IP12 - Air Pressure Testing

IP#12 Appendix A
INSPECTION PROCEDURE NO. 12
AIR PRESSURE TESTING
Where air pressure testing is specified the following essential precautions will be observed :
1. The allowable test pressure will be stated in writing on an approved EMPAC Worklist.
2. A pressure measuring device of suitable sensitivity to measure the pressure involved will
always be used. A manometer should be used for pressures of 3 psig or less. (For
pressure below 11/2 psig, a water manometer should be used).
3. A suitable pressure relieving device will be fitted to relieve pressures in excess of 11/3
times the test pressure and will be of adequate capacity to accommodate any pressure
build-up from the supply.
DFC/PJV
#12 Appendix B
STANDARD PREPARATION OF TANKS FOR INSPECTION
ON-STREAM INSPECTION
Shell Gauging
On the outside of the tank shell a number of 6" high x 18" wide areas at top, middle and bottom
of each course, generally equally spaced around the tank periphery in vertical lines, will be
selected as given below, in order to provide the areas for on-stream ultrasonic thickness
measurements :
Diameter of Tank Number of Strips
Up to 20' 2
21' to 60' 4
61' to 120' 6
121' to 160' 8
Over 160' 10
Preparation for inspection will depend on the individual tank and the gauging method. For
manual U/T
gauging 3 "Blocks" approx. 1' long by 6" wide will be prepared on each plate of every strip.
These blocks can be gritblasted, paint stripped or gauged as is at the discretion of the SRIE (NB:
Paint stripper is the default option). Where automated crawler U/T is being carried out no further
preparation is required.
OUT-OF-SERVICE INSPECTION
The tank will be thoroughly cleaned to remove all grit, loose scale, dust and sludge, etc., from
roof, shell and floor. All manways, covers and nozzles will be opened to give access to enclosed
spaces and flange faces.
Shell
A number of 2' wide strips chosen by the Inspector will be gritblasted, on the inside of the shell,
to SA2 in accordance with the table below.
On each strip at each course six areas, 3 inches in diameter, chosen by the Inspector, will be
ground to half the depth of general pitting. 2 of these spots will be 1' from the bottom of the
course, 2 will be in the centre of the course, and 2 will be one foot from the top of the course.
Cont'd....../2
OUT-OF-SERVICE INSPECTION (Cont'd.)
Floor
A number of floor coupons per the table following may be cold cut if desired, but MFE scanning
is the preferred method . If coupons are cut they will be gritblasted to SA2 on both sides,
numbered in paint or by stamps, and delivered to RED. Unless the floor is clean and obviously
in good condition it should be gritblasted to SA2 for visual inspections and vacuum box testing
(this includes floor to shell weld).
Visual inspection underside after gritblasting (on floating roofs) coupled with spot U/T or
crawler U/T is the preferred method of determining roof condition. However, a number of roof
coupons per the table below may be hot cut, if required, gritblasted to SA2 both sides and
identified by stamp.
Tank Diameter Shell Floor Coupons Roof Coupons Roof Coupons Roof.
Coupons.
Strips
& Gritblasted Centre Deck Pontoon Bottom Cone Roof
Areas Floating Roof Floating Roof
____________________________________________________________________________
0' to 30' 2 4 2 2 4
31' to 60' 4 6 6 4 8
61' to 120' 6 8 6 4 10
212' to 160' 8 10 7 5 12
160' and above 10 12 10 6 16
______________________________________________________________________________
Where floating roofs show evidence of corrosion serious consideration should be given to
blasting the wetted surface to SA2. As a very minimum the vapour space on Hi Deck roofs and
the outer rim of all floating roofs should be gritblasted.
General
Gauging strips should be numbered so that strip 1 is closest to North and then sequentially round
the tank towards East, South and West etc.
The external tank sketch plate and first 1' of shell will be gritblasted to SA2.
All roof shoes and horses etc. will be removed from the tank and laid out for inspection. Carbon
steel roof shoes will be gritblasted to SA2 for inspection.
The following are standard items but will only be requested if corrosion or paint failure make
them necessary.
Gritblast the wind girder to SA2

Gritblast the stairway and rolling ladder to SA2
See also the SD&MM document that itemises the preparation work for contract purposes.
DFC/PJV
rev 2003
IP#12 Appendix C
CALCULATION OF MINIMUM ALLOWABLE THICKNESS AND

SAFE FILLING HEIGHT FOR WELDED ATMOSPHERIC
STORAGE TANK SHELLS
1. Minimum allowable thickness (MAT) calculations for tank shell courses will be generally
in accordance with API Standard, with local amendments as follows:
1.1 On tanks with all shell courses constructed from ordinary grades of mild steel,
as original or replacement e.g. ASTM Grades A7, A36, A131, A283, A285,
A201, (this includes all Bapco tanks built before 1973).
1.1.1 For in-service operation the calculations will be made on the basis
of the stresses imposed when the tank is full of the stock to be stored at 60
oF. The SG to be used is the Approved Specific Gravity as set out in 6.3 in
the body of IP 12, the maximum allowable stress will be 21 000 psi,
multiplied by the Joint Efficiency Factor of 0.85 where applicable. (See
note 1).
NB: The figure of 21000 is higher than later versions of 653 (i.e. 20000) but
agrees with older versions including API 12 A&C.
1.1.2 For hydrotest the calculations will be made on the basis of the
stresses imposed when the tank is full of Seawater of SG 1.03. The
maximum allowable stress will be 23 000 psi, multiplied by the Joint
Efficiency Factor of 0.85 where applicable. (See note below).
NB: The allowable higher stress of 23 000 psi for the hydrotest case was
adopted as (i) it will give additional confidence in the tanks integrity for the
"in service" case and (ii) a similar approach is used in later versions of the
code.
1.2 On tanks with shell courses constructed from intermediate tensile strength
steels, the calculations for in-service operation and for hydrotest will be in
accordance with the edition of API 650 to which they were built. These are
Tanks 705, 706, 716, 726, 736, 741, 751, 760, 965, 1101, 1102, 1103, 1112
and 1302.
1.3 Where the MAT's calculated above are still of concern, API 653 may be
invoked provided that (i) the tank is welded and (ii) it will be (or has
recently been) hydrotested to essentially full height.
2. No shell course will have an MAT less than that of the course above it.
3. The variable design point method will not be applied to riveted tanks and must be used for
the complete tank (i.e. individual courses will not be treated in this manner).
4. No MAT will be less than 0.10 inches.
5. Composite welded / riveted construction will be handled on a course by course basis as

appropriate.
6. A table of the relevant formulae for MAT calculations is given below.

Formulae for MAT Calculations
Service MAT Hydrotest MAT
For tanks per para. 1.1 requiring 2.6xDx(H-1)xG 2.6xDx(H-1)x1.03

Joint Efficiency. Factor 21,000x0.85 23,000x0.85
(see note 1 above)
For tanks per para. 1.1 not requiring 2.6xDx(H-1)xG 2.6x(H-1)x1.03

Joint Efficiency. Factor 21,000 23,000
(see note 1 above)
For tanks per para. 1.2 --Refer Construction Code--
Where D = Nominal diameter of tank in feet.

H = Height in feet from centre line of the bottom circumferential weld of the
course in question to the maximum filling height of the tank.
G = Approved Specific Gravity.
MAT = Minimum allowable thickness for course under consideration - inches.
Limited Filling Heights
The calculation for limited filling height for tanks designed by the one-foot method will be as
follows:-
RFH = t min x h + s
MAT
Where RFH = Restricted filling height in feet.

t min = Effective plate thickness, inches, for course under consideration.
MAT = Minimum allowable thickness, inches, for course under consideration.
h = Height of tank, from 1' above bottom gage line of course under consideration
to the maximum filling height of the tank, in feet.
s = Sum of course height in feet, below course under consideration, plus 1'.
For tanks designed to the variable design point method, refer to the RED Supt. at interest.
Note 1 The Joint Efficiency Factor of 0.85 should be included in calculations for tanks
defined in para. 1,1, except:-
(i) those constructed to API 650 Appendix D - Alternate Design Basis, in
Editions of the Code up to 1978,
(ii) all tanks constructed since 1980. (Tanks 276, 277, 443, 444, 714, 715,
734, 743, 750, 944, 1104, 1105, 1106, 1107, 1108, 1109,
1110 and 1111),
(iii) individual courses in any tanks where the complete course was replaced
to API 650 (1980) or later.
In all above cases JE is 1
(iv) individual courses where retrospective radiography and repair has been
employed to expressly bring the Joint Efficiency up to 1.
DFC/PJV
rev19/4/2000
IP#12 Appendix D
CALCULATION OF MINIMUM ALLOWABLE THICKNESS

AND SAFE FILLING HEIGHT FOR BAPCO RIVETED ATMOSPHERIC
STORAGE TANK SHELLS
Minimum allowable thickness calculations for riveted tank shell course will be made in
accordance with API 12A, except that
a) for in-service operation the stresses will be taken as those imposed with the tank full of
stock at the Approved Specific Gravity as defined in 6.3, and
b) for hydrotest and operating the maximum allowable shear stress in the shell plate will be
23 000 psi. NB: This figure is in excess of the API 12A maximum allowable of 21 000 psi.
and a short discussion on this point can be found in the file memo below.
The standard format for the calculations is given below. The results obtained from these
calculations give the MAT's for sweet water i.e. SG = 1.00 on the assumption that the tank is full
to the kerb angle. To obtain the MAT's for the contained stock it is necessary to multiply the
sweet water MAT's by the stock specific gravity. The water MAT's (SG = 1.00 and SG = 1.03)
for standard size API 12A tanks are also given below in tabular form.
An arbitrary minimum MAT of 0.10 inches will be used when the calculated minimum falls
below this figure.
Limited filling heights will be calculated similarly to those for welded tanks. Refer Appendix C.
DFC/PJV
rev19/4/2000
File Memo 28th December, 1998
MAT of API 12 A Tanks

File: C 241
While rewriting IP#12 it became apparent that some anomalies exist in the calculation of MAT
values for riveted API 12 A tanks. The main issue revolves around why Bapco uses a figure of
23000 psi as the allowable stress when the original code specifies 21000.
The MAT's for riveted tanks were calculated manually many years ago and tabulated into IP#12
as appendix D. This tabulation provides an MAT for water - the corresponding figure for product
is obtained by multiplying by the contained SG. The figure that was used in the calculations is
23000. The change over from the code figure to the higher occurred in the late 50's at the same
time maintaining for contained SG was accepted. These values have been used ever since and to
revert to the lower value (of some 8.7% less) would immediately put many of our tanks below
MAT and / or drastically reduce remaining life.
In order to try and establish the reasons behind the change a survey of the C241 file was made
and relevant references extracted. After reviewing the available information the following
conclusions were drawn.
. A reasoned decision was made to use 23000 rather than the original code
figure of 21000.
. The change probably occurred around 1958/9.
. At the same time maintaining for contained product was accepted.
. By nature of the MAT tabulation and its use, there is no differentiation
between the hydrotest and product stress.
. The reason for adopting the higher figure is not spelt out specifically but the
assumption is that the (then) current SOCAL acceptance of it would have been a
major influence.
Recommendation:
Continue to use 23000 as the allowable stress for both hydrotest and product conditions in API
12 A tanks and do not recalculate them to the original design code.
_________ ________________
P J Valvona Noted: Y G Abdulla
[NB: Accepting that to use 23000 is the correct way to go then one small anomaly remains. Appendix C of IP#12
(MAT Calculation for Welded Tanks) specifically precludes the use of 23000 for product stress and requires the use
of 21000 for this calculation even though, in many cases, the material is identical.]
PJV/pjv/mat_12A
M.A.T. CALCULATIONS FOR RIVETED TANKS
Stresses are to be computed on the assumption that the tank is filled full of liquid at the
Approved Specific Gravity and the tension in each ring is to be computed 12 inches above the
bottom gage line of the ring in question.
The following maximum allowable working stresses shall be used:
Maximum tensile stress in net section of plate = 23,000 psi. (see "b" on previous page)
Maximum shear in net section of rivet = 16,000 psi.
Maximum bearing stress on plates or rivets = 35,000 psi. (when rivets are in double
shear).
= 32,000 psi. (when rivets are in single
shear).
The calculation of the minimum allowable thickness of riveted tank shell plates will be based on
the development of the maximum permissible stresses with all rivets assumed to be equally
loaded. The formulae are developed for butt strap joints but may be adapted for lap joints.
The following notation is used in the calculation:
t = plate thickness in inches for the course in question.

L = load on the tank shell in pounds per lineal inch of vertical joint which is equal to
the static head in pounds per square inch times the radius of the tank in inches.
P = pitch of rivets in inches on row having the greatest pitch.
d = diameter of rivet in inches which shall be taken as the nominal diameter plus
1/16" in the case of hot driven rivets and the nominal diameter plus 1/32" in the case of
cold driven rivets.
D = diameter of rivet hole in inches. Rivet holes when punched 1/16" over nominal
diameter for hot driven rivets are to be assumed 1/8" larger than the nominal diameter of
the rivet. Rivet holes when punched 1/32" over nominal diameter for cold driven rivets
are to be assumed 3/32" larger than the nominal diameter of rivet. Rivet holes when
drilled or when sub-punched and reamed, are to be assumed 1/16" larger than the nominal
diameter of the rivet.
n = total number of rivets in single shear in a length of joint equal to 'P'.
N = total number of rivets in double shear in a length of joint equal to 'P'.
N & n with subscript = number of rivets in a given row counting rows from the centre of the joint
in a length of joint 'P'.
s = shearing load on each rivet in single shear.
S = shearing load on each rivet in double shear.
ft = tensile stress in net section of shell plate.
a = cross sectional area of rivet (see d).
fi = tensile stress in net section of inside butt strap.
fo = tensile stress in net section of outside butt strap.
fs = shearing stress in the rivets.
c = bearing stress in shell plate for rivets in single shear.
C = bearing stress in shell plate for rivets in double shear.
ci = bearing stress on the outside butt strap.
i = thickness of inside butt strap.
o = thickness of outside butt strap.
Cont'd....../2
FORMULAE
1. s = LP
n+2N
2. S = 2s
3. fs = s
a
4. ft (fifth outer row of rivets) = LP

t (P-D)
5. ft (fourth outer row of rivets) = LP-sn5

-----------
t (P-Dn4)
6. ft (third outer row of rivets) = LP-s(n5+n4+n3)

----------------------
t (P-Dn3)
7. ft (second outer row of rivets) = LP-s(n5+n4+n3)

-----------------------
t (P-DN2)
8. ft in first row assuming equal spacing in first and second rows = 1/2 stress in second row.
9. fi = S (N+n)
i (P-DN1)
10. fo = sN
o (P-DN1)
11. c = s
td
12. C = S
td
13. ci = s
id
14. co = s
od
THE BAHRAIN PETROLEUM COMPANY LIMITED
AWALI - BAHRAIN
MAT's FOR API RIVETED TANKS FOR WATER
TANK DIAMETER 144 FEET.
HEIGHT 46' - 2 1/4" HEIGHT 40' - 6 1/2"

Course Height ONT ONT MAT Course Height ONT ONT MAT
Feet Fraction Decimal SG 1.00 Feet Fraction Decimal SG 1.00
SG 1.03 SG 1.03
1.00 5.57 7/8 0.875 .786 1.00 5.66 25/32 0.781 .710
.810 .731
2.00 5.73 25/32 0.781 .711 2.00 5.63 11/16 0.688 .610
.732 .628
3.00 5.63 11/16 0.688 .610 3.00 5.73 9/16 0.563 .507
.628 .522
4.00 5.73 9/16 0.563 .507 4.00 5.76 15/32 0.469 .427
.522 .440
5.00 5.76 15/32 0.469 .427 5.00 5.78 13/32 0.406 .344
.440 .354
6.00 5.78 13/32 0.406 .344 6.00 5.81 5/16 0.312 .247
.354 .254
7.00 5.81 5/16 0.312 .247 7.00 5.81 1/4 0.250 .127
.254 .131
8.00 5.81 1/4 0.250 .127
.131
HEIGHT 46' - 4 11/16" HEIGHT 40' - 8 11/16"

Course Height ONT ONT Decimal MAT Course Height Feet ONT Fraction ONT Decimal MAT
Feet Fraction SG 1.00 SG 1.00
SG 1.03 SG 1.03
1.00 5.62 3/4 0.750 .682 1.00 5.71 5/8 0.625 .567
.703 .584
2.00 5.78 5/8 0.625 .570 2.00 5.67 9/16 0.563 .509
.587 .524
3.00 5.67 9/16 0.562 .509 3.00 5.76 15/32 0.469 .424
.524 .437
4.00 5.76 15/32 0.469 .424 4.00 5.78 7/16 0.437 .393
.437 .405
5.00 5.78 7/16 0.437 .393 5.00 5.80 11/32 0.344 .300
.405 .309
6.00 5.80 11/32 0.344 .300 6.00 5.81 1/4 0.250 .213
.309 .219
7.00 5.81 1/4 0.250 .213 7.00 5.81 1/4 0.250 .105
.219 .108
8.00 5.81 1/4 0.250 .105
.108
HEIGHT 46' - 6 7/8" HEIGHT 40' - 10 3/16"

