces
require testing for lead before the surface is disturbed (contact Industrial
Hygiene). Precautions must be taken to check for hidden pockets of
hydrocarbons, such as the primary seal, supports, legs, columns, pontoons,
internal piping and floor areas.
NOTE: Respiratory protection may be required when removing epoxy coatings from
surfaces. Remove enough epoxy material so that when hot work begins that the
material is not affected by the heat. Respiratory protection is required whenever
applying epoxy materials. MSDS must be present at jobsite for chemicals.
c. Repairs on tank bottoms require adherence to the Welding on Tank Bottoms
Procedure.
d. Repairs to floating roof tanks, because of additional areas where hydrocarbon
liquid and vapor may be trapped, requires the following to be checked:
1. Pontoons and/or flotation device
2. Seals
3. Roof support legs
4. Internal product piping and supports
III. TRAINING
All Assigned Supervisors and potential upgrades must have completed the associated training
module prior to the commencement of tank cleaning operations. This training module must also
be used to provide awareness training for all other individuals involved in the tank cleaning
operation, including contractors.

Appendix A ExxonMobil Joliet Refinery

Tank Cleaning
Planning and Execution Checklist
Records Review:
 Review the tank service history, including:
 history of leaded gasoline storage,
 product(s) storage since last cleaning,
 solid contaminates,
 any reactive materials or processes byproducts,
 Mechanical or "as built" construction drawings.
 Provide Material Safety Data Sheets (MSDS) and review flash point, vapor
pressure, and toxic hazard concerns.
 Verify contractor personnel and their subcontractors assigned to cleaning
project have completed all appropriate training, including confined space
entry and respiratory/breathing air protection. Ensure contractor training is
suitable. Ensure contractor is utilizing a minimum of short service
employees.
 Review gas tester qualifications and initial and refresher training.
 Verify gas test equipment certification and review calibration and "bump-test"
records. Verify that the gas testing equipment manufacturer's
recommendations are followed.
 Review work control permit requirements. Each activity requires a permit and
permit requirements vary depending on task. No work will begin unless a
permit has been issued by the appropriate supervisor responsible for the
operations of the tank.
 Confirm arrangements for hazardous waste disposal at approved
transport/storage/disposal site.
 Ensure regulatory/environmental permits are secured.
 Ensure workers meet all regulatory requirements to perform task.
Tank Cleaning Preparations:

 Review facility safety orientation and evacuation plan.
 Review local emergency response contacts and hospitals.
 Review general safe work procedures for site and routine operations which
may impact project (e.g., adjacent operations, vapor/ignition sources, other
projects, etc.).
 Develop a Job Safety Analysis (JSA) for the planned work, including an
overview of tank emptying, venting, and cleaning.
 Discuss with the work crew(s) the JSA and planned sequence of activities
including overview of tank emptying, venting, and cleaning.
 Confirm product level in tank.
 Review plans for transfer of residual product, (e.g., connection points on tank,
valve for water draw-off, vacuum truck placement, product receipt point)
 Identify potential ignition sources.
 Identify equipment (including Cathodic Protection) to be isolated and locked
out and review plan.
 Verify contractor equipment requirements.
 Review equipment placement locations.
 Explain work control permit requirements.
 Review tank isolation and blinding.

APPENDIX A - Planning and Execution Checklist (continued)
 Review tank ventilation and vapor/gas-freeing methods to be used.