Feet Decimal SG Feet Fraction Decimal SG
Fraction 1.00 1.00
SG SG
1.03 1.03
1.00 5.67 1/2 0.500 .445 1.00 5.76 15/32 0.469 .411
.458
2.00 5.81 15/32 0.469 .411 2.00 5.71 7/16 0.437 .394
.423
3.00 5.71 7/16 0.437 .394 3.00 5.78 3/8 0.375 .335
.406
4.00 5.78 3/8 0.375 .335 4.00 5.81 5/16 0.312 .278
.296 .296
5.00 5.81 5/16 0.312 .287 5.00 5.81 1/4 0.250 .213
.296 .154
6.00 5.81 1/4 0.250 .213 6.00 5.81 1/4 0.250 .149
.154 .154
7.00 5.81 1/4 0.250 .149 7.00 5.81 1/4 0.250 .100
.154 .103
8.00 5.81 1/4 0.250 .100
.103
HEIGHT 46' - 7 3/8" HEIGHT 40' - 10 5/16"

Fraction 1.00 1.00
SG SG
1.03 1.03
1.00 5.71 15/32 0.469 .414 1.00 5.78 13/32 0.406 .356
.426 .367
2.00 5.83 13/32 0.406 .356 2.00 5.76 11/32 0.344 .306
.367 .315
3.00 5.76 11/32 0.344 .306 3.00 5.81 5/16 0.312 .270
.315 .278
4.00 5.81 5/16 0.312 .270 4.00 5.81 1/4 0.250 .222
.278 .229
5.00 5.81 1/4 0.250 .222 5.00 5.81 1/4 0.250 .164
.229 .169
6.00 5.81 1/4 0.250 .164 6.00 5.81 1/4 0.250 .115
.169 .119
7.00 5.81 1/4 0.250 .115 7.00 5.81 1/4 0.250 .100
.119 .103
8.00 5.81 1/4 0.250 .100
.103
HEIGHT 46' - 9 7/8" HEIGHT 41' - 0 9/16"

Fraction 1.00 1.00
SG SG
1.03 1.03
1.00 5.73 3/8 0.375 .333 1.00 5.80 11/32 0.344 .289
.343 .298
2.00 5.84 11/32 0.344 .289 2.00 5.77 5/16 0.312 .261
.298 .269
3.00 5.77 5/16 0.312 .261 3.00 5.81 1/4 0.250 .225
.269 .232
4.00 5.81 1/4 0.250 .225 4.00 5.81 1/4 0.250 .178
.232 .183
5.00 5.81 1/4 0.250 .178 5.00 5.84 1/4 0.250 .142
.183 .146
6.00 5.84 1/4 0.250 .142 6.00 5.88 3/16 0.188 .100
.146 .103
7.00 5.88 3/16 0.188 .100 7.00 5.88 3/16 0.188 .100
.103 .103
8.00 5.88 3/16 0.188 .100
.103
HEIGHT 46' - 11 9/16" HEIGHT 41' - 1 1/2"

Fraction 1.00 1.00
SG SG
1.03 1.03
1.00 5.77 5/16 0.312 .264 1.00 5.81 5/16 0.312 .230
.272 .237
2.00 5.84 5/16 0.312 .230 2.00 5.78 1/4 0.250 .203
.237 .209
3.00 5.78 1/4 0.250 .203 3.00 5.81 1/4 0.250 .169
.209 .174
4.00 5.81 1/4 0.250 .169 4.00 5.84 1/4 0.250 .144
.174 .148
5.00 5.84 1/4 0.250 .144 5.00 5.88 3/16 0.188 .106
.148 .109
6.00 5.88 3/16 0.188 .106 6.00 5.88 3/16 0.188 .100
.109 .103
7.00 5.88 3/16 0.188 .100 7.00 5.88 3/16 0.188 .100
.103 .103
8.00 5.88 3/16 0.188 .100
.103
TYPICAL CALCULATION FOR A STANDARD API 12A TANK DFC 29/11/89
120 FT DIA STANDARD TANK 40'- 8 11/16" HIGH
7th Course Joint L1
h = 5'-9 3/4" + 1 3/4" - 12" = 4'-11 1/2" = 4.958'
p = 2.0515" D=3/4" d=11/16" t=1/4"
L = 4.958 x 60 x 12 = 4.958 x 311.7 = 1545 lb/in
s = 1545 x 2.0515 = 3170 lbs

1
fs = 3170 = 3170 x 4 x 16 x 16 = 8530 psi

S/4(11/16)2 S x 11 x 11
ft = 3170 = 3170 = 9747 psi

0.25(2.0515 - 0.75) 0.25 x 1.3015
MAT = 0.25 X 9747 = 0.1059" say 0.106"

23000
6th Course Joint L2
h = 4' - 11 1/2" + 5' - 9 3/4" = 10'-9 1/4" = 10.772'
p = 2.375" D= 3/4" d= 11/16" t= 1/4"
L = 10.772 x 311.7 = 3358 lb/in
s = 3358 x 2.375 = 7973 = 3986 lbs

2 2
fs = 3986 = 3986 x 4 x 16 x 16 = 10730 psi

S /4(11/16)2 S x 11 x 11
ft = 7973 = 19630 psi

0.25 x 1.625
MAT = 0.25 X 19630 = 0.2133" say 0.213"

23000
5th Course Joint L3
h = 10' - 9 1/4" + 5' - 9 5/8" = 16' - 6 7/8" = 16.573'
p = 3.00" D = 3/4" d = 11/16" t = 11/32"
L = 16.573 x 311.7 = 5165 lb/in
s = 5165 x 3.00 = 5165 lbs

3
fs = 5165 = 5165 x 4 x 16 x 16 = 13800 psi

S/4 (11/16) 2 S x 11 x 11
ft = 0.344 x 19630 = 0.2993" say 0.299"

23000
4th Course Joint L4
h = 16' - 6 7/8" + 5'- 9 5/16" = 22' - 4 3/16" = 22.439'
p = 3.8125" D = 7/8" d = 13/16" t = 7/16"
L = 22.349 x 311.7 - 6968 lb/in
s = 6968 x 3.8125 = 663 9 lbs

4
fs = 6639 = 6639 x 4 x 16 x 16 = 12800 psi

S/4(13/16)2 S x 13 x 13
ft = 6968 x 3.8125 = 6968 x 3.8125 = 20640 psi

0.438(3.8125 - 0.875) 0.438 x 2.938
MAT = 0.438 x 20640 = 0.3931" say 0.393"

23000
3rd Course Joint B4
h = 22' - 4 3/16" + 5' - 9 1/8" = 28' - 1 5/16" = 28.109'
t = 15/32" = 0.469" P = 14 5/16" d = 13/16" D = 7/8"
i = 11/32" = 0.344" n4= 1 N2 = 4 n =3
o = 13/32" = 0.406" n3=2 N1 = 4 N-8
L = 28.109 x 311.7 = 8764 lb/in
s = 8764 x 14.313 = 6600 lbs

3 + 16
S = 2 x 6600 = 13200 lbs
fs = 6600 = 6600 x 4 16 x 16 = 12700 psi

S/4(13/16) 2 S x 13 x 13
4th Outer ft = 8764 x 14.313 = 19890 psi

0.469(14.313 - 0.875)
3rd Outer ft = (8764 x 14.313) - 6600 = 125400 - 6600 = 20170 psi

0.469(14.313 - 0.875 x 2) 0.469 x 12.563
2nd Outer ft = (8764 x 14.313) - (6600 x 3) = 105600 = 20830 psi

0.469(14.313 - 0.875 x 4) 0.469 x 10.813
1st Row ft = 20830 = 10415 psi

2
MAT based on 2nd Outer Row = 0.469 x 20830 = 0.4248" say 0.425"
23000
2nd Course Joint B4
h = 28' - 1 5/16" + 5' - 8 1/16" = 33' - 9 3/8" = 33.782'
t = 9/16" = 0.563" P = 16 1/2" d = 15/16" D = 1"
i = 13/32" = 0.406" n4 = 1 N2 = 4 n = 3
o = 7/16" = 0.438" n3 = 2 N1 = 4 N = 8
L = 33.782 x 311.7 = 10530 lbs
s = 10530 x 16.5 = 9143 lbs

3 + 16
S = 18286 lbs
fs = 9143 = 9143 x 4 x 16 x 16 = 13240 psi

S/4(15/16) 2 S x 13 x 13
4th Outer ft = 10530 x 16.5 = 10530 = 19910 psi

0.5563(16.5 - 1) 0.563 x 15.5
3d Outer ft = (10530 x 16.5) - 9143 = 173800 - 9143 = 20170 psi

0.563(16.5 - (1.0 x 2)) 0.563 x 14.5
2nd Outer ft= (10530 x 16.5) - (9143 x 3) = 173800 - 27429 = 20810 psi
0.563(16.5 - (1.0 x 4)) 0.563 x 12.5
1st Row ft = 20810 =10405 psi

2
MAT based on 2nd Outer Row = 0.563 x 20810 = 0.5093" say 0.509"
23000
1st Course Joint B5
h = 33' - 9 3/8" + 5' - 8 9/16" = 39' - 5 15/16" = 39.495'
t = 5/8" = 0.625" P= 16 5/8" d=15/16" D=1"
i = 15/32" = 0.469" n5 = 1 N2 = 4 n= 4
o = 15/32" = 0.469" n4 = 1 N1 = 4 N =8
n3 = 2
L = 39.495 x 311.7 = 12310 lbs
s = 12310 x 16.625 = 10230 lbs

20
S = 20460 Lbs
fs = 10230 = 10230 x 4 x 16 x 16 = 14830 psi

S/4(15/16)2 S x 13 x 13
5th Outer ft = 12310 x 16.625 = 20960 psi

0.625 x 15.625
4th Outer ft = 204600 - 10230 = 194370 = 19900 psi

0.625 x 15.625 0.625 x 15.625
3rd Outer ft = 204600 - 40920 = 184140 = 20730 psi

0.625 x 14.625 0.625 x 14.625
2nd Outer ft = 204600 - 40920 = 163600 = 20730 psi

0.625 x 12.625 0.625 x 12.625
1st Row ft = 10365 psi
MAT based on 5th Outer Row = 0.625 x 20960 = 0.5697" say 0.570"
23000
IP#12 Appendix E
____/____/____
OUT OF SERVICE INSPECTION CHECKLIST for Tank No. _______
This checklist contains items that are to be considered and / or actioned as part of the Out Of
Service Inspection of each TRP tank. The inspector must initial next to each point and indicate it
was considered and either completed or not applicable. For convenience all the NDT items have
been duplicated on the last page.
The completed checklist is to be held in the working file of the respective tank.
NB: Some of the items may already have been covered by a recent ATOP .
REQ'D DONE PROCEDURAL

Read the records (including Kardex) prior to starting the OOS.
View the last ATOP record or its summary
Carry out pre T&I check 3 - 6 months before due date noting any
preparation or special maintenance items
During pre T&I check observe condition of floating roof while in operation.
Note any abnormalities for follow up at T&I
Compile and forward "preparation for inspection" work request
Check that the tank contents, SG and course heights are current
Check with ROP that the tank will return to the same service after the T&I
or determine new service
Determine the current approved runlength
Be sure that all observations / measurements that result from the OOS are
recorded in the working file and that this checklist is completed
Obtain the required entry and work permits if applicable
Satisfy yourself that the tank is properly isolated, safe to enter and permits
in order
Perform preliminary internal inspection
Issue work requests for any additional preparation required
Inspect the tank noting repairs and documenting "as is" condition
Check that all EMPAC data is present and correct - if not make
arrangements to obtain
Compile a draft work request to rectify any deficiencies found and include
owner / Engineering items
Discuss draft work request with Superintendent
Attend pre-tender meeting to discuss the draft work request and the scope
of repairs
Transfer final work request to owner for approval
During repair period visit the tank at least weekly to check on progress and
to perform Q/A or Q/C checks on contractors work
Follow through to completion on all repair / Engineering work
Analyse gauging data to calculate remaining life and confirm that the
calculated figure is more than adequate to get the tank through to the next
T&I
Highlight to Supt. where gaugings are very different from those expected,
give inadequate remaining lives or are within .05" of MAT
Write suitable records to cover all inspection findings plus any future
recommendations and have them checked for completeness / accuracy
Attend pre-hydrotest meeting if required per 8.1
Witness hydrotest after a suitable holding time of at least 48 hours
Attend pre-acceptance meeting and ensure all items are complete
Issue Release Sheet specifying the Approved Specific Gravity, Contained
Product, Maximum Filling Height, Hydrotest Height, IBV Numbers and
Repair Worklist Number
If the records have been entered into the working file (rather than typed
directly into EMPAC) have them typed and then check the typing for any
errors or omissions. (see II 14)
Advise the Superintendent that the OOS is complete, all records written
and present the working file for checking, final acceptance and schedule
updating
Update operating record stating contained product and approved specific
gravity
REQ'D DONE TANK BOTTOM / BUND AREA

Check for settlement around perimeter of tank
Check entire foundation visually for levelness and get Eng. to provide
bottom elevations if in doubt
If steam tracing or heaters are present check for signs of condensate
getting under the floor
Check that runoff rainwater or shell condensation drains away from tank
Determine the general condition and adequacy of the tank pad / berm
Inspect back of water draw basins and top surface of berm for indications
of bottom leakage
Look for areas where leaching of oil has left foundation filler stained or
exposed
Check for the presence incorrect sump details on floor nozzle exits
Inspect the area for build-up of rubbish, vegetation, and other
inflammables
Where double bottoms are present check for vent nozzles between them
and that they are not plugged up
Check for incorrectly installed asphalt pads retrofitted below set through
external annular rings of sketch plates
If pads are new or remade ensure compaction to 95% is tested for and
verified by a third party
Check line systems and pipe supports within the bunded area. If in doubt,
excavate any buried pipe work for further investigation
Check for adequate thermal pressure relief of piping in the bunded area
and that the relief valves have been overhauled in the last 2 years
REQ'D DONE SHELLS
Visually inspect externally for paint failures, pitting, and corrosion
especially on the bottom course, stairs and at the windgirder
Select internal "strips" to be gritblasted and ground for gauging
Gauge the shell internally at each "strip" per Standard Procedure
Visually inspect each strip, check the grinding was in fact done to half pit
depth and measure general pit depths
Measure and record pit depts
Scan gauge shell (1' in each 20') below retrofitted annular
If indicated by the general condition of the shell or as a result of the
"strip" examination, obtain access and visually inspect other areas of the
shell until satisfied that its true condition is determined
Establish the condition of rivet heads, butt straps and adjacent shell
Supplement the standard ultrasonic gauging externally using either a shell
crawler or manual gauging if necessary
Calculate remaining life and proximity to MAT
Note location and estimate extent of any kinks, bulges or out of roundness.
If in doubt request an Eng. survey
If insulated, establish that the weather proofing is sound and that the
insulation stops at least 3" above grade level
Remove insulation in suspect areas to check underlying condition of shell
Inspect the external surface for evidence of shell, rivet or seam leaks
Measure course heights if not done since last T&I
Check for corrosion of shell internally at water bottom interface
If painted internally for corrosion protection establish effectiveness of
paint system and especially if it will remain adequate for the planned run.
If in doubt-repaint after consultation with M&C group as required
If shell has externally painted "Black Stripe" check for accelerated
corrosion in and adjacent to the stripe and have stripe painted out.
If tank is in caustic service spot check floor to shell and vertical welds
around normal liquid level with WFMPI to check for caustic cracking
If tank is constructed of intermediate tensile steel and H2S can be present
then WFMPI lower 6" of the bottom course for SSC
REQ'D DONE SHELL APPURTENANCES
Inspect for cracks or signs of leakage on joints at nozzles, manways, and
reinforcing plates
Inspect for shell plate distortion around nozzles, caused by excessive pipe
deflection
Inspect sealing of insulation around manways and nozzles
Remove insulation at locations where water ingress is suspected
Check for inadequate manway flange and cover thickness on mixer
manways and that the mixer supplementary support system (hanger) is
sound
Spot gauge nozzles on shell, roof and floor
Inspect fixed foam fire fighting system components
Hammer test and check sample connections and small bore lines for
thinning, leaks, sealwelding and for proper bracing / supports
Inspect for evidence of shaft damage or leakage at mixer seals
Check that the mixer propeller is sound and not cracked
Check distributor nozzles and internal pipework
Check floating suctions for alignment and airtest pontoon floats
Hydrotest / steam test any heating coils
Inspect wind girder and handrail for corrosion damage (paint failure,
pitting, corrosion product build-up), especially where it occurs at stitch
welds
Check windgirder / stair support and bracing welds to shell for pitting,
especially on shell plates. If supports do not have reinforcing pads
welded to shell, have them installed per Eng. drwg.
Remove any painting cradle and construction staging support brackets
Weld up construction rivets
Remove , overhaul and test tank isolating block valves
Ensure valves are certified tested within the last 12 months and their
numbers recorded for the release sheet
Check that mixer wetted component material is suitable for sour
service(if applicable)
REQ'D DONE SHELL REPAIRS
Check for valid and appropriate welders certificates
Is approved Eng. drwg available and being followed
Check material / weldability of old and new plates to determine if any
special considerations apply
Check welding procedure is correct and being followed properly
(especially preheat)
Check welding consumables for correctness, usage and storage
Check for materials certificates of new plates (assume items withdrawn
from Bapco materials are in order)
Spot thickness gage any replacement shell plates when in position
Carry out radiography of replacement shell joints to latest API 650
Radiograph door sheets (100% verticals, spot horizontal)
Check for removal and grind flush of dogging system attachments on
shell or floor and WFMPI tack / attachment welds as required
Check for distortion of shell plates on completion of course inserts
Where new welded courses are installed in riveted tanks check that
adjacent rivets and butt straps have been seal welded
Paint shell internally with approved Glassflake system if near MAT
Check that correct painting procedure has been specified for internal
coatings, that it is being followed properly and that the Material and
Corrosion group are monitoring Q/A
Check expiry date of any coatings being used
Ensure that all gritblasting is approved prior to priming
Check that final dry film thickness' have been attained
Externally paint / repair paint where new course plates are added
Arrange for hydrotest if required per 8.1
Check that roof drain IBV is open during hydrotest of the tank
Check capability of the tank to take water (SG 1.03) at full height for
test or determine the maximum level. NB: Seal pop out considerations
may apply
Radiograph and repair shell welds as per code if J.E. to be increased
ROOFS
For safety, before accessing the roof, check with ultrasonic instrument or a ball peen hammer
to test the plate. Use duckboards until the roof condition is positively established to be
safe.
Do not enter below floating roofs unless the required precautions have been taken to
prevent roof collapse.
REQ'D DONE ROOFS