 Verify gas testing equipment is functioning properly and has been properly
calibrated.
 Review tank internal atmospheric conditions.
 Discuss anticipated tank atmospheric conditions and mitigating plans.
 Review contractor’s supplied air breathing equipment.
 Confirm provisions for confined space attendant and rescue service.
 Establish decontamination process.
 Position portable emergency eyewash stations and/or showers consistent
with local safety or industrial hygiene requirements.
Additional Precautions:
 Equipment shall be bonded and grounded, as appropriate, e.g.,
a. compressors
b. air-driven eductors and air- or hydraulic-driven blowers
c. stacks and ducts
d. vacuum trucks or other vehicles
e. metal spill pans (no plastic spill pans)
f. spray nozzles
g. manway covers
h. hoses (conductive required) and metallic connections
i. water washing equipment
j. other tools and equipment
 Do not break a bond within 30 seconds after pumping stops.
 Workers shall ensure they ground themselves when they may be exposed to
potentially flammable atmospheres.
 Workers aware of requirement to cease all work and secure work site when
an electrical storm is approaching or threatening the area.
 Recycled wash water, or water heated above 140 degrees F (60 degrees C),
should not be used for tank cleaning when LEL exceeds 10%.
 Hoses and clamps shall be secured (e.g., wired, taped, etc).
 Absolutely no electrical connections or tools allowed inside the tank until it is
certified cleaned and vapor/gas free.
 No diesel or gasoline engines are to be inside the diked area of the tank until
conditions permit.
 All sources of ignition shall be placed outside the diked area and a
minimum of 50 feet (15 meters) upwind from the tank (longer distances may
be required when there is no wind, or because of other weather conditions or
special circumstances, like downwind location), until the hydrocarbon
concentration in the tank is <10% LEL. Install a wind-sock to monitor wind
direction.
 Ensure air compressors are equipped with filters to remove moisture, scale,
rust, and oil from the compressed air to avoid static generation.
 Minimum of two 20-lb (9 kg) dry chemical extinguishers Type BC shall be at
the work site, located within 30 feet of the potential fire hazard. [Two 30-lb
(13.6 kg) dry chemical extinguishers Type BC may be used, located within 50
feet of the potential fire hazard.]
 Only explosion proof lighting is permitted.

APPENDIX A - Planning and Execution Checklist (continued)
 Combustible gas/oxygen/toxicity meter shall be at the work site (meters shall

be calibrated and bump tested daily, with records available).
 Confined space attendant shall be assigned while personnel are inside the
tank. Spare breathing apparatus, harness, and life-line shall be at the work
site during the period that breathing air is required.
 All energy/electrical equipment shall be locked-out including appropriate
identifying tags and documentation (locks required, “tag-out” only is not
acceptable).
 Gas cylinders, including oxygen, acetylene, hydrogen, propane or other
flammables should not be allowed inside the tank.
 Understand where fresh air supply intake is to be located (upwind from
manway).
 Understand safe handling of residual product/sludge.
 Understand that workers shall change clothing and shower at end of work
shift (check for availability of washing and cleaning facilities at the site).
Onsite decontamination processes may be required.
Tank Walk-Around:
 Identify vehicle/equipment access concerns and provide barricades.
 Review tank entry access and egress points.
 Identify ventilation hazards.
 Identify the means and locations for proper tank isolation.
 Identify water source.
 Identify emergency equipment access routes.
Preparation for Tank Entry

 Check entrants for proper Personal Protective Equipment (PPE).
 Properly fitted and donned air mask.
 Check for sufficient breathing air supply.
 Monitor atmosphere in all work zones.
 Check for compliance with applicable safety regulations.
 Ensure entrants are properly assisted with entry (Note: In the US, a
mechanical lifting/personnel extraction device is required by OSHA for
vertical entries greater than five feet).
 Ensure air line hose and life line do not become twisted, knotted or kinked.
Signatures:
Assigned ExxonMobil Supervisor: _____________________________

Cleaning Contractor Supervisor: _____________________________
Mechanical Contractor Supervisor: _____________________________
Pre-Cleaning Conference Date: _____________________________

APPENDIX B
Additional Resources and References
1. ExxonMobil Pipeline Company (EMPCo) Global Practice GP 09-77-23, "Tank Cleaning