Check that roof support and anti-rotation devices have been installed on
floating roofs
Satisfy yourself that the condition of the roof legs and their attachment is
capable of supporting the roof safely for the duration of the T&I. Have
auxiliary supports added per Eng. drwg. if in doubt
Visually inspect the roof topside for paint failure, holes, pitting, corrosion
or evidence of product on the roof deck
Hammer test and gauge the roof (cone roof and centre deck)
ultrasonically per standard procedure
Ultrasonically gauge outer rim, pontoon bottoms and product side inner
rim (if present) on floating roof tanks per standard procedure
Cut coupons from centre deck and pontoons if necessary
Ultrasonically gauge / calliper gauge rafters, support columns and shell
attachment brackets on cone roof tanks
Scan gauge the Hi deck to outer pontoon area for local thinning of roof
and pontoon in the vapour space
Gauge roof drain WDO box and any internal manifolds
Gritblast underside of floating roof and outer rim for inspection (unless in
obviously uncorroded state)
Inspect for cracks of fillet welds within a 2 feet radius of roof legs
Air test all pontoons to 3" WG. Ensure the entire wetted surface is tested
not just the seams
Pinhole test all pontoons (internal visual, looking for light sources)
Diesel test pontoon wetted surfaces prior to hydrotest and after all repairs
MFE test the centre deck and cone roof if necessary
Look for indications of standing water. (Significant sagging of fixed roof
deck indicates potential rafter failure. Large standing water areas on a
floating roof indicate inadequate drainage design or, if to one side, a
unlevel roof with possible leaking pontoons.)
Look for and record any distortion of the roof. Consider photographs of
roof if distortion is evident or if major repairs are to be carried out
Visually inspect for cracks or leaks in the insulation weather coat on
insulated tank roofs where runoff rain water could penetrate the
insulation. If in doubt remove small test sections of insulation and check
roof deck for corrosion and holes near the edge of the insulated area
Check for bulged up areas of centre deck and spot gauge ( these may
have contained vapour during operation with resulting higher corrosion
rates)
REQ'D DONE ROOF APPURTENANCES
Check and record the seal condition, before it is stripped and after
especially for the presence of protruding bolt heads
Inspect secondary seals for signs of thinning, buckling or distortion
Inspect condition of sample hatch and cover
Inspect and gauge stilling well for thinning or buckling
On floating roofs, inspect condition of roof guide for the gauge well,
particularly the condition of the rollers
Check that earthing shunts are in place and contacting the shell
Check separate earthing cables are sound
Check that the rolling ladder is free to move correctly and in good
functional condition
Ensure rolling ladder wheels and track comply with Eng. Std
Inspect for corrosion of the autogauge and check the cable for wear or
fraying caused by rubbing on the cover
Check roof manways for nozzle neck thinning
Open pontoon covers and visually inspect inside. Check especially for
evidence of previous pontoon leakage
Check that pontoon cover vent tubes are not plugged up
Check operability of the flapper and condition of locking / pivot pins on rim
vents
Check condition of roof legs and that they have drain notches at the bottom
Inspect automatic vacuum breakers valves for operability, seating and
opening
Remove, overhaul. and test roof drain check valve
Check plumbness of roof legs
Remove and overhaul any vacuum / vent valves
Check seal attachment system to outer rim and tensioning system
Check that cone roof vents are not plugged or fouled
Check that internal bracing in pontoons is not distorted (if applicable)
MPI check for cracks of welds at recesses in pontoons where mixer
clearance has been added
Ensure all pontoon bulkheads are fully seal welded
Check roof rafters and beams for thinning, twisting or looseness
Hydrotest coflexip roof drain hose and pivot master joints to 50 psig and
knuckle joints to 100 psig. Test any hard piping on the above to 425 psig
Visually inspect coflexip hoses for external damage and ensure that shields
are installed around nearby roof legs
Test, overhaul and check reinstalled alignment of JKD joints
Check roof drain restraining chain and attachments
REQ'D DONE ROOF REPAIRS
Does Eng. std MW/650/000/001/00 apply regarding extent of floating roof
repairs?
Check for materials certificates of new plates ( assume plates withdrawn
from Bapco materials are in order)
Spot check thickness of any replacement roof plates
Check for removal and grind flush of dogging system attachments and
WFMPI tack/attachment welds as required
Double weld roof lap joints within 2' radius of all roof legs
Check for distortion of roof on completion of repairs
Vacuum box test new centre deck and cone roof welds
Paint underside of floating roof and outer rim if corrosion is a problem
Check that correct painting procedure has been specified for internal
Check expiry data of any coatings being used
Externally paint / repair paint where new roof plates are added
Locally hydrotest WDO sump
REQ'D DONE FLOOR

If one doesn't exist, draw up a floor map for the "as found" state including
any overplating present
MFE scan all floor plates and annular ring (99% coverage expected)
MFE hand scan all plate edge, repads and obstructed areas that the main
scanner may not have reached
Ultrasonically spot thickness gauge floor and annular per standard
procedure
Vacuum box test all floor welds including any repairs and overplating
Vacuum box test floor to shell weld internally
Visually inspect floor to shell weld internally
Scan gauge 1' long x 3" wide strips of the annular of existing floors as
close to the shell weld as possible at 20' intervals around the inside of the
tank
Clean off the annular / sketch area and inspect / hammer test for corrosion
and thinning on plate and weld
On existing floors scan gauge the full width of the projecting annular
/sketch at standard "strip" locations ( concentrating close to the weld toe)
If necessary make small (1' wide) excavations below sketch plate and
shell. Repair locations per Eng. Std. Drwg
Visually inspect each and every floor plate and complete annular for
pitting etc. after suitable preparation. NB: Use a strong torch held close
and parallel to the floor
Map out all significant defects found on the floor by visual and MFE
scanning
Look for discoloured/damp spots where product may be leaching back
into the tank
Check visually for floor elevations (consistent with cone up or down
design), ripples, poor drainage; voids or bulging upwards. Have Eng.
check levels if in doubt and consider taking photographs if required
Locate and measure any upward bulging of the floor in excess of 4"
WFMPI floor to shell weld internally (100% for new, spot for existing at
1' in every 20')
WFMPI floor new floor to shell welds externally (100% for intermediate
tensile steels, spot only for others at 1' in 20')
Cut coupons as required to confirm MFE results in both good and bad
locations
Spark test existing GRP lining if not to be replaced
Inspect any existing paint system and asses its ability to last for the next
run. If it is to remain , carry out a holiday detection test and repair as
necessary
REQ'D DONE FLOOR APPURTANANCES

Check that thickened plate has been installed where floor outlet nozzles
require the floor to span a sump box
Ultrasonically gauge and hammer test any central WDO sump and drain
line
Remove vortex breakers and hydrotest any floor outlet nozzles
Check that any hard piping on the floor has a free sliding support so that
any expansion or reaction forces will not tear the floor
Check for evidence of additional floors and measure distance between
internal floor and external sketch plate
Check for doubler pads and their condition at mixers and dipping points
Ensure wear pads are installed below all floating roof legs
Check column bases for adequate pads and restraining clips
REQ'D DONE FLOOR REPAIRS

Map out all repairs and any overplating done to the floor
Check weldability of annular to shell weld to determine if any special
considerations apply
Check for materials certificates of new plates ( assume plates from Bapco
materials are acceptable)
Spot check thickness of replacement annular and floor plates
Check for removal and grind flush of dogging system attachments and
WFMPI tack/attachment welds as required
Check for distortion of replacement floor plates, overplated area and
especially annulars on completion
Check that correct painting or GRP procedure has been specified for floor
Spark test GRP coatings after application
Check expiry date of any coatings being used
Arrange for hydrotest if required per 8.1
PJV:OOSCHECK
14thNovember,1998
REQ'D DONE SUMMARY OF NDT Items
Gauge the shell internally at each "strip" per Standard Procedure
Scan gauge shell (1' in each 20') below retrofitted annular
Supplement the standard ultrasonic gauging externally using either a shell crawler
or manual gauging if necessary
Spot gauge shell, roof and floor nozzles
Thickness gage any replacement shell plates
Carry out radiography of replacement shell joints to latest API 650
Radiograph door sheets (100% vert, spot horizontal)
Check for removal and grind flush of dogging system attachments on shell or
floor and WFMPI tack / attachment welds as required
Radiograph and repair shell welds as per code if J.E to be increased
Hammer test and gauge the roof (cone roof and centre deck) ultrasonically per
standard procedure
Vacuum box test new centre deck and cone roof welds
Ultrasonically scan gauge outer rim, pontoon bottoms and product side inner rim
(if present) on floating roof tanks per standard procedure
Ultrasonically gauge / calliper gauge rafters, support columns and shell
attachment brackets on cone roof tanks
Scan gauge the Hi deck to outer pontoon area for local thinning of roof and
pontoon in the vapour space
Gauge roof drain WDO box and any internal manifolds
Air test all pontoons to 3" WG. Ensure the entire wetted surface is tested not just
the seams
MFE test the centre deck and cone roof if necessary
MPI check for cracks of welds at recesses in pontoons where mixer clearance has
been added
Spot check thickness of any replacement roof and floor plates
MFE scan all floor plates and annular ring (99% coverage expected)
MFE hand scan all plate edge, repads and obstructed areas that the main scanner
may not have reached
Ultrasonically spot thickness gauge floor and annular per standard procedure
Vacuum box test all floor welds including any repairs and overplating
Vacuum box test floor to shell weld internally
Scan gauge 1' long x 3" wide strips of the annular as close to the shell weld as
possible at 20' intervals around the inside of the tank
Scan gauge the full width of the projecting annular /sketch at standard "strip"
locations ( concentrating close to the weld toe)
WFMPI floor to shell weld internally (100% for new, spot for existing, 1' / 20')
WFMPI floor new floor to shell welds externally (100% for intermediate tensile
steels, spot only for others at 1' in 20')
Ultrasonically gauge and hammer test any central WDO sump and drain line
Spot check thickness of replacement annular and floor plates
WFMPI lower 6" of 1st course welds in intermediate strength steels fro SSC
WFMPI spot test vert welds in tidal zone of tanks in caustic service
IP#12 Appendix F
IP#12 Appendix G
____/____/____
ON STREAM INSPECTION CHECKLIST for Tank No. _________
This checklist contains items that are to be considered and / or actioned as part of the On Stream
Inspection of each TRP tank. The inspector must initial next to each point and indicate it was considered
and either completed or not applicable. The completed checklist is to be held in the working file of the
respective tank.
NB: Some of the items may have been covered by a recent ATOP .
REQ'D DONE FOUNDATION / TANK BOTTOM / BUND AREA

Check for settlement around perimeter of tank
Check entire foundation visually for levelness and get Eng. to
provide bottom elevations if in doubt
If steam tracing or heaters are present check for signs of condensate
getting under the floor
Check that runoff rainwater or shell condensation drains away from
tank
Determine the general condition and adequacy of the tank pad / berm
Inspect back of water draw basins and top surface of berm for
indications of bottom leakage
Look for areas where leaching of oil has left foundation filler stained
or exposed
Inspect the area for build-up of rubbish, vegetation, and other
inflammables
Where double bottoms are present check for vent nozzles between
them and that they are not plugged up
Check for incorrectly installed asphalt pads retrofitted below set
through external annular rings of sketch plates
Check line systems and pipe supports within the bunded area. If in
doubt, excavate any buried pipe work for further investigation
REQ'D DONE SHELLS

Visually inspect externally for paint failures, pitting, and corrosion especially on the
bottom course, stairs and at the windgirder
Select external "strips" to be gauged (manually or with crawler)
Calculate remaining life and proximity to MAT
Scan gauge short shell (1' in each 20') below retrofitted annular
Note location and estimate extent of any kinks, bulges or out of roundness. If in doubt
request an Eng. survey
If insulated, establish that the weather proofing is sound and that the insulation stops at
least 3" above grade level
Remove insulation in suspect areas to check underlying condition of shell
Inspect the external surface for evidence of shell, rivet or seam leaks
If painted internally for corrosion establish effectiveness of paint
REQ'D DONE SHELL APPURTENANCES
Inspect for cracks or signs of leakage on joints at nozzles, manways, and reinforcing
plates
Inspect for shell plate dimpling around nozzles, caused by excessive pipe deflection
Inspect sealing of insulation around manways and nozzles
Remove insulation at locations where water ingress is suspected
Check for inadequate manway flange and cover thickness on mixer manways and that
the mixer supplementary support system (hanger) is sound
Inspect for evidence of shaft damage or leakage at mixer seals
Check sample connections and small bore lines for leaks
Inspect wind girder and handrail for corrosion damage (paint failure, pitting, corrosion
product build-up), especially where it occurs at stitch welds
Check windgirder / stair support and bracing welds to shell for pitting, especially on
shell plates
ROOFS
For safety, before accessing the roof, check with ultrasonic instrument or a ball peen hammer to test the
plate. Use duckboards until the roof condition is positively established to be safe.
REQ'D DONE ROOFS

Visually inspect the roof topside for paint failure, holes, pitting, corrosion or evidence
of product on the roof deck
Gauge cone roof ultrasonically with crawler
Look for indications of standing water. (Significant sagging of fixed roof deck indicates
potential rafter failure. Large standing water areas on a floating roof indicate
inadequate drainage design or, if to one side, a unlevel roof with possible leaking
pontoons.)
Check floating roof for evidence of upward bulging of the centre deck while in service
as these bulges may constitute vapour spaces and can corrode more rapidly than the rest
of the roof
Look for and record any distortion of the roof. Consider photographs of roof if
distortion is evident (without flash and permit required)
Visually inspect for cracks or leaks in the insulation weather coat on insulated tank
roofs where rain water could penetrate the insulation. If in doubt remove small test
sections of insulation and check roof deck for corrosion and holes near the edge of the
insulated area
REQ'D DONE ROOF APPURTENANCES

Check and record the seal condition where visible
Inspect secondary seals for signs of thinning, buckling or distortion
Check that earthing shunts are in place and contacting the shell
Check separate earthing cables are sound
Check that the rolling ladder is free to move correctly and in good functional condition
Open pontoon covers and visually inspect inside
REQ'D DONE FLOOR
Clean off the annular / sketch area and inspect / hammer test for corrosion and thinning
on plate and weld
Gauge the full width of the projecting annular /sketch at standard "strip" locations (
concentrating close to the weld toe)
REQ'D DONE REPAIRS