Guidelines"; Version 1; January 2003
2. ExxonMobil Research and Engineering Co. (EMRE) "Tank Maintenance Guide"; EETD050;
December 2002
3. ExxonMobil Research and Engineering Co. (EMRE) Report; Updated Guidelines for
Prevention of Electrostatic Ignitions; EE.2M.98; January 1999
4. American Petroleum Institute (API) Recommended Practice 2003; "Protection Against
Ignitions Arising Out of Static, Lightning, and Stray Currents," Sixth Edition; September
1998
5. American Petroleum Institute (API) Standard 2015; "Requirements for Safe Entry and
Cleaning of Petroleum Storage Tanks"; Sixth Edition; August 2001
6. American Petroleum Institute (API) Recommended Practice 2016; "Guidelines and
Procedures for Entering and Cleaning Petroleum Storage Tanks"; First Edition; August
2001
7. ExxonMobil Research & Engineering (EMRE) Safety Technology Manual (TMEE073)

Appendix C
SECTION 4 - VENTILATING THE TANK
Air out
Air In Air Eductor

(Bonded to Tank)
Example of ventilating space above Internal Floating Roof
88
ExxonMobil - Nobody Gets Hurt

APPENDIX D-1
RESPIRATORY PROTECTION LIMITS FOR TANK ENTRY
This table indicates respiratory protection requirements for tank entry prior to vapor free certification
(1) Tests to Without Half Mask Full Face- Full Face Supplied Air
Substance or Conduct Respiratory Air Purifying piece Air [Self contained
Product Protection Respirator Purifying breathing apparatus or
Respirator hoseline with egress
cylinder if >IDLH (4)]
Oxygen Oxygen Not Permitted Not Permitted Not Permitted < 19.5%
<19.5% and <19.5% and <19.5% and > Not Permitted above
> 23.0% > 23.0% 23.0% 23.0%
Hydrogen Sulfide Hydrogen < 10 ppm > 10 ppm Not > 10 ppm Not > 10 ppm (IDLH = 100 ppm)
Sulfide Permitted Permitted
Benzene Benzene < 0.5 ppm <5 ppm < 25 ppm > 25 ppm (IDLH = 500 ppm)
Crude Oils THC <100 ppm < 1000 ppm < 1000 ppm > 1000 ppm
(Sweet and Sour) Benzene, (as THC) (as THC) (as THC) (as THC)
[measured as THC(2)] Hydrogen Sulfide
Middle Distillate THC
Fuels (Diesel Fuel, Benzene, < 100 ppm < 1000 ppm < 1000 ppm > 1000 ppm
Jet Fuels, Heating Oil, Hydrogen (as THC) (as THC) (as THC) (as THC)
Kerosene) Sulfide
[measured as THC(2)]
Gasolines (3) THC < 100 ppm < 1000 ppm < 1000 ppm > 1000 ppm
(mogas/avgas) Benzene, (as THC) (as THC) (as THC) (as THC)
[measured as THC(2)] Organic Lead
Naphthas THC < 100 ppm < 1000 ppm < 1000 ppm > 1000 ppm
(Straight-run/Virgin, Benzene, (as THC) (as THC) (as THC) (as THC)
Cat, Steam-Cracked Hydrogen
Alkylate, Isomerate Sulfide
Naphthas)
[measured as THC(2)]
Propane Propane < 1000 ppm < 1000 ppm < 1000 ppm >1000 ppm (IDLH=2100ppm)
Butane Butane < 800 ppm < 800 ppm < 800 ppm > 800 ppm
1,3-Butadiene 1,3-Butadiene < 2.0 ppm < 20 ppm <100 ppm >100 ppm (IDLH= 2000 ppm)
Organic Lead(3) Organic Lead Certified / Certified / Certified / Required for "Lead
(Tetraethyl Lead - Tested Tested Tested Service" Equipment or
TEL; Tetramethyl "Lead Free" "Lead Free" "Lead Free" where not previously
Lead - TML) (<0.1 mg/m3) (<0.1 mg/m3) (<0.1 mg/m3) certified "Lead Free"
(IDLH = 40 mg/m3)
Toluene Product Toluene < 50 ppm < 500 ppm < 500 ppm >500 ppm (IDLH = 500ppm)
Xylene Product Xylene < 100 ppm < 900 ppm < 900 ppm >900 ppm (IDLH = 900 ppm)
Hexane Product Hexane < 50 ppm < 500 ppm < 1000 ppm >1000 ppm
(n-Hexane) (IDLH=1100ppm)
NOTES ON TABLE
1. Note that the table includes a partial list of compounds with respiratory protection requirements. Consult Safety/IH
contacts for additional guidance and for the latest updated values. Gas test results deviating from normal (within the meter
accuracy) should be investigated and understood prior before entry is allowed (e.g. Oxygen readings <20.9%). Local
regulations may be more stringent. The more conservative guidelines should be applied.
2. Total Hydrocarbon (THC) may be measured via detector tube, chip reader device, or using a photoionization detector
(PID) using the manufacturer's recommended correction factor.
3. Organic lead tests for tanks in leaded service or for tanks previously in leaded service but not yet certified organic "lead
free". In the USA OSHA limit is 0.075mg/m3.
4. IDLH is defined by the USA National Institute for Occupational Safety and Health (NIOSH) as an exposure condition "that
poses a threat of exposure to airborne contaminants when that exposure is likely to cause death or immediate or delayed
permanent adverse health effects or prevent escape from such an environment." The purpose of the IDLH is to "ensure
that the worker can escape from a given contaminated environment in the event of failure of the respiratory protection
equipment." Entry into areas where contaminant levels are at or above IDLH levels should be reviewed with
management with the same level of diligence and precaution as inert entry.

APPENDIX D-2
ALLOWABLE CONCENTRATION LIMITS FOR SELECTED SUBSTANCES(1)(2)
Substance or Lower Upper Comments

Product Explosive Explosive
Limit (LEL) Limit (UEL)
Oxygen NA NA Concentrations above 23% by
volume greatly enhance the
combustibility/flammability of
substances
Hydrogen Sulfide 4.3 45.5
Benzene 1.2 8.0
Crude Oils 0.6 15 Range Varies Significantly with
Type of Crude
Middle Distillate Diesel 0.6 7.0 For specific products check MSDS
Fuels (Diesel Fuel, Jet Fuel/ 0.7 5.0 for LEL-UEL ranges
Jet Fuels, Heating Kerosene
Oil, Kerosene)
[Measured as THC (3)]
Gasolines 1.4 7.6 For specific products check MSDS
(mogas/avgas) for LEL-UEL ranges
Naphthas 1.1 7.6 For specific products check MSDS
(Straight-run/Virgin, for LEL-UEL ranges
Cat, Steam-Cracked
Alkylate, Isomerate
Naphthas)
Propane 2.0 9.5
Butane 1.1 9.5
1,3-Butadiene 2.0 12.0
Toluene Product 1.4 7.4
Xylene Product 1.9 12.3
Hexane Product 1.2 6.9
(n-Hexane)
NOTES
1. The values above are expressed in percent by volume of total atmosphere NOT as percentage of the
lower explosive limit (which is the % LEL values mentioned throughout this document and is the
indication given by most explosimeter readouts). Measuring percent by volume of an explosive
material in air takes a special instrument. All measurements shall be conducted in an atmosphere
containing normal levels of oxygen, unless special techniques are used to increase oxygen levels in
the sample to 20.9% and proportionally adjust the meter reading.
2. Explosive ranges may vary depending upon specific product composition.
3. Total Hydrocarbon (THC) may be measured via detector tube, chip reader device, or using a
photoionization detector (PID) using the manufacturer's recommended correction factor.