List below any items for action at next T&I and worklist any others that can be done
immediately
osicheck
Appendix H
Bapco On Stream Gauging - 2008
Scope and Timing:
The tanks that Bapco requires to be gauged in 2008 by a self contained ultrasonic shell crawler system
are shown in the attached table. Also included in the table is information relating to their size, type and
degree of coverage required. Work may commence in February and must be completed by the end of
June 2008. Both floating and cone roof tanks are included and gauging is required on the shells of all
tanks and roofs of cone roof tanks.
Access to Shells and Roofs:
Access to the roofs of cone roof tanks is prohibited. All gauging operations have to be carried out from
the gaugers platform or from two scaffold towers provided by Bapco at 180 degrees or at 120 and 240
degrees from the platform. As the UT machine is to be operated without access to the roof the control /
data gathering system must allow for remote operation at distances up to 150’ for the largest of Bapco’s
tanks.
Floating roof tanks have either a plate or lattice type of windgirder, but only certain plate types are
suitable for access by personnel. Where such access is possible, this is noted under the column
"Windgirder Type" by the word "Walkway". No other form of access will be provided by Bapco to
shells or roofs.
IN VIEW OF THE FOREGOING THE CONTRACTOR MUST PROVIDE A WRITTEN

STATEMENT TO THE EFFECT THAT HIS SYSTEM CAN PERFORM THE REQUIRED WORK
WITH NO ADDITIONAL ACCESS, BEFORE BEING CONSIDERED FOR CONTRACT AWARD.
In addition to the above, some tanks may have additional stiffening rings at one or more locations on
their shells. This information, along with the course(s) concerned, will also be found on the attached
table under the “Windgirder Type” column. These rings hamper vertical scans and the contractor will
need to plan for this accordingly.
Rivet and Lap Obstructions:
The tanks may be of riveted, welded or mixed construction and the table indicates which courses are
riveted. NB: The combined drop off distance, or step, from rivet head to adjacent shell (i.e. rivet height
plus lap height) can be as much as 2". The cone roofs are constructed with lap joints with steps in the
order of 0.25" to 0. 30". THE CONTRACTOR MUST PROVIDE A WRITTEN STATEMENT TO
EXPLAIN HOW HIS GAUGING SYSTEM CAN ACCOMMODATE THESE OBSTRUCTIONS,
BEFORE BEING CONSIDERED FOR CONTRACT AWARD.
Special Permit Requirements:
As a special permit requirement for gauging in service tanks it is mandatory to have an audible gas
monitor attached to the crawler and set to alarm if the hydrocarbon mixture exceeds 10% LEL. The
Drager Explometer is a suitable device for this purpose. THE CONTRACTOR MUST PROVIDE A
WRITTEN STATEMENT TO THE EFFECT THAT HIS UNIT COMPLIES WITH THIS
REQUIREMENT BEFORE BEING CONSIDERED FOR CONTRACT AWARD.
Shell Gauging "Strips":
The table column "Strips" refers to the number of locations around the tank where the thickness
information is required and this is generally dependant on the tanks' diameter. These locations, or
gauging "strips", will be numbered and marked on each tank by Reliability Engineering Department
(RED) personnel. The location of the centre of the strip with respect to a locatable "landmark" (e.g.
nozzle, vertical weld) must be noted and included in the report so that subsequent contractors can
precisely relocate the position even when the marking has faded. The numbering system used by RED
must be noted by the contractor and used in the report to identify the strip gauged. The strips are to run
vertically up the tank with a maximum deviation of 2' from top to bottom
Unless the "Comments" column specifically states otherwise the gauging information will be required
on all courses in the "strip" from the sketch plate to the Kerb angle or windgirder.
NB: Gauging above the windgirder of a floating roof tank is neither required nor allowed. Gauging
above an external stiffening ring on a cone roof tank is required. If necessary the crawler can be
launched above the stiffening ring at the stairs and traverse round the tank to each strip.
Certain tanks may require additional "strips" on some courses and for other tanks "strips" may only be
required on specific courses that have been selected for gauging. Where this is the case the information
is contained in the "Comments" column of the attached table.
At each individual "strip" the shell thickness will be measured by a number of vertical ultrasonic "scans"
of the shell. The actual number of "scans" per "strip" will depend on the characteristics of the ultrasonic
machine used. (See below – Ultrasonic Machine).
Roof Gauging:
The roofs of all cone roof tanks are to be gauged on a similar basis to the shell. Unless advised otherwise
the "strips" will start within 1' radially of the perimeter of the roof and be in line with the shell "strips".
All roof "strips" are required to extend from the roof perimeter (as noted above) to within 3' radially of
the centre.
The first UT scan should be made from the gauging platform to the center. If the roof is obviously
severely thinned then report this to RED before proceeding, as further gauging may not be necessary.
Annular Ring Gauging:
At each strip location a 3’ length of the annular/sketch plate is to be 100% manually scan gauged. The
results are to be presented as part of the report and should include general thickness, minimum thickness
and an assessment of the underside condition.
NB: This requirement only applies to tanks where the effective tank floor is at grade level. In other
words it is not necessary to gauge set through annular rings or original sketch plates above a short shell
or the original sketch of a bracket supported floor.
Ultrasonic Machine:
The preferred machine is one able to perform and record a more or less continuous scan (i.e. readings
at no more than 2 mm intervals). In this case then only one scan per "strip" is required. If the ultrasonics
of the system can only record gaugings at intervals between 3 mm and 13 mm (i.e. point readings) then
2 parallel "scans" per "strip" are required and these should be separated by approximately 150 mm. Point
gaugings at a greater interval than 13 mm would not be acceptable
Operator Testing:
Bapco reserve the right to test and verify the competence of any operator / machine combination
supplied by the contractor. If found deficient, the contractor will be expected to substitute an acceptable
combination within 2 weeks or forfeit the contract.
Sub-Contracting:
If the primary contractor finds it necessary to sub-contract all or part of this work, then this fact must be
disclosed with the bid submission and the proposed contractor identified. Bapco reserve the right to
reject any sub-contractor if such company is either unknown, or if RED's NDT specialist does not
approve their use.
Effect of Paint Thickness:
The contractor must be able to demonstrate before commencement of the work that his system will (i)
eliminate the effect of paint thickness on the results or (ii) compensate for measured paint thickness and
(iii) positively identify where coupling is lost due to paint delamination. NB: If coupling is lost over
more than 10% of any course in a "strip" then the probe's location in the non coupled band must be
adjusted and the area re-scanned until the figure is below 10%.
If manual correction for paint thickness is the preferred system then the paint thickness must be
measured on each course, preferably with an "Elcometer" type recording paint film thickness monitor.
At least 20 readings per course should be taken and the average as well as deviation computed. The
paint thickness value used, the deviation and the raw data must be included in the report as an
appendix .
NB: The contractor must be aware that a paint thickness survey taken from the stairs may be completely
erroneous unless the paint thickness is measured above or below any previously gritblasted zone. See
below for the reasons.
Varying Paint Thickness:
All tanks are painted and most have been painted numerous times. The contractor MUST NOT assume
that the paint thickness is uniform throughout the tank or even on a course. Typically, the paint will be
noticeably thinner around the bottom 12" of course 1 (Black Ring), within 4 feet either side of the stairs
and for several feet below the wind girder. This is because Bapco's pervious maintenance painting
policy dictated that these areas be painted at T&I's on a gritblasted surface. The remainder of the tank
was painted on an ad-hoc basis, mostly for cosmetic reasons, over a wire brushed surface and could thus
have a considerably greater paint thickness than the former areas.
In addition, previous on stream gauging procedures have required that gauging of "strips" be manually
carried out from staging. This generally involved scanning after the removal of paint at 3 locations,
approximately 2 feet wide by 1 foot high, on each course of a “strip”. In a few other cases a complete
strip 2' wide may have been blasted over the full height of the tank for gauging. The paint in these
scanned areas will usually be significantly thinner than the surrounding areas.
Lastly, when carrying out the cosmetic repaints, poorly adherent paint will be dislodged by the power
wire brush preparation or subsequent chipping. This will result in random shaped areas where the final
paint thickness will be lower than the adjacent area.
In all the above cases, the difference in paint thickness is readily apparent from a visual examination,
even from grade. The magnitude of the variation is sufficient to noticeably affect the measured thickness
unless this is compensated for, or eliminated by, the gauging system adopted. Where "strips" pass
through areas of varying paint thickness the contractor MUST annotate the report to show any effect it
may have on the final thickness recorded. Failure to compensate correctly for the varying paint thickness
typically shows up as a step change in thickness near the windgirder or bottom of the tank or where
previously gritblasted areas are crossed.
Presentation of Results:
The thickness data may be recorded in metric units but is to be presented in imperial units. The
preferred presentation would be graphically and this should be for each "scan" in a "strip" showing a
cross section of the shell and clearly indicating course boundaries. Other forms of reporting will be
considered but will have to be accepted by RED before commencement of the contract. The thickness
values displayed and reported must include any correction factors for paint thickness etc. as they will be
used by Bapco to compare the tanks assessed thickness with allowable values to determine remaining
life.
The contractor is also required to provide a written interpretation for any anomalies encountered e.g.
lamination, pitting etc. Minimums and general thickness values, corrected for the effect of paint
thickness, must be clearly discernible on the graphical output and the raw data must be easy to
interrogate to find or verify the readings. Software that is able to interpret the gaugings to API 653
would be an additional bonus, but this feature must be user selectable and in no way over rides the basic
presentation requirement.
Verification of Results:
Bapco has substantial history of past gaugings as well as extensive experience of gauging its own tanks.
In most cases the thickness values expected are known within quite tight limits. Where the results
provided by the contractor fall outside these anticipated values Bapco will utilise its own NDT specialist
to manually recheck the readings. In addition, Bapco also reserves the right for Q/A purposes, to
randomly check / verify any readings reported (including paint thickness). Where discrepancies are
found it will be up to the contractor to prove that his readings are correct. Failure to do so could result in
a dispute situation which, if not resolved, could lead to the cancellation of the contract and the removal
of the contractor from any future bid list.
Notification of Problem Tanks:
Bapco will provide Minimum Allowable Thickness (MAT) information for each course to be gauged.
This is to be used by the contractor IN REAL TIME to determine how close the individual courses are to
their minimum. NB: In all cases where the gauged minimum is equal to, or less than 0.05" above the
MAT, Bapco must be verbally informed within 48 hours as this may necessitate a revised scan
pattern.
Reporting:
A full report for each tank should be available within 5 days of the gauging being completed and all
reports prior to the last tank gauged must be available before demobilising.
Self Sufficiency:
The contractor selected will be expected to be totally self sufficient in terms of importing the gauging
equipment, transport, accommodation, consumables etc. Vehicles used on site must be inspected by
Bapco representatives to ensure they are suitable. A driver for the vehicle will also be required to
demonstrate his competence to the satisfaction of Bapco's Security Department. Bapco will endeavor to
provide an office on site for clerical work or reporting, but this is not guaranteed and said office may not
be suitable for secure storage of the contractor's equipment.
Work Visas:
It is general Bapco policy that contractors working on site for any extended period should have the
requisite work visa as required by the Bahrain authorities. It is the contractors responsibility to obtain,
pay for and maintain said visas for the duration of the contract.
Permits to Work:
A representative of the contractor (preferably the technician in charge) will be expected to attend and
pass Bapco's permit receivers course and handle all onsite permitting requirements. Delays due to
scheduling and permit compliance can occur, though every attempt will be made to minimise them.
Claims from the contractor for "waiting time" in excess of 1 hour per day will only be considered if the
contractor advises the delegated Bapco representative at the time that a delay is being incurred. In
addition, time sheets including "waiting time" must be submitted within 24 hours of the completion of
the shift concerned.
Alternative Tanks:
Lastly, it is possible that priorities may change prior to or during the gauging program. Bapco reserves
the right to substitute other tanks for those listed, but on the understanding that the total number of
courses and cone roofs to be gauged (i.e. the total amount of work) will not exceed that specified on the
table below.
TANKS FOR ON-STREAM INSPECTION- 2008
TANK SERVICE LOCATION DIAM. HEIGHT No. OF No. OF RIVETED ROOF W/GIRDER SPECIAL
No. FT FT COURSES STRIPS COURSE TYPE TYPE REMARKS
87 Diesel Sitra Tank 12 15 3 2 Flat

89 Water Sitra Tank 36 40 5 4 Open
104 Kerosene Refinery 78 40.02 7 6 Floating Lattice
Tank
108 Sweet MCN Refinery 78 40.88 7 6 All Floating Lattice
Tank
120 Medium Refinery 78 40.33 7 6 1-6 Cone
DSL Stock Tank
124 Unleaded Refinery 78 40.95 7 6 Floating Lattice
Slop Tank
127 Unifinate Refinery 78 41 7 6 Floating Ring
Tank
164 Slop Refinery 38 30 5 4 Open
Tank
265 Sour LLCN Refinery 48 41 7 4 Floating Walkway
Tank
455 Diesel Refinery 30 35.42 6 2 All Cone
Tank
466 Slop Leaded Refinery 36 41 7 4 1-4 Floating Ring
Tank
601 Water Awali 36 40.29 6 4 Cone
614 Water Awali 36 40 7 4 Cone
705 Fuel Oil Sitra Tank 283 56 7 10 Cone
712 Diesel Gas Sitra Tank 144 45.1 6 8 Cone
Oil
716 Jet A1 Sitra Tank 259 64 6 10 Floating Walkway
733 Fuel Oil Sitra Tank 140 48.4 8 8 Cone
734 Fuel Oil Sitra Tank 184 48 6 10 Cone
751 Kerosene Sitra Tank 250 64 7 10 Floating Walkway
900 Slop Leaded Sitra Tank 50 30 4 4 Floating Ring
901 Kerosene Sitra Tank 120 40 6 6 Floating Ring
906 Gasoline Sitra Tank 144 46.06 8 8 Floating Walkway
914 Diesel Gas Sitra Tank 144 46.19 8 8 All Cone
Oil
945 Naphtha Sitra Tank 160 56.04 8 10 Floating Walkway
957 Diesel Marketing 48 48 6 6 Floating Ring
958 Jet Fuel Marketing 67 48.83 7 6 Internal
floating
(Dome)
960 Gasoline Marketing 43 40 5 4 Floating Ring
IP#12 Appendix I
Memorandum To:
Date:____/____/____
Manager - _______________
TANK RELEASE SHEET

File: C241 - _______
The [Inspection] [Repair] [Hydrotest] [Change of Service Review] [Restricted Filling Height
Review] of Tank No. _______________ has been completed and the tank may now [Return to
Service Unrestricted] [Remain in Service Unrestricted] [Change Service] [Return to Service with
RFH] [Remain in Service with RFH]. The following information is correct at time of issue:-
Is a Restricted Filling Height in effect? [YES] [NO]
Approved Specific Gravity - ________ (This is the SG used for MAT calculations)
Previous Product - __________________________

Future Product - __________________________
Structural Height to Kerb Angle - ________ ft ________ mm

[Restricted Filling Height] - ________ ft ________ mm
[Maximum Safe Filling Height] - ________ ft ________ mm
[Hydrotested Height] - ________ ft ________ mm
Maximum Operating Height - ________ ft ________ mm (To be filled in by Owner)
Main T&I Work Request No. - _____________________