APPENDIX E - Equipment Requirements
Equipment Required for Tank Cleaning

Mechanical
All equipment shall be in good working condition to include but not be limited to the
following:
 Air-driven or hydraulic transfer pump.
 Vacuum truck, tank truck, or approved drums for disposal of waste or cleaning
material.
 Minimum of two Type BC fire extinguishers (20 lb / 9 kg dry chemical), located
within 30 feet of the potential fire hazard, or two Type BC fire extinguishers (30 lb
/ 13.6 kg dry chemical) located within 50 feet of the potential fire hazard.
 Miscellaneous non-sparking equipment: brooms, shovels, scrapers, squeegees,
rags, etc.
 Mechanical blower/exhauster or eductor.
 All mechanical equipment not certified explosion-proof shall be located outside of
dike wall and a minimum distance of 50 ft (15 m) away from the tank [100 ft (30
m) when removing the manway for the first time] if the potential for flammable
vapor exists.
 Conductive hoses.
Monitoring Equipment
Equipment for atmospheric / gas testing (i.e. oxygen and LEL testing) inside tanks prior
to entry shall be certified and calibrated as required by the manufacturer, tested at the
site prior to use and bump tested a minimum of once per day. Monitoring equipment that
may be needed is:
 Continuous combustible/flammable vapor and oxygen gas tester/alarm.
 Lead-in-air analyzer kit.
 Other testing equipment as appropriate: H2S, Benzene, Toluene, Carbon
Monoxide, and static electricity/grounding.
Total Hydrocarbon (THC) can be measured using direct reading tubes or chip reader
devices. Alternate methods such as photoionization direct reading instruments may be
used as well provided the manufacturer correction factor is applied for the specific
substance measured.
LEL readings of 0% do not indicate the tank is free of hydrocarbon vapors and may not
be used as a substitute for other tests (e.g. benzene and THC). High benzene
concentrations (over 6 ppm) have recently been observed while cleaning heavy scale
from the walls of a tank even though the LEL readings inside the tank were 0%.

APPENDIX F - Personal Protective Equipment
I. Protective Clothing
Protective equipment should be reviewed by the Assigned Supervisor to ensure that it is proper
for the hazards expected, of good quality, clean, and in proper working condition.
The minimum protective equipment typically required is:

 Safety glasses.
 Disposable, anti-static coveralls approved for petroleum products; fire-retardant where
required.
 Gauntlet gloves impervious to petroleum products.
 Footwear impervious to petroleum products and constructed of anti-static materials.
They should keep the feet dry and be capable of withstanding any chemical with which
they may come in contact.
 Supplied air respirator with auxiliary self-contained (five-minute) air supply with positive
pressure full face-piece for workers in the tank.
 Harness and life line for each person in tank.
 Disinfectant for face-piece masks.
 Hard hats.
 Hearing protection and appropriate means of communication consistent with the hearing
protection type used.
 Portable eye-wash available.
 Decontamination equipment, if required.
II. Respiratory / Breathing Air Protective Equipment
Pressurized breathing airline or self-contained breathing apparatus is required for personnel

cleaning tanks until gas tests indicate that the hydrocarbon vapor concentration is 0% LEL and
the oxygen and toxic substances are at acceptable levels (See Appendix D).
Workers and others using respiratory/breathing air protective equipment shall be trained and
qualified on the proper donning, testing, and use of the equipment provided.
Respirator/breathing air users shall receive an annual fit test and medical review.
III. General Safety
Prior to permitting vertical entry into a tank a qualified person shall test the internal atmosphere
at 4-foot (1.2 meters) vertical intervals (from top to bottom) to assure that flammable and toxic
vapors have not stratified within the tank.
Continuous gas testing, with audible alarm shall be performed where the movement of workers
or equipment may cause the release of potentially hazardous gases from deposits or sediments
within the vessel.