EMPAC Data Ratified - [YES] [NO]
Isolating Valve Test Data

Valve No. Test Type Test Press. Test Date
___ = FIELDS TO BE FILLED IN
[ ] = DELETE THOSE NOT APPLICABLE.
_________________________________
For: Manager - Reliability Eng. Dept.
IP#12 Appendix J
Tanks Containing Caustic Or Hydrogen Sulphide
Tanks containing >10 ppm H2S
1) All Arabian & Bahrain crude oil tanks - 132, 132, 134, 135, 136, 138, 143, 152 & 153.
2) All slop oil tanks (leaded & unleaded tanks) - 261, 262, 466, 467, 124, & 144.
3) All slop oil recovery system tanks - 38, 40 & 42.
4) Sitra slop oil tanks - 900 & 920.
5) Foul water stripper feed tanks - 8601 & 8603
Tanks containing >1q Be' Caustic
1) All tanks & vessels at 1PbS & 2PbS units - 71 to 78 inc. , 97 & 98.
2) All feed / rundown tanks of 1PbS - none (was 245, 345, 351, 248, 249, 348, 443, 444, 447, 448)
3) LLCN rundown tanks from the Merox unit - 139, 140, 264 & 265.
4) MCN rundown tanks from the Inhibitor Sweetening Plant - 108 & 1108.
5) VBN rundown tanks from (2PbS) #1Treater or #4Treater - 469 & 470.
6) Spent caustic tanks - 269, 270 & 271.
7) Caustic streams in 1LPG Treater & 2Poly - 57 to 62 inc.
8) Kero Merox Unit from upstream of the electrostatic coalescers to the water wash vessels -
1601 & 1602.
IP#12 Appendix K
IP#12 Appendix K “TANKMAT”
IP#12Appendix L
ITEM SURFACE TYPE OF PRIMER NO. OF MICRONS TYPE OF FINISH COAT NO. OF MICRONS NOTES
PREP COATS DFT / COAT COATS DFT / COAT
SHELL; INTERNAL - DIESEL SA 2 1/2 HOLDING PRIMER 1.00 50.00 HIGH BUILD COAL TAR EPOXY 2.00 100.00 P&CP 7
(CONE) ZINC FREE
SHELL INTERNAL - SA 2 1/2 HOLDING PRIMER 1.00 50.00 HIGH BUILD EPOXY 2.00 375.00 P&CP 23
GASOLINE / NAPHTHA ZINC FREE REINFORCED WITH GLASS /
(FLOATING ROOF) MINERAL FLAKES
SHELL; INTERNAL - JET FUEL SA 2 1/2 HOLDING PRIMER 1.00 50.00 HIGH BUILD EPOXY 2.00 375.00 NOTE 1
/ KERO (FLOATING ROOF) ZINC FREE REINFORCED WITH GLASS / P&CP 23
MINERAL FLAKES
SHELL; ROOF & FLOOR; SA 2 1/2 EPOXY POLYAMIDE 1.00 50.00 HIGH BUILD POLYAMIDE EPOXY 2.00 150.00 P&CP 20
INTERNAL - POTABLE / (WITH ZnPO4)
ZALLAQ WATER
SHELL; EXTERNAL - SA 2 OR ALKYD ZINC 2.00 40.00 ALKYD BASED SELF 2.00 40.00 NOTE 4
GENERAL ST 3 PHOSPHATE CHALKING WHITE P&CP 2
SHELL; EXTERNAL - WIND SA 2 1/2 EPOXY POLYAMIDE 1.00 50.00 EPOXY MASTIC PLUS 1 200 - 230 P&CP 18
GIRDER WALKWAY (WITH ZnPO4) POLYURETHANE 1 50
SHELL; EXTERNAL - LOWER SA 2 1/2 EPOXY POLYAMIDE 1.00 50.00 HIGH BUILD COAL TAR EPOXY 2.00 100.00 P&CP 7
1 FOOT PLUS SKETCH (WITH ZnPO4)
FLOATING ROOF; SA 2 1/2 INORGANIC ZINC 1.00 75.00 NONE -- -- NOTE 2
EXTERNAL SILICATE P&CP 6
FLOATING ROOF; SA 2 1/2 HOLDING PRIMER 1.00 50.00 HIGH BUILD EPOXY 2.00 125.00 NOTE 1
UNDERSIDE ZINC FREE P&CP 25
CONE ROOF; EXTERNAL SA 2 1/2 OR EPOXY POLYAMIDE 1.00 50.00 EPOXY MASTIC PLUS 1 200 -230 NOTE 4
ST 3 (WITH ZNPO4) POLYURETHANE 1 50 P&CP 21
FLOOR; DIESEL OR WITH SA 2 1/2 GRP SYSTEM NOTE 5 NOTE 5 GRP LAMINATE SYSTEM NOTE 5 NOTE 5 NOTE 3
UNDERSIDE CORROSION GLASS REINFORCED POLYESTER P&CP 24
FLOOR; GENERAL SA 2 1/2 HOLDING PRIMER 1.00 50.00 HIGH BUILD EPOXY OR 2 125 NOTE 3
ZINC FREE GLASS FLAKE REINFORCED 1 500 NOTE 1
POLYESTER P&CP 19
P&CP 10
NOTE 1: IF OWNER IS CONCERNED WITH PRODUCT QUALITY (e.g. AVIATION GAS) TANK WILL BE PAINTED TO MIL SPEC'S - LATEST REVISION.
NOTE 2: IF PRODUCT IS LIGHTER THAN KERO, OVERCOAT WITH A TIE COAT AND HEAT INSULATING PAINT.
NOTE 3: GRP LAMINATE IS STANDARD FOR DIESEL TANKS. ON OTHER TANKS THE DECISION TO USE GRP OR EPOXY IS DRIVEN BY ACTUAL OR ANTICIPATED
UNDERSIDE CORROSION AND TOPSIDE CONDITION (i.e. EPOXY IS USED IF UNDERSIDE CORROSION IS NOT A PROBLEM AND TOPSIDE HAS NOT BEEN
SUBJECTED TO SEVERE / HEAVY PITTING).
NOTE 4: ST3 (POWER WIRE BRUSH) IS USED IF TANK IS PAINTED WHILE STILL IN SERVICE OR FOR SMALL AREAS.
NOTE 5: APPROVED GRP SYSTEMS HAVE VARIOUS COMPONENTS BUT FINAL SYSTEM THICKNESS WILL BE APPROX. 2 - 3MM.
IP#12 APPENDIX M
PONTOON GAUGING SHEET

IP#12 APPENDIX N
Berm Remediation and Telltale Holes
Background
RED had expressed a concern that on tanks with multiple floors, which may be seal welded
circumferentially at the sketch plate, in the event of a leaking floor that the unmaintained short shell
may experience full tank head pressure. At the time, 'false' berms prevented external inspection.
RED proposed a berm remediation and tell tale drilling programme, commencing at Sitra Tanks
involving shaving of the false berm down to the original pad height and making good on each tank.
Once the short shell had been exposed, tell tale holes would then be drilled under the existing floor
to allow this area to vent to atmosphere.
A $50k budget has been established for Sitra and Refinery Tanks in 2000.
Diesel service, cone roof tanks 701, 702, 703, 712, 721, 722, 723 and 731 had been targeted for trial
purposes due to the nature of the product and relative ease of identification of the false floors.
Internal angle floors on other tanks have not been considered from a safety point of view and this
work will continue to be undertaken at T&I only.
Agreed method statement
The optimum method of drilling the tell tale holes in the short shell with the above tanks in service
is summarised below:-
x Reduce tank inventory to minimum operating level.

x Drill full size hole at water draw off sump area initially, check for leaks over a period of
time.
x Drill tell tale holes at the cardinal points around the tank short shell. Tap holes for ease of
connection of drain valves and fittings, if required.
x Refill tank to maximum operating level, check for leaks. Lower tank to minimum operating
level.
x Drill holes around tank short shell at 20' intervals, check for leaks.
x Refill tank to maximum operating level and check for leaks.
x Have tapered wooden plugs available to stem any leaks.
x Route any displaced product to sewer using drilled and tapped (valved) holes in short shell.
x Have foam/fire fighting equipment ready for immediate use.
DJH/djh/01/2001
IP#12 Appendix O
25 June 2001
Revision 2
METHOD STATEMENT
AIR TESTING OF TANK 946 FLOOR
1. Caulk outer periphery of annular with clay material to reduce escape of air.
2. Tap short shell vent holes.
3. Fit plugs to six of the vent holes.
4. Fabricate two U-bend full bore 9” water gauge seals and install in the remaining two tapped
holes in the short shell. These will function as additional safety pressure relief valves.
5. Fabricate four U-Bend full bore 9” water gauge seals and install into the floor on a radius of 50’
from the floor apex. These will function as safety pressure relief valves.
6. Air test apparatus – Inner Ring. Drill and tap five by ¾” holes in the floor plate to take air hose
fittings. One of the holes being drilled in close proximity to the floor apex and the other four
drilled equally spaced, on a radius of approximately 40’ outwards from the floor apex.
7. Air test apparatus – Outer Ring. Drill and tap eight ¾” holes in the floor plate to take air hose
fittings. Holes to be equally spaced on a radius of 65’ outwards from the floor apex.
8. Fabricate and install air test apparatus so as to allow inducement of air into the floor via the
thirteen inlet points simultaneously. Air compressor to be fitted with a regulating valve and set at
30 psi.
9. Each air inlet point to be fitted with an air shut off valve and a pressure release valve. All valves
will be ball type construction. These will function as pressure balance valves as well as
emergency relief.
10. Drill and tap one ¾” hole on an approximate radius of 20’ outwards from the floor apex. Drill
and tap an additional four ¾” holes equally spaced on an approximate radius of 60’ outwards
from the floor apex. Fit Manometers to all holes.
11. Fill the tank with water leaving a dry area of approximately 80’ in radius from the apex. Allow
the water to calm.
12. Slowly induce air under the floor. Monitor pressure build up on five installed Manometers.
13. Working systematically, visually examine the area covered with water for signs of a leak. Use
valves fitted to throttle pressure if necessary.
14. Increase the water level further so that the floor is ¾ covered and test, adjusting the air pressure
to the maximum allowed differential (see note below), and visually examine for signs a leak.
After completing this, increase the water level until the apex is marginally covered with water
(say 1/8”), adjust the test pressure and continue visual examination.
15. Clearly mark any identified leaks in the floor using weighted marker “flags”. Once testing has
been completed and the tank floor dry, remark these positions on the floor using white
paint/marker pen.
16. Positions of all drilled holes to be recorded on the floor layout sketch.
17. Remove test apparatus.
18. Convene meeting with RED, PED, OS&E and SD&MM to determine method of repairing floor
and closing off redundant holes used for test purposes.
NOTE: The maximum differential pressure allowed shall be 3". Since the floor is sloped, this will be
calculated based on the depth of water at the middle point of the area covered. (i.e. assuming that the
average height water at a point of the test is 2”, then the allowable pressure would be 5” water
gauge). For the purpose of testing, the maximum allowable pressure applied is limited to 9”.
TANK SERVICE AND SPECIFIC GRAVITY
IP#12 Appendix P
PRESENT TANK NO. APPROVED MAX.

SERVICE "S.G."
ARABIAN CRUDE 132,134,135,136,138 0.8762
133 0.8871
BAHRAIN CRUDE 143,152,153 0.8871
CAT NAPHTHA. 369,468, 470 0.8398
PLATFORMATE 137, 1401 0.7972
SOUR LLCN 264 0.8156
265 0.8251
SWEET LLCN 139, 140 0.7972
MCN 108,1108 0.8156
POLYMER 475, 476 0.8251
1110 0.7587
SOUR VBU NAPHTHA 457 0.8251
356 0.7547
GASOLINE 710, 933, 934 0.7796
906, 935 0.7624
915, 916, 926 0.7628
924 0.7760
LSR (B220) 460 0.6953

129 0,8251
LSR+MSR (B220+B210) 741, 945 0.7972
760, 936, 946 0.8109
JET A1 716, 726, 736(CHEVRON) 0.8602
965(CHEVRON) 0.8765
961 0.8702
UNIFINATE 127 0.7628

UNIFINER CHARGE. 128, 1106 0.7628
SOUR MSR 1104, 1105 0.7628
KRU FEED 113, 114 0.8109
B440 REF KERO 105,115, 125, 0.8109
B440 SITRA KERO 730, 740, 751 0.8109
750, 944 0.7972
ARAD JET FUEL 901, 902, 903 0.8109
DIESEL BLEND 360, 107 0.8927
DIESEL (BFO BACKUP) 461 0.9402
FCCU CHARGE 142 0,9930
1201, 1301 0,9279
TANK SERVICE AND SPECIFIC GRAVITY
IP#12 Appendix P
KERO MEROX FEED 103, 104 0.8109

131 0.8762
HCN/KERO CUTTER 363, 465, 1109 0.8762
HDU DIESEL 101, 121 0.8762
102, 1112 0.8927
111 0.9593
HCU DIESEL 106 0.8927
117 0.9930
120 0.9218
ALBA DIESEL 452,455 0.8708
DIESEL GAS OIL 701, 702, 703, 706, 712, 0.8871
721, 722, 731, 913
723 0.9930
904, 914 0.9861
MED DIESEL / LVGO 116 0.9827
WHARF DIESEL 160 0.8498
909 0.8871
910 0.9712
2HDU DIESEL FEED 1101, 1102 0.9279
1 HCU FEED CHARGE 1103, 1302 0.9279
CUTTER 118 0.9789
119 0.9465
6 VDU FEED 122 0.9930
126 0.9902
REF FUEL OIL 112 0.9930
FUEL OIL 705, 713, 714, 715, 724, 733, 0.9930
734,743
REFINERY SLOP 124,144 0.9725
261, 262, 466, 467 0,9593
SITRA SLOP 900, 920 0.9593
LPG 80, 81, 82, 83, 84, 85 0.5859
B1138 (60/70 PEN) REF 170, 171, 172, 180, 181, 183, 184 1.0443
B1149 (60/70 PEN) SITRA 907, 908, 1.0443
JAYYID 91R 952, 959, 963 0.7628
MUMTAZ 95R 951, 960, 964 0.7628
B440 KERO MARKETING 958, 0.8109
962 0.8702
B825 MARKETING 954 0,8702

957 0.8602
966 ????
AIA 911 0.9710
922 1.0500
PJV/pjv:TANKSG2008
24th January, 2008
OIL STORAGE & EXPORT DEPARTMENT
CHECK LIST OF RETURNING CONE ROOF TANK TO SERVICE
IP#12 Appendix Q
Tank No. _______________________ Date __________________________
Page 1 of 4
ITEM NO ITEM TO BE CHECKED PED DATE RED DATE MAINT. DEPT. DATE OS&E DEPT DATE
A) PRIOR TO HYDRO TEST
INSTALL/MODIFY ROOF VENTS AND/OR VACUUM
1 N/A N/A
BREAKERS.
CHECK HIGH VOLUME VENT HATCH FLAPPER OPERABLE

2 N/A N/A
(WHERE FITTED).
3 CLEAN:
a) WATER DRAW NOZZLES. N/A N/A
b) SUCTION WEIR. N/A N/A
c) BOTTOM DIFFUSER. N/A N/A
4 FIT BOILER MAKER ON DIFFUSER END. N/A N/A
MODIFY STILLING WELL FOR ENRAF (AS PER PLT. ENG.
5 N/A
DRAWING).
INSTALL SAMPLING/GAUGE HATCH AND REFERENCE

6 N/A N/A
POINT FOR CUSTODY TRANSFER TANKS.
INSTALL TEMPERATURE ELEMENT FOR CUSTODY

7 N/A
TRANSFER TANKS.
8 CHECK ACCURACY OF TEMPERATURE ELEMENT. N/A
INSTALL DATUM PLATE UNDER STILLING WELL AND

9 N/A
MANUAL GAUGE PIPE.
10 INSTALL REINFORCING PLATES ON TANK FLOOR UNDER:
a) CONE ROOF COLUMNS. N/A

b) MIXER MANWAYS. N/A
REMOVE REDUNDANT VAREC GAUGE EQUIPMENT
11 INCLUDING GUIDE-WIRES AND SUPPORT INSIDE THE N/A N/A
TANK.
Page 2 of 4
A) PRIOR TO HYDRO TEST (cont'd.)
REMOVE SWING ARM WINCH AND ASSOCIATED N/A N/A
12 EQUIPMENT AND REPAIR SHELL AT PULLEY JOINTS AND
BRACKETS INTERNALLY AND EXTERNALLY.
a) INSTALL SAMPLE BLEEDERS AS PER STANDARD N/A N/A
13
DRAWING.
b) REPACK AND FREE-UP SAMPLE POINT VALVES N/A N/A
c) SEAL WELD TO THE SYSTEM. N/A N/A
14 CHECK STILLING WELLS/GAUGE PIPE PLUMB. N/A N/A MTCE/INST

VORTEX BREAKERS INSTALLED ON SUCTION AND WATER N/A
15
DRAWS.
INSTALL 30"MIXER MANWAYS (IF APPLICABLE) AS PER N/A N/A MTCE/MECH.
16
PLANT ENGINEERING DRAWING.
17 REINSTALL MIXERS (IF APPLICABLE). N/A
ALL WORK PER INSPECTION WORK LISTS SATISFACTORY N/A
18
COMPLETED.
ENRAF GAUGE RE-INSTALLED, CHECKED AND CALIBRATED N/A N/A MTCE/INST
19
DURING THE HYDRO TEST.
ESTABLISH REFERENCE HEIGHT AND STAMP ON N/A N/A MTCE/INST
20
REFERENCE PLATE.
BEFORE HYDRO TEST CHECK TANK ACCEPTABILITY, N/A
21
CLEAN AND FREE OF ALL MATERIALS.
BEFORE HYDRO TEST AGREE VENTING PROCEDURE WITH N/A
22
ENGINEER TO COVER THE WATER FILLING AND DRAINING.
BEFORE HYDRO TEST ENSURE BEAM/SKETCH PLATE ARE N/A N/A
23
CLEAN
B) DURING HYDRO TEST
24 ENRAF GAUGE CHECKED AT TWO DIFFERENT LEVELS.
__________ METERS N/A N/A
__________ METERS N/A N/A
Page 3 of 4
B) DURING HYDRO TEST (cont'd.)