APPENDIX F - Personal Protective Equipment (continued)
The confined space entrant and the standby person shall always be capable of visual and
audible communications.
Source of supplied fresh air should be upwind and away from manway and other vapor sources.
Workers entering a tank that has contained leaded gasoline shall wear approved safety boots,
gloves, cap or hood, disposable coveralls, safety glasses, hard hats, and appropriate
respiratory/breathing air protection. All clothing shall be removed at the end of the shift and
cleaned before reuse (disposable clothing should not be reused). Clothing that is drenched with
leaded gasoline or residue should be removed immediately, any area of skin which came in
contact with product or residue thoroughly washed, and clean clothing and disposable coveralls
put on before re-entering the tank. [Consult the Material Safety Data Sheet (MSDS) or Industrial
Hygiene decontamination plan.]

Tank Cleaning

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ExxonMobil JOLIET REFINERY safety procedures

Tank Entry/Cleaning Procedure August 2012

TANK ENTRY/CLEANING PROCEDURE

Revision & Review Record

Section 9 – Tank Entry Cleaning Procedure -1-

Section 9 – Tank Entry Cleaning Procedure -2-

2. The Assigned Supervisor must:

6. Perform Non-Destructive Testing procedures to qualify structural integrity of floor,

Exposure to hydrocarbon liquid and vapor should be avoided. Health

4. Falls through corroded tank roofs.

5. Tripping over hoses, piping, or equipment.

6. Floor openings such as sumps.

7. Slipping on wet or oily surfaces.

8. Inadequate personal protective equipment (PPE).

9. Improper use of tools.

Note: This list is not all-inclusive.

Section 9 – Tank Entry Cleaning Procedure -6-

d. Respiratory protective equipment as required by the Respiratory Protection

Section 9 – Tank Entry Cleaning Procedure -7-

Section 9 – Tank Entry Cleaning Procedure -8-

d. Remove non-intrinsically safe electrical equipment (e.g. alarms, transformers)

4. Characteristics and amount of residual sludge on the tank bottom.

Section 9 – Tank Entry Cleaning Procedure - 10 -

2. When the tank is initially entered:

Section 9 – Tank Entry Cleaning Procedure - 12 -

3. Continuous mechanical airflow is required through the tank during entry.

Section 9 – Tank Entry Cleaning Procedure - 14 -

Appendix A ExxonMobil Joliet Refinery

Tank Cleaning Preparations:

Section 9 – Tank Entry Cleaning Procedure - 15 -

APPENDIX A - Planning and Execution Checklist (continued)

 Review tank ventilation and vapor/gas-freeing methods to be used.

Section 9 – Tank Entry Cleaning Procedure - 16 -

APPENDIX A - Planning and Execution Checklist (continued)

 Combustible gas/oxygen/toxicity meter shall be at the work site (meters shall

Preparation for Tank Entry

Assigned ExxonMobil Supervisor: _____________________________

Section 9 – Tank Entry Cleaning Procedure - 17 -

Additional Resources and References

1. ExxonMobil Pipeline Company (EMPCo) Global Practice GP 09-77-23, "Tank Cleaning

Section 9 – Tank Entry Cleaning Procedure - 18 -

SECTION 4 - VENTILATING THE TANK

Air In Air Eductor

Example of ventilating space above Internal Floating Roof

Section 9 – Tank Entry Cleaning Procedure - 19 -

Section 9 – Tank Entry Cleaning Procedure - 20 -

Substance or Lower Upper Comments

Section 9 – Tank Entry Cleaning Procedure - 21 -

APPENDIX E - Equipment Requirements

Equipment Required for Tank Cleaning

Section 9 – Tank Entry Cleaning Procedure - 22 -

APPENDIX F - Personal Protective Equipment

The minimum protective equipment typically required is:

II. Respiratory / Breathing Air Protective Equipment

Pressurized breathing airline or self-contained breathing apparatus is required for personnel

III. General Safety

Section 9 – Tank Entry Cleaning Procedure - 23 -

APPENDIX F - Personal Protective Equipment (continued)

Section 9 – Tank Entry Cleaning Procedure - 24 -

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