25 CHECK REFERENCE HEIGHT. N/A N/A
26 CHECK SHELL/FLOOR FOR LEAK. N/A
CHECK SUCTION VALVES PRESSURE TESTED,
27 N/A
REPACKED AND CERTIFIED BY RED.
CHECK RUNDOWN VALVES PRESSURE TESTED,
28 N/A
CHECK WATER DRAIN VALVES PRESSURE TESTED,
29 N/A
C) AFTER HYDRO TEST
30 AFTER HYDROTEST CHECK TANK ACCEPTABILITY,
CLEAN INTERNALLY AND ALL INTERNAL SUCTION/DRAIN N/A
SUMPS ARE CLEAN AND FREE OF LOOSE MATERIAL.
31 AFTER HYDROTEST, INSTALL SHELL AND ROOF
MANWAYS WITH NEW PROPER GASKETS (ALL ROOF N/A
VENTS CHECKED CLEAR).
32
RECEIVED RELEASE SHEET FROM RED. N/A
33 TANK BUND AREA CLEANED AND EQUIPMENT
N/A N/A
REMOVED.
34
BUNDS REPAIRED/RESTORED. N/A N/A
35 RUNDOWN LINE BLINDS PULLED AT TANK SHELL. N/A N/A
36 SUCTION LINE BLINDS PULLED AT TANK SHELL. N/A N/A
37 WATER DRAW DRAIN LINE BLINDS PULLED AT TANK
N/A N/A
SHELL.
38 a) PLANT ENG. DRAWINGS CHECKED AGAINST TANK
"AS BUILT" AND PROVED SATISFACTORY.
c) TANK "AS BUILT" INFORMATION OBTAINED FOR
UPDATING PLANT ENG. DRAWINGS.
SIGNED PLANT ENGINEERING………………………………… DATE…………………………
39 CHECK LIST REVIEWED AND TANK RELEASED FOR

RETURN TO SERVICE
SECTION SUPT……………………………. DATE………………….………
Form No. BP 4113(6/00)
Page 4 of 4
ADDITIONAL FOR HEATED TANKS
1 REPAIR TO STEAM/THERMAL FLUID COILS, PER N/A
INSPECTION WORK LIST, SATISFACTORY.
2 HEATING COIL TESTED AS PER RED PROCEDURE. N/A
3 HEATING COIL SUPPLY/RETURN VALVES REPLACED. N/A

4 REPLACED DAMAGE/REMOVED INSULATION ON N/A
STEAM/THERMAL FLUID LINES.
5 REPAIR/REPLACE STEAM TRAPS. N/A
6 REPLACE INSULATION ON TANK SHELL/ROOF, REMOVED N/A N/A

DURING OVERHAUL.
7 INSTALL THERMOWELLS/THERMOMETERS ON TANK/COIL. N/A
8 a) PLANT ENG. DRAWINGS CHECKED AGAINST TANK "AS

BUILT" AND PROVED SATISFACTORY.
c) TANK "AS BUILT" INFORMATION OBTAINED FOR
UPDATING PLANT ENG. DRAWINGS.
SIGNED PLANT ENGINEERING :................................................................ DATE..................................
9 CHECK LIST REVIEWED AND TANK RELEASED FOR RETURN

TO SERVICE.
SECTION SUPT.:............................................................. DATE.................................
Form No. BP 4113(6/00)

CHECK LIST FOR RETURNING FLOATING ROOF TANKS TO SERVICE
IP#12 Appendix Q
TANK NO. _____________________________ DATE:_________________________
PAGE 1 OF 4
NO ITEM TO BE CHECKED PED DATE RED DATE SD&MM DATE OS&E DATE
A) PRIOR TO HYDROTEST
1 a) CUT SLOT IN BOTTOM OF ROOF LEGS AND AUTO VACUUM BREAKER.
N/A
b) HEIGHT OF ROOF LEGS AND AUTO VACUUM BREAKER CHECKED BY PED.
ROOF VENTS AND/OR VACUUM BREAKERS INSTALLED AND/OR MODIFIED AS PER

2
PED. N/A
3 a) RIM VENTS, AUTO VACUUM BREAKER CHECKED.
b) PRESS/VACUM FLAPPER TYPE VENT CHECKED.
ALL THE FOLLOWING CLEANED:-
4 a) ROOF RIM VENT ELBOW/FLAPPER N/A

b) ROOF DRAIN AND CHECK VALVE N/A
c) WATER DRAW NOZZLE N/A
d) SUCTION WEIR N/A
e) BOTTOM DIFFUSER N/A
a) BOILER MAKER FITTED ON DIFFUSER END. N/A N/A
5
b) ROOF DRAIN CHECK VALVE CORRECTLY INSTALLED. N/A N/A
6 a) ROOF SEALS/SHOES AND COUNTER WEIGHTS ALIGNMENT CORRECT.
b) THE GAP BETWEEN ROOF AND SHELL IS UNIFORM AND ACCEPTED.
c) WEATHER SEAL INSTALLED.
7 ENRAF STILLING WELL MODIFIED AS PER ENG. DRAWING. N/A
a) 6" SAMPLING/GAUGING PIPE INSTALLED AS PER ENG. DRAWING (FOR CUSTODY
8 TRANSFER TANKS)
b) REFERENCE POINTS FOR ENRAF AND GAUGING PIPE INSTALLED.
c) GAUGE PIPE COVER INSTALLED.
9
TEMPERATURE ELEMENT INSTALLED (FOR CUSTODY TRANSFER TANKS)
10
DATUM PLATE INSTALLED UNDER STILLING WELL AND MANUAL GAUGE PIPE.
N/A
11 REINFORCING PLATES INSTALLED ON TANK FLOOR UNDER:
a) ROOF LEGS.
N/A
b) AUTO VACUUM BREAKER.
N/A
c) MIXER MANWAYS.
N/A
d) FLOATING SUCTION AND RUNDOWN SUPPORTS.
N/A
e) ROOF DRAIN SUPPORTS.
N/A
f) COFLEXIP HOSE EXTENSIONS.
N/A
PAGE 2 OF 4
A) PRIOR TO HYDROTEST (cont'd.)
EXTERNAL STILLING WELL AND REDUNDANT VAREC GAUGE EQUIPMENT
12
REMOVED AND BLANK OFF FLOAT WELL ON ROOF. MTCE/INST
N/A N/A
13 SWING ARM WINCH AND ASSOCIATED EQUIPMENT REMOVED AND SHELL AT
PULLEY JOINTS AND BRACKETS REPAIRED INTERNALLY AND EXTERNALLY.
N/A N/A
14 a) SAMPLE BLEEDERS INSTALLED AS PER STANDARD DRAWING.
b) SAMPLE POINTS VALVES REPLACED. N/A
c) SEAL WELD TO THE FIRST VALVE. N/A N/A
15 ROOF DRAIN SYSTEM HYDROTESTED.
SPLIT PINS FITTED TO THE FOLLOWING:-
a) ROOF LEG PIN. N/A N/A

16 b) ROLLING LADDER PIVOTS. N/A N/A
c) ROLLING LADDER WHEEL AXLES. N/A N/A
d) AUTO ROOF VENTS. N/A N/A
e) FLOATING SUCT/RUNDOWN ROLLERS. N/A N/A
17 GREASE NIPPLES FITTED TO ROLLING LADDER WHEELS AND GREASED. N/A N/A
18 STILLING WELL/GAUGE PIPES PLUMB CHECKED. N/A N/A MTCE/INST
19 ADJUST STILLING WELL ROLLERS FREED-UP AND LUBRICATED. N/A N/A
20 VORTEX BREAKERS AND BAFFLE PLATE INSTALLED ON SUCTION AND WATER
DRAW OFF NOZZLES. N/A
21 BOLTED ROOF PONTOON MANWAY COVERS INSTALLED WITH GOOSE NECK VENTS
(AS PER ENG. DRAWING) N/A
22 FLOATING SUCTION ELBOW IS TURNED DOWNWARD AND VORTEX BREAKER
FITTED. N/A
23
FLOATING RUNDOWN ELBOW IS TURNED UPWARD WITH DIFFUSER PLATE FITTED.
N/A
24 30" MIXER MANWAY INSTALLED AS PER ENG. DRAWING. N/A
25 MIXERS RE-INSTALLED (IF APPLICABLE). N/A N/A MTCE/MECH
26 ALL WORK PER RED WORK LISTS SATISFACTORILY COMPLETED.
ROLLING LADDER, SHOES, FABRIC, SHELL, AND ROOF ARE ELECTRICALLY

27
BONDED BY THE SHUNT PLATES AND BONDING CABLE AT GAUGING PLATFORM.
ROOF MANWAYS INSTALLED WITH NEW GASKET.
FIXED FORM FACILITY INSTALLED FLUSHED. NOZZLE CHECKED, HYDROTESTED
28
WITNESSED BY RED..
29 ROOF PONTOONS CHECKED, PRESSURE TESTED AND WITNESSED BY RED.
PAGE 3 OF 4
A) PRIOR TO HYDROTEST (cont'd.)
a) ENRAF GAUGE RE-INSTALLED, CHECKED AND CALIBRATED DURING THE N/A N/A MTCE/INST
30
HYDROTEST.
b) REFERENCE HEIGHT STAMPED ON REFERENCE PLATE N/A N/A MTCE/INST
31 FAST-FLUSH VESSELS INSTALLED (IF APPLICABLE) N/A N/A
32 SUCTION VALVES REPACKED, TESTED AND CERTIFIED BY RED.

N/A
33 COFLEXIP HOSE INSTALLED AS PER ENG. DRAWING. COFLEXIP/PIVOT MASTER
HOSE HYDROTESTED TO 50 PSI AND HARD PIPE TO 425 PSI.
34
RUNDOWN VALVES REPACKED, TESTED AND CERTIFIED BY RED.
N/A
35
WATER DRAW/DRAIN VALVES REPACKED, TESTED AND CERTIFIED BY RED.
N/A
TANK CLEANED, OF ALL MATERIAL AND ACCEPTABILITY VERIFIED BEFORE
36
HYDROTEST.
VENTING PROCEDURE AGREED WITH PLANT ENGINEER TO COVER THE WATER
37
FILLING AND DRAINING BEFORE HYDROTEST N/A
B) DURING HYDROTEST
ROOF ALIGNMENT AND GAP BETWEEN THE ROOF AND SHELL CHECKED AT TWO
DIFFERENT LEVELS.
38
______ METERS
______ METERS
ENRAF GAUGE CHECKED AT TWO DIFFERENT LEVELS.
39
______ METERS N/A N/A
______ METERS
40 SHELL, FLOOR, REVITS, FLOOR AND PONTOONS CHECKED FOR LEAKE.

N/A
41
ROOF DRAIN CHECKED FOR LEAK DURING THE TANK HYDROTEST.
C) AFTER HYDROTEST BUT PRIOR TO RETURNING TANK IN SERVICE

AFTER TANK HYDROTEST:
42
A) ROOF DRAIN JOINTS CHECKED AND ADJUSTED. N/A N/A
B) COFLEXIP HOSE CHECKED FOR LEAK.
C) PIVOT MASTER CHECKED FOR LEAK/ADJUST JOINTS.
43 TANK CLEANED INTERNALLY AND TANK ACCEPTABILITY VERIFIED AFTER
HYDROTEST. N/A N/A
44 SHELL MANWAYS INSTALLED WITH NEW GASKET AFTER HYDROTEST. N/A N/A
PAGE 4 OF 4
C) AFTER HYDROTEST BUT PRIOR TO RETURNING TANK IN SERVICE (cont'd.)
AFTER TANK HYDROTEST:
42
A) ROOF DRAIN JOINTS CHECKED AND ADJUSTED. N/A N/A
B) COFLEXIP HOSE CHECKED FOR LEAK.
C) PIVOT MASTER CHECKED FOR LEAK/ADJUST JOINTS.
43 TANK CLEANED INTERNALLY AND TANK ACCEPTABILITY VERIFIED AFTER
HYDROTEST. N/A N/A
44 SHELL MANWAYS INSTALLED WITH NEW GASKET AFTER HYDROTEST. N/A N/A
45 RELEASE SHEET RECEIVED FROM RED. N/A N/A
46 TANK BUND AREA CLEANED AND EQUIPMENT REMOVED. N/A N/A
47 BUNDS REPAIRED/RESTORED N/A N/A
48 RUNDOWN LINE BLINDS PULLED-AT TANK SHELL. N/A N/A
49 SUCTION LINE BLINDS PULLED-AT TANK SHELL. N/A N/A
50 WATER DRAW/DRAIN BLINDS PULLED-AT TANK SHELL.
51 PIPE SUPPORTS OUTSIDE TANK REPAIRED.
52 SEWER SYSTEM CHECKED AND CLEANED.
53 PLANT ENG. DRAWING CHECKED AGAINST TANK "AS BUILT" AND APPROVED SATISFACTORY.
TANK "AS BUILT" INFORMATION OBTAINED FOR UPDATING PLANT ENG. DRAWING RECORDS.
SIGNED PLANT ENGINEERING :......................................................................

.DATE..............................
CHECK LIST REVIEWED AND TANK RELEASED FOR SERVICE.
54
SECTION SUPERINTENDENT:...........................................................................
DATE................................
Form No. BP4114 (6/00)

IP#12 Appendix R
ANNUAL TANK MAINTENANCE (ATOP) TANK NO. ROOF TYPE LOCATION
CHECKLIST
MAINTENANCE AND INSPECTION Work Done Comp. Satisfactorily REMARKS
CHECKLIST ITEMS Yes N/A SD&MM OWNER
A. ALL TANKS
1. Clean, expose sketch plate (notify RED if
corroded) & check shell buckling
2. Clean bottom outlet & water draw off boxes.
Check flat sewer cover is in place.
3. Clean oil spills & check mixer leaks.
4. Clean sample box & clear drain lines.
5. Free up all sample valves & lubricate.
6. Check cone roof condition from gauging platform
B. FLOATING ROOF TANKS
7. Clean scale from roof & seal. Check roof paint
condition. Water wash painted roofs.
8. Water flush roof drain & ensure its clear Free up
check valve flapper and clean roof drain box.
9. Lubricate pontoon manway covers and gas test Gas Test Result
each pontoon. Open & check for leakage.
10. Check & free up roof legs & vacuum beakers.
Ensure legs & vac. breakers are put back on low
position.
11. Check rim vent flappers and free up.
12. Water flush foam system, check valves,
connectors and carry out foam test.
13. Lubricate rolling ladder wheels, axles and pivot
points.
14. Free up & lubricate ladder self levelling treads.
15. Ensure rolling ladder wheels run freely. Visually
check for wheel wear and any obstruction of
track-wheel interface.
16. Visually check for distortion or misalignment of
rolling ladder track, supports and the condition of
its attachments to roof.
17. Check center deck bulging.
C. FLOATING ROOF SEALS
18. Bailey hangers: check springs & lubricate
19. Pantagraph hangers: pull back 6 shoes and check
for corrosion.
20. Foam seal: check seal canvas and prove weather
shield free.
21. Scissor seal: pull back secondary seal and visually
check primary seal.
22. Check seal fabric, patch tears, and refit where loose.
23. Check bonding shims on seal and ladder.
COMMENTS Date Work Completed
SIGNED DATE
FOR SHUTDOWN & MAJOR MAINTENANCE

DISTRIBUTION NOTE SIGNED DATE
Original : Mgr.Owner Items requiring other depts. Involvement
Copy : Mgr. SD&MM i.e. RED/PED etc. should be reported to the
Supt. Concerned for action and be noted
Copy : Mgr. R.E.D. under COMMENTS section above. FOR OWNER DEPARTMENT
IP#12 Appendix S
4. Maximise Target Tank T&I Frequency
18
17.1 17.2
16.9
17 16.6
16.2
16 15.6
15
Ave. Freq. (yrs)
15 14.6
14 14.1
14 13.8
13 12.6
12
10.9
11
10.4
10
1994 1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
Year
IP#12 Appendix T
5. Minimise Tank Failure in Service 1995 - 2007
14000000 12
13000000
12000000 10
10
11000000
Total "Bbl-Mths" Unavailable per Year
10000000
8
Total Failures per Year

9000000 7
7 7
7 7
8000000
7000000 6
6000000 5
4
5000000 4 4
4
4000000
3 3
3000000
2
2000000
1
1000000
0 0
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
Year
5. Minimise Tank Failure in Service

Analysis of Failures (1995 - 2007) Floor (31 Failures)
Pontoon (12 Failures)
Centre Deck (5 Failures)
Seal (4 Failures)
Mixer (3 Failures)
Shell < MAT (3 Failures)
Nozzle Leak (2 Failures)
Cone Roof (2 Failures)
Over Fill (2 Failures)
1.4% 1.4% 1.4% Gas Entrap. (1 Failure)
2.9% 1.4% 1.4%
Shell Holed (1 Failure)
2.9%
Shell Distortion (1 Failure)
2.9%
Roof Drain (1 Failure)
4.3% Float Roof Ladder (1 Failure)
4.3% 44.9%
5.8%
7.2%
17.4%
IP#12 Appendix U
Discussion on Hydrotest Heights versus Operating Height
Subject: Re: Tank 933

Author: DAVID J HURLOCK at BHNSTANK
Date: 10/8/00 12:57 PM
Peter,
I am confused. Our release sheet dated 26.3.94 shows a hydrotest height of 44' from which we calculate
our maximum operating height of 13.036m which allows a 45 minute filling margin for the largest
capacity Gaso pump.
Is any change, or out of service inspection therefore required?

Please advise. Thanks.
Regards
Dave
______________________________________________________________________________
Dave,
The hydrotest height is just that - it is the level of water in the tank at test. What you want is maximum
OPERATING height.
The release sheet shows the Max. SAFE Filling Height which is ~48'. This is the level of product we have
used to calculate required shell thickness. Unless the tank has an RFH this will be the kerb angle height. I
think this is the best figure to calculate from. From that you subtract (for a floater) whatever you deem
necessary to keep your seals in the tank AS WELL AS your 45 minutes. In the case of a cone roof you just
use the 45 min figure.
RED do not specify how close your seal top can come to the kerb angle - that is your decision. All I care
about is that the liquid level never exceeds the Max. SAFE Fill Height. If this is at the kerb it's a fairly
safe bet, but on a tank with RFH or cone roof the level can go higher - possibly with catastrophic results.
I believe that some owners use the hydrotest to work out their normal Max. OPERATING height in real
time but under controlled filling conditions with water instead of product. In other words when the seal is
say 6" from the kerb angle the level is noted and then 45 minutes subtracted. I am not sure this is 100%
correct and I doubt it was the original intent. As I understand it the roof floats differently in product. You
will need someone smarter than me to work it out, but at the same liquid level, then the seal top would be
lower for a tank where the SG is below 1.03, as the roof floats lower in the product.
The other problem with this approach (calculating form hydrotest height) is that not all tanks can be
hydrotested to a height where the seals are 6" from the kerb angle. In tanks containing low SG products it
is quite possible that a full height Hydrotest or even one to within say 4 feet of full, could wreck the tank.
The bottom line is that the Hydrotest height bears no DEFINITE relation to how high you can fill with
product and I feel it is best left alone. We only mention it on the release sheet for your info.
Peter
IP#12 Appendix V
6. Minimise Operating Tanks with Restricted Filling Heights
2000000
1800000
1600000
Total "Bbl-Mths" Lost per Year
1400000
1200000
1000000
800000
600000
400000
200000
0
1995 1996 1997 1998 1999 2000 2001 2002 2003 2004 2005 2006 2007
Year
IP#12 Appendix W
7th May 2002
Tank 922 vacuum Test Procedure and Roof & Bottom

Pneumatic Pressure Test Procedure
Tank 922 is designed for additive service storage which requires a nitrogen blanket. Tank is designed to hold
a maximum build up pressure set at 2 psig ( 55.4 inches W.G ). The breathing facilities on the tank roof are as
follows:
1- off 10"/4" pilot operated relief valve RV5036 set to open at 1.8 psig ( 49.86 inches W.G ).
1- off 6" vacuum relief valve RV5034 set to open at 1.5 inches W.G.
1- off 10" Emergency relief valve RV5035 set to open at 1.9 psig (52.63 inches W.G).
Preliminiaries to tank tests:
1- Ensure permanent connections between tank and pipe lines are disconnected.
2- Climatic changes can cause sharp fluctuations in pressure during tests e.g. change in barometric
pressure. change in ambient temperature. high wind speed.
3- The pnematictest shall not be carried out during high wind speed which will cause flauctuating
differential pressure on a sealed roof.
4- Vigilance should be maintained to relive pressure or vacuum in the event of climatic fluctuations whilst
the tank is undergoing tests.
5- Personnel are forbiden on the roof or within 20 feet of the tank periphery of the tank bottom until such
times as stated in the procedure. All required witness/supervision for the tank and pressure gauges shall
be controlled for a remote safe area.
Tank hydrostatic test
I- With the 20" roof manway opened fill the tank with water to 30 feet in height.
II- Hold the tank under static hydrotest for 48 hours and check for leaks.
III- Close the roof manway and install water manometer on the tank roof. The manometers shall be located
at ground level at a distance of not less than 20 feet from the edge of the tank and in vicinity of the valve
which will control the air supply to the tank. Also provide 0-5 psi gauge for reading comparison.
Personnel are forbidden on the roof or within 20 feet of the periphery of the tank bottom until such
times as stated in the procedure.
Procedure test with RV 5035 emergency Relief Valve
1- Blind off 4" nozzle under RV 5036.
Action: SDMM
2- Close half the width of the wharf access road adjacent to tank 922.
Action: OS&E/SDMM
3- Install a manometer and connect to point "A" on the tank. Locate the manometer at the ground level at a
distance of not less than 20 feet from the edge of the tank and in the vicinity of the valve which will
control the air supply to the tank. Set up the equipment
as per attached sketch.
Action: SDMM/OS&E
4- Connect the air supply to point "B". Ensure piping is free from any blockage.
Action: SDMM/OS&E
5- Install a pressure regulator "D" set at 2.0 psig on the air manifold to ensure air delivery pressure will not
exceed 2.0 psig.
Action: Plt Eng/SDMM
6- Install a globe valve "C" to control air supply to the tank.
Action: SDMM
7- 100% supervision of the tank's testing is to be maintained by OS&E (Gen. Supt/Supt Wharf), PLt.Eng.,
RED. & SDMM.
Action:OS&E/Plt.Eng/RED /SDMM
8- Slowly raise the air pressure in the tank by controlling valve "C".
Action: OS&E
9- Continue to raise the air pressure in the tank until the pressure reaches 52.63 inches W.G
( 1.9 Psig). Hold the pressure at 52.63 inches W.G for 10 minutes. Observe the RV 5035 lifting from
adjacent tank 911 or by noticing the change in manometer reading.
Action: OS&E
Procedure test with RV 5036 Relief Valve
10- Remove blind under 4" RV 5036.

Action: SDMM/OS&E
11- Install a temporary weight of eight (8) LBS on RV 5035. The weight shall be secured.
Action:Plt. Eng./SDMM/OS&E
12- Raise the pressure same as in 8 above.

Action: OS&E
13- Continue to raise the pressure until the pressure reached 49.86 inches W.G. Hold for10 minutes. before
releasing the pressure in the tank.
Action: OS&E
14- If the pressure in the tank increases above the 55.4 inches W.G (2 Psig), immediately open valve "E"
and close valve "C".
Action: OS&E
Procedure for Vacuum Strength Test with RV 5034
1- Install a vacuum gauge on 4" gauge hatch on top of tank platform. See sketch attached.
Action: SDMM
2- 100% OS&E supervision by tank drain valve "H" and RED inspector and OS&E on tank platform.
Action: OS&E/RED
3- Slowly open tank drain valve and closely monitor the vacuum gauge. Ensure the vacuum on the tank
does not exceed 1.5 inches W.G. RED inspector to check the opening of the RV 5034. Hold vacuum at
1.5 inches W.G for 10 minutes.
Action: OS&E/RED
4- If the vacuum in the tank increases above 1.5 inches W.G, break the vacuum by immediately opening
valve "G" and closing tank drain valve "H".
Action: OS&E
5- When the above test is satisfactory open the 20" roof manway and gradually open valve "H" to drain
the tank by until its empty.
Action: OS&E/SDMM
_______________ ________________ _________________ __________________

Supt Wharf Plt. Engineering SD & MM RED
tank922a
IP#21 Appendix X
IN-SITU INSPECTION OF PRESSURE / VACUUM VENT VALVES
Pressure / Vacuum vent valves are by their nature usually relatively large valves, but of a fairly simple design.
Typically this involves a weighted pallet which is either guided (pressure side) or hinged (vacuum side).
Basically, there is no adjustment provided and the valves will either work as designed or they will not.
Pressure / Vacuum vent valves are given an inspection frequency of no more than 60 months, whereas tanks
are generally over 180 months. Intermediate inspections are thus required and this can be done by removing
the valves to the shops in the normal way. However, removing the valves requires a crane and various crafts
and can take several days per valve. Proof testing of these types of valves on a rig is notoriously inaccurate
and, under Bapco's operating conditions, rarely necessary provided certain basic inspection / maintenance is
regularly carried out.
The purpose of this procedure is to provide guidance for inspectors when checking the functionality of
Pressure / Vacuum vent valves in –situ on Bapco tankage. If there is any doubt about a valves ability to
function as designed, then it must be removed to shops for a complete overhaul. In addition, during a tank
T&I the valves must be removed for a full shops overhaul & test.
x The valves operate under low pressure gas blanketing, steam blanketing or normal hydrocarbon tank
atmospheres.
x The valves are located on cone roofs and all normal access and permitting requirements must be
strictly adhered too.
x Under gas blanketing or hydrocarbon atmosphere conditions breathing apparatus will be required.
x Steam or gas blanketing will need to be depressured prior to any inspection and the tank should be
stationary or emptying to minimize exhaust gasses.
x A metal trades or other suitable craftsman will need to be in attendance to open and reassemble the
valve.
x Check and note the valve number and position.
x Open the pressure side by unbolting the protective cover.
x Lift the pallet in its guides to make sure it is free to move.
x Examine the pallet for any signs of deposit accumulation or damage, especially to gasket faces.
x Clean pallet or replace in kind if damaged. *1

x Check the wire mesh screen to make sure it is not corroded or fouled.
x Clean or replace mesh as required.
x Reassemble the pressure side.
x Open the vacuum side.
x Ensure the pallet is free to move on its hinge.
x Examine the pallet for any signs of deposit accumulation or damage, especially to gasket faces.
x Clean pallet or replace in kind if damaged. *1
x Check the wire mesh screen to make sure it is not corroded or fouled.
x Clean or replace mesh as required.
x Reassemble the pressure side.
x Update the records and schedule the next inspection.
*1 - NB: Replacement must be exactly in kind to the original manufacturers specification and weight or the
valve must be removed and tested.
Original Signed by
Yousif G. Abdulla
__________________________________________
MANAGER – RELIABILITY ENGINERING
Issued: 16th August, 2003

IP#21 Appendix Y
IP#21 Appendix Z
Draft Procedurefor theDeclassification of Tanks

Previously in Leaded Gasoline Service
Purpose
The purpose of this document is to provide a detailed procedure on what must be accomplished to declassify
tanks which have previously been in leaded gasoline service or slop service which may have contained leaded
gasoline.
Declassification of a tank which has previously been in leaded gasoline service will eliminate the need for
wearing impervious suits and airline respirators specifically for the protection against organic lead; also health
surveillance and biological monitoring will no longer be necessary.
Scope
The contents of this document shall be limited to those tanks that have been in leaded gasoline service or have
been slop tanks which may have contained leaded gasoline at any time within their service life.
This document does not cover the following:

1. tanks with rivetted shell plate where no effective method of decontamination other than flame
washing exists.
2. issues pertaining to inorganic lead such as paints or coatings nor does it cover issues arising from
the demolition of tanks which have been in leaded gasoline service or not.
3. the decontamination or weathering requirements of plate from non declassified tanks which have
been in contact with leaded gasoline.
NOTE: All other OS&E procedures regarding tank entry, cleaning and repair shall be complied with.
Responsibilities
Snr Occupational Hygienist
The Snr Occupational Hygienist (or his designate) shall have the sole authority for declassifying tanks which
have previously been in leaded gasoline service or slop service which may have contained of leaded gasoline.
He shall witness and collect the necessary samples for the analysis of fume. He shall also act as the chairman
of the meetings responsible for declassification.
Supt Sitra Tanks / Supt Refinery Tanks
The Supt Sitra Tanks / Supt Refinery Tanks shall be responsible for providing a complete and detailed history
of the service of the tank identified for declassification.
Supt Offsites & Utilities Reliability
The Supt Offsites & Utilities Reliability shall be responsible for providing a complete and detailed history of
the maintenance of the tank identified for declassification.
Supt Shutdown Major Projects Section
The Supt Shutdown Major Projects Section shall be responsible for arranging for the necessary bottom plate
to be cut according to the requirements of the sampling and analysis of fume procedure and shall conduct the
necessary work indicted below.
Procedure
1. Prior to taking the tank out of service, the interested party shall notify the Snr Occupational Hygienist of
their desire to declassify a tank which has been previously in leaded gasoline service or slop service which
may have contained of leaded gasoline. The Snr Occupational Hygienist shall request a Pre-Shutdown
Declassification Meeting with all revelant partices in order to obtain the necessary information regarding tank
service and mainteneance history and clarify the work to be done in order to achieve declassification.
2. The tank shall be cleaned in accordance with established procedures for the cleaning of leaded tanks.
3. Two plates shall now be removed form the floor by cold cutting measuring approximately 24" x 48" and
tested/analysed according to the following Sampling Methodology and shall be witnessed by the Snr
Occupational Hygienist (or his designate) who shall take the samples to the Refinery Laboratory for analysis.
NOTE: If multiple floors exist it should be agreed in the pre-declassification meeting which floors should be
sampled based on service and maintenance history.
4. Depending on the service of the tank as established above, one of the following procedures shall be
applied:
4.1 If the tank has contained a petroleum product other than leaded fuel for the last 2 years then the
bottom course and floor should be grit blasted (or equivalent) to a standard of SA2.
4.2 If the tank has been in leaded service within the last 2 years the entire tank including underside of
roof should be grit blasted (or equivalent) to a standard of SA2.
5. The tank floor and tank pad shall be removed and disposed of in accordance with normal leaded practice.
If multiple floors exist then all the floors shall be removed.
6. If bottom coatings and wall coatings exist these shall be inspected by the Coating Specialist with the Snr
Occupational Hygienist (or his designate) deciding what action shall be taken and whether this procedure can
apply on a case by case basis.
7. A lead-in-air test shall be conducted.
8. Once the Snr Occupational Hygienist (or his designate) has obtained all the necessary service and
maintenance information and the laboratory results, he shall call a meeting of all parties to discuss the results.
At that meeting the Snr Occupational Hygienist may declassify the tank in question or request further
information or testing to confirm the condition of the tank or indicate that the tank cannot be declassified.
9. If the Snr Occupational Hygienist is satisfied that all the clauses have been met and that the test results are
satisfactory then an MOC shall be conducted indicating what paper work needs to be amended and that the
markings on the tank shall be removed. The MOC shall consist of the tank owner (normally OS&E);
SD&MM; RED and OHU.
NOTE: Any warning signs regarding the burial pits should remain in place.
10. Upon satisfactory completion of the preceding, the Snr Occupational Hygienist (or his designate) shall
issue a certificate indicating that the tank has been declassified accordingly.
NOTE: If it is desirable for maintenance purposes to relax the requirements for tank entry and repair but it is
not desirable to remove the floor at that time, a Partial Declassification can be achieved by following the
same procedures as stated above. However, if the floor is breached, the tank returns to "leaded" status until
the floor is repaired and a lead-in-air test is conducted. In the case of Partial Declassification the Snr
Occupational Hygienist (or his designate) shall still be the administrator of the procedure; warning signs shall
NOT be removed and the change should be reflected in the RED records. This status can be retained for
future shutdown and start up situations under the same conditions indicated above.
Sampling Methodology
If at all possible following the removal of all scale, two sections of bottom plate should be obtained; however,
tank bottom shell plate may also be used provided that all traces of paint are removed. The two sections of
plate should measure 24" x 48" and be taken from areas which have obviously suffered from corrosion and
been in contact with the sludge. The areas of the tank wall or floor selected for the hot work must be part of
the original tank or as agreed in a Pre-Shutdown Declassification Meeting. The plates are laid on channel bars
or I-beams at a safe height off the tank floor and cut into strips, using an oxy-acetylene torch, for a period of
30 minutes. Care will need to be taken to ensure that the samples of fume which are taken are representative
of that which is present in the plume of emitted fume. Both fume samples will be taken to the Refinery
Laboratory for analysis as soon as possible. The concentration of total lead (i.e. organic lead plus inorganic
lead) in the plume of fume generated by the worst-case hot work shall not exceed 0.05 mg/m3 over the sample
period.
References
1. IP GUIDANCE ON THE DECLASSIFICATION OF TANKS PREVIOUSLY IN LEADED SERVICE -

1998.
2. Correspondence with the IP authors dated 2.1.03 & 23.12.02
_______________________________
Jeffrey K. Niemann
Snr Occupational Hygienist
Appendix AA
On Stream Work Restrictions
Memorandum 20th December, 2004

To: Manager Reliability Engineering
Ultra High Pressure (UHP) Water Blasting

Of In-Service Tank Roofs
Reference the file memorandum dated 27th July, 2004 regarding the subject matter. We in OS&E have
debated the issue of UHP Water Blasting of tank roofs while the tank is still in service and came to the
conclusion that such operation is still considered of high risk for the time being.
The following are OS&E’s comments on the Core Team’s UHP Water Blasting proposal:
, OS&E agree that a suitable surface preparation is the foundation of any coating system. This is
evident at the Wharf where the UHP Water Blasting has produced excellent results when used for
surface preparation for painting the hose rig structures, under the decking beams and pipe lines.
,, We believe that UHP Water Blasting will also produce an excellent surface preparation when used
for painting product tanks.
,,, As stipulated in the File Memo one of the precautions that needs to be addressed is the generation of
“Static Electricity”. Proper earthing of the blasting nozzle and bonding of equipment is mandatory
to avoid static arcing during the UHP Water Blasting. Bad earthing could generate static arcing,
which may lead to igniting hydrocarbon vapor if conditions are favorable, leading to a catastrophic
incident.
,9 Another concern OS&E anticipate occurring during the UHP Water Blasting is potential damage to
the tank’s roof. Such risk may likely occur to a cone roof tank where the roof plates normally
corrode internally rather externally. Should the tank roof be breached it may become necessary to
take the tank out of service for repairs.
9 Should a floating roof tank be breached during the UHP Water Blasting it will create a hazardous
condition of having hydrocarbon product on the roof and may lead to a partial or even fully sunken
roof, if not handled swiftly.
9, Another major concern that OS&E foresee, is having so many people and equipment on top of an
in-service tank. This will require proper supervision at all times to ensure that all permit to work
special instructions are enforced and people are monitored against taking short cuts or deviating
from the stipulated instructions.
9,, With the current direction adopted by the Tank Repair Core Team to paint the tanks using UHP
Water Blasting while they are out of service and under T&I, such action is believed to eliminate the
need to carry out any further painting on the tanks till the tanks next T&I.
9,,, With the introduction of the Aluminum Roofs on the cone roof tanks, the future requirement to
paint such tanks’ roofs will be eliminated.
,; Should it become necessary to paint a tank roof using the UHP water Blasting while the tank is still
in service, OS&E would prefer to take the tank out of service and gas free it prior to handing it over
to the contractor for painting. This will eliminate the risk of fire/explosion as a result of having
hydrocarbon in the tank.
; OS&E will have no objection to using UHP Water Blasting to prepare the tank’s shell for painting
while the tank is in service. The current precautions/conditions will be enforced for painting or
carrying out work on an in-service tank from beneath the wind girder or ????? angle.
In summary, the following are OS&E views on UHP Water Blasting on an In-service Tanks:
D OS&E, for safety reasons, has reservations for allowing UHP Water Blasting on tank roofs
(floating and cone), which are in-service.
E OS&E has no objection to using UHP Water Blasting as surface preparation on tank shells
subject to RED’s approval.
F Should it become necessary to paint an in-service tank’s roof, the tank will be taken out of
service and gas freed prior to allowing people and equipment on top of the tank’s roof.
G OS&E concur that UHP Water Blasting is currently the best method for surface preparation
prior to painting.
H OS&E still believe more information is required on the risks associated with UHP Water
Blasting with regard to static electricity generated prior to implementing such method on an in-
service tank.
Original Signed By:

Khalid E. Sabbagh
_________________________
Manager Oil Storage & Export
CC
Mgrs FH&S, SD&MM
Tank Repair Core Team Members
------------------------------------------------------------------------------------------------------------
Memorandum 20th December, 2004
To: Chairman - Tank Repair Core Team
Installation Of Tank’s Floating Roof Seal

While Tanks in-Service
Reference is made to the Tank Repair Core Team Minutes of Meeting No 17/04 item 7.9. regarding the
subject matter.
OS&E have closely reviewed the method adopted/proposed by the manufacturer in replacing floating
roof seals on in-service tank’s. Although it is possible to carry out such task, the risks involved, in the
opinion of OS&E, outweigh the benefits. The following are OS&E reservations for carrying out such task
while the tank is in service:
x It is believed that the practice of replacing an in-service tank’s floating roof seal is performed
elsewhere where there is a considerable commercial/operational penalty if the tank is taken out of
service. Such circumstances will rarely occur in Bapco. With our current tanks
situation/availability it is far safer to take the tank out of service and gas free it to allow replacing
the seal in a safe environment.
x The application of foam on top of the product to seal the liquid, where the primary seal has been
removed, poses an increased risk to health by personnel being exposed to vapors emitted from the
exposed product.
x The application of the foam on top of the exposed product may reduce the evaporation rate but the
fire and explosion risks will remain high with people working directly on exposed product. The
foam will have to be constantly checked to maintain a reasonable barrier between the product and
the people.
x The foam application on top of the product may cause product quality degradation.
x The mere fact of having people working on top of an in-service tank, with partially exposed
primary seal, is considered a high risk. This will require very close supervision to ensure that all
precautions and instructions are followed.
x The opportunity was taken to discuss the subject matter with some independent consultants who
contribute to an API Tankage Fire working committee and recently conducted a Fire And
Explosion Risk Management workshop in Bapco. They concurred with our concerns with regards
to having people carrying out activities on top of a floating roof with a partially exposed primary
seal.
In summary, OS&E’s present position on replacing floating roof tank seals with the tank still in service is
that this work should only be undertaken in exceptional circumstances. This type of work should normally
only be conducted on planned basis and only after the risks have been fully evaluated and adequate
control measures implemented. Routine change out of seal with a tank still in service is not considered
safe practice for the reasons previously outlined and is therefore not supported.
Original Signed By:

Khalid E. Sabbagh
_________________________
Manager Oil Storage & Export
CC.
Mgrs F,H&S, SD&MM
TK Rpr. Core Team Members
Appendix AB
Appendix AC
TANK MFH CALCULATION SHEET
TANK NO. DIAMETER: HEIGHT:
L= ta (H-x) + x
tm
Where:
L is limited filling height in feet.
ta is adjusted minimum gauged course thickness in inches.
tm is minimum allowable thickness for contained stock in inches.
H is tank height in feet.
x is sum of courses heights below course in question + 1 foot.
COURSE ta ta (H-x)+x
x tm ta (H-x) Remarks
No. Height tm tm
1
2
3
4
5
6
7
8
9
______________________
INSPECTOR
PJV/ng:MFH
7th February, 2007
APPENDIX AD
9th June 2008
File Memorandum
Tank Hydrotest Heights

File: C 241
RED has two primary objectives in hydrotesting a tank namely to (i) prove the structural integrity at a stress
level in excess of that seen under the normal operating conditions and (ii) confirm there are no leaks.
Hydrotest Policy
The relevant codes (API 650 & 653) permit 11% or 14.5% (respectively) higher stresses under hydrotest
conditions than they do for operating conditions and it is RED’s policy to subject a tank under hydrotest to the
highest stresses possible within this constraint. The codes however assume that the tank will be maintained for
a specific gravity (SG) of 1.0 (fresh water) whereas Bapco’s policy is to maintain the tank for the highest
possible SG of the contained product. On this basis some leeway exists in the amount of overstress that needs
to be applied during hydrotest to meet the structural integrity intent of the hydrotest.
Maximum Test Level Allowed
Attaining the 11% to 14.5% overstress during hydrotest is usually quite feasible to do as the operating level of
the tank is well below the kerb angle and the product SG (with the exception of Asphalt) is lower than the
1.03 assumed for seawater. In this context any tank with an SG of 0.93 or below will see at least 111% of the
normal maximum operating stress if just hydrotested at the maximum operating height.
RED establishes the effective thickness of each shell course and uses this figure to calculate the maximum
liquid head that each course could withstand per the code in use. In most circumstances this figure is in excess
of the height of the tank above that particular course and thus it is not actually possible to subject the tank to
as much “excess” stress as would be allowed.
Generally speaking, RED requires the tank to be hydrotested to the highest permissible level consistent with
its structural limitations. For a cone roof tank this would be no more than 1” ABOVE the kerb angle. This
level is chosen so that the leak tightness of the roof to kerb angle joint can be checked, but there is no
possibility of an uplift situation developing. For dome roof tanks and open (i.e. roofless) this should be no
more than 1” BELOW the kerb angle to prevent an overflow. An overflow during hydrotest is not an integrity
concern for the tank, but it is a situation that should be avoided as it would be impossible to conduct a leak
tightness test under such conditions.
Also it must be born in mind that some of Bapco’s tanks have seen uneven settlement and thus the actual kerb
height above a datum point will not be the same around the entire tank. In this case the lowest established
kerb angle height would govern for an open, floating roof or dome roof tank, but the highest kerb angle height
will govern for a cone roof tank.
Floating roof tanks present a slightly different problem from cone, dome or open tanks with respect to the
maximum hydrotest level and this is expanded upon below.
Tank shells often corrode in service and typically the shells of floating roof tanks (which generally contain
light products) are far more prone to this than cone roof tanks (typically containing heavy products). In
addition the middle courses (usually 3-5) often see more corrosion that the courses above or below them. This
can result in an intermediate course being thinned to the point where it would be overstressed if a full height
hydrotest were to be attempted. For this reason RED calculates the maximum head of liquid that each course
can be subjected too and this occasionally becomes the limiting factor in establishing the maximum hydrotest
height.
Unfortunately, with a low SG product the above calculation could theoretically result in a maximum test level
that is actually below the maximum operating level. This theoretically could occur on a tank that has corroded
the intermediate shell courses, but is extremely rare. Having a hydrotest height below the maximum operating
height would of course defeat the leak detection aspect of the test for the zone between the maximum
operating level and the test level. In the event of this unusual circumstance an individual decision would have
to be taken on whether to (i) reduce the maximum operating height or (ii) exceed the maximum stress level for
the test or (iii) accept that part of the shell has not been leak tested.
In the same way as open and dome roof tanks, the maximum level for a floating roof tank is also constrained
by not wishing to overflow the tank, so purely from this point of view 1” BELOW the kerb angle would still
be adequate; however another factor has to be considered. With a liquid level of 1” below the kerb angle a
large proportion of the pontoon outer rim and primary seal would be out of the tank. In the case of a
conventional low deck design, the center deck, which is generally immersed 1-2” in the liquid, would
however still be below the kerb angle by 2”-3”.
Although modern seal systems are designed to reseat and prevent roof hang up even after overflow conditions,
the above degree of seal/pontoon exposure above the kerb angle may not be deemed acceptable to the Owner.
The degree of seal/pontoon exposure that is considered acceptable is a decision that should be established by
others, as it is not a primary concern in RED’s hydrotesting objectives.
Minimum Test Level Required
Following on from the test philosophy of API 650/653 the minimum hydrotest height that would satisfy RED
with respect to proof stressing aspect of the test would therefore be 111% – 114.5% of the actual maximum
operating stress the tank will see. This would be lower than the pure code requirement because the actual
SG of the product is taken into account. This determination can be approached from two perspectives, one of
which is less conservative than the other.
For the less conservative approach we assume that the liquid will never be allowed to pass the maximum
operating level and then insert this figure in the equation below. To obtain the minimum test level required for
this case the maximum operating height is multiplied by 1.1 (or 1.145 for API 653 ), multiplied by the
approved SG and then divided by 1.03 (seawater SG). This is not the favoured approach, as it will invariably
lead to a hydrotest figure below operating, which is not logical. The only time this should be considered is if
other extraneous factors make the conservative approach impractical.
The conservative approach is to assume that the tank could be overfilled accidentally during operation and in
this case we take the maximum height of liquid as the kerb angle height and insert it in the equation above.
This can also occasionally lead to a figure below the maximum operating height and when this occurs the
Minimum Test Level Required defaults to the maximum operating height.
Tank Top Extensions
Following on from the above discussion of minimum and maximum levels there may be rare occasions where
tank top extensions are required. In critical cases where high SG products are to be stored in a corroded
floating roof tank it may be necessary to prove the tank at a hydrostatic head that is actually above the Kerb
angle. In this case a temporary liquid tight top course extension may be called for. More common may be the
case where the required minimum height will result in unacceptable seal protrusion during the test. In this
case a temporary seal restraint extension (that does not have to be liquid tight or even continuous) may be
required.
Actual Hydrotest Height
In effect then, RED can specify a minimum and maximum range wherein our hydrotest requirements can be
met.
For cone roof tanks the minimum and maximum will generally be the same at 1” above the kerb angle.
Similarly for Dome roof tanks and open tanks the maximum and minimum will generally be the same at 1”
below the kerb angle.
For floating roof tanks the minimum of the range will generally be at or above the maximum operating height
and the maximum will be 1” below the lowest established kerb angle height. The actual figure will be
governed by the amount that the Owner department will permit the roof rim and seals to protrude by.
Conclusion
RED shall specify in writing to the owner department the Minimum Test Level Required and the Maximum
Test Level Allowed for all tank hydrotests. Provided the attained test level is within these constraints, RED
requirements will be satisfied. In the case of floating roof tanks, it is up to the Owner department to decide on
where in the range this level should be, based on their constraints for the amount of floating roof seal
protrusion.
The Actual Test Level attained must in turn be advised to RED by the Owner for our records and the release
sheet.
Original signed by: P. J. Valvona

P J Valvona
PJV/pjv/Tank Hydrotest Heights.doc

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IP#12 Appendix A

INSPECTION PROCEDURE NO. 12

AIR PRESSURE TESTING

INSPECTION PROCEDURE NO. 12

STANDARD PREPARATION OF TANKS FOR INSPECTION

Diameter of Tank Number of Strips

Gritblast the wind girder to SA2

INSPECTION PROCEDURE NO. 12

CALCULATION OF MINIMUM ALLOWABLE THICKNESS AND

4. No MAT will be less than 0.10 inches.

5. Composite welded / riveted construction will be handled on a course by course basis as

6. A table of the relevant formulae for MAT calculations is given below.

Service MAT Hydrotest MAT

For tanks per para. 1.1 requiring 2.6xDx(H-1)xG 2.6xDx(H-1)x1.03

For tanks per para. 1.1 not requiring 2.6xDx(H-1)xG 2.6x(H-1)x1.03

For tanks per para. 1.2 --Refer Construction Code--

Where D = Nominal diameter of tank in feet.

Limited Filling Heights

Where RFH = Restricted filling height in feet.

INSPECTION PROCEDURE NO. 12

CALCULATION OF MINIMUM ALLOWABLE THICKNESS

MAT of API 12 A Tanks

The following maximum allowable working stresses shall be used:

The following notation is used in the calculation:

t = plate thickness in inches for the course in question.

4. ft (fifth outer row of rivets) = LP

5. ft (fourth outer row of rivets) = LP-sn5

6. ft (third outer row of rivets) = LP-s(n5+n4+n3)

7. ft (second outer row of rivets) = LP-s(n5+n4+n3)

MAT's FOR API RIVETED TANKS FOR WATER

TANK DIAMETER 144 FEET.

HEIGHT 46' - 2 1/4" HEIGHT 40' - 6 1/2"

TANK DIAMETER 120 FEET.

HEIGHT 46' - 4 11/16" HEIGHT 40' - 8 11/16"

HEIGHT 46' - 6 7/8" HEIGHT 40' - 10 3/16"

TANK DIAMETER 60 FEET.

HEIGHT 46' - 7 3/8" HEIGHT 40' - 10 5/16"

HEIGHT 46' - 9 7/8" HEIGHT 41' - 0 9/16"

TANK DIAMETER 36 FEET.

HEIGHT 46' - 11 9/16" HEIGHT 41' - 1 1/2"

120 FT DIA STANDARD TANK 40'- 8 11/16" HIGH

7th Course Joint L1

h = 5'-9 3/4" + 1 3/4" - 12" = 4'-11 1/2" = 4.958'

p = 2.0515" D=3/4" d=11/16" t=1/4"

L = 4.958 x 60 x 12 = 4.958 x 311.7 = 1545 lb/in

s = 1545 x 2.0515 = 3170 lbs

fs = 3170 = 3170 x 4 x 16 x 16 = 8530 psi

ft = 3170 = 3170 = 9747 psi

MAT = 0.25 X 9747 = 0.1059" say 0.106"

6th Course Joint L2

h = 4' - 11 1/2" + 5' - 9 3/4" = 10'-9 1/4" = 10.772'

p = 2.375" D= 3/4" d= 11/16" t= 1/4"

L = 10.772 x 311.7 = 3358 lb/in

s = 3358 x 2.375 = 7973 = 3986 lbs

fs = 3986 = 3986 x 4 x 16 x 16 = 10730 psi

ft = 7973 = 19630 psi

MAT = 0.25 X 19630 = 0.2133" say 0.213"

h = 10' - 9 1/4" + 5' - 9 5/8" = 16' - 6 7/8" = 16.573'

p = 3.00" D = 3/4" d = 11/16" t = 11/32"

L = 16.573 x 311.7 = 5165 lb/in

s = 5165 x 3.00 = 5165 lbs

fs = 5165 = 5165 x 4 x 16 x 16 = 13800 psi

ft = 0.344 x 19630 = 0.2993" say 0.299"

4th Course Joint L4

Structural Height to Kerb Angle - ft mm