Safety and environmental updates for HPI storage tanks | Hydrocarbon Processing | May 2015

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Safety and environmental updates for HPI

storage tanks
05.01.2015 |

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Storage tanks are common in any hydrocarbon processing industry (HPI) facility or receiving/shipping
terminal. Crude oil, refined products and petrochemicals are safely stored in aboveground tanks to facilitate
daily operations of HPI facilities. These tanks hold flammable materials for processing and product
distribution. The oversight and maintenance of storage tanks remains a high priority for HPI companies.

LEAK DETECTION IN STORAGE TANKS

Storage tanks are a key part of any HPI distribution operation, according to Li-Chuan Liu of the Logistical
Engineering University, China. Notably, tank-bottom plates are very vulnerable to corrosion, which
compromises the integrity of the tank wall and bottom. Result: Leaks and even complete failure of the tank
are linked to corrosion attacks.

“Leaks and containment failures are high-risk events that impact plant safety and the environment,” said Liu.
“Such events result in a direct loss of revenue. Contamination of soil and water can potentially lead to punitive
action from federal and state environmental agencies.”

Fires and explosions due to the accidental release of flammable materials are the main catastrophic events
from storage tank failures. Such events are a threat to employees, the public and property.

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Safety and environmental updates for HPI storage tanks | Hydrocarbon Processing | May 2015

There are a number of techniques available in the marketplace to qualitatively identify leaks. Tank entry has
often been seen as the only real choice. Unfortunately, it is very difficult to detect leaks from a tank bottom in
the early phase.

How to effectively detect a leaking tank bottom

Leak detection methods range from simple visual inspection to automated electronic-data gathering systems.
Most continuous monitoring systems include automatic alarm capabilities. Other methods are conducted as
part of regularly scheduled maintenance programs and rely on daily visual inspections. Electronic level gauges
or transducers, along with temperature probes, can be used as part of a monitoring system.

Other leak-detection systems rely on a wide variety of parameters, from sampling and testing the soil for
hydrocarbon vapors to acoustic emissions monitoring. These technologies are performed non-invasively and
have a reliable track record. Non-invasive leak detection technologies include liquid sensing cables, soil
monitoring or acoustic-emissions testing. These systems can be programmed to continuously monitor a tank
or can be part of the regularly scheduled tank testing and maintenance programs.

No silver-bullet methods

There is no single leak-detection system that is best for all sites. Each leak-detection method has unique
characteristics. For example, vapor-detection devices work rapidly and are most effective in porous soils, while
liquid detectors are only appropriate. Identifying the best leak-detection system depends on many factors
including cost, facility configuration, groundwater depth, soil type and other variables.

Although there are many methods for detecting oil leaks from storage tanks, it may not be easy to discover the
leak. With the increasing capacity and size of storage tanks, the level changes from a very slow leak may be too
small and not measurable by automatic or manual gauging until a substantial volume of product has been
released, said Liu.

Very small level changes due to oil leaking from large storage tanks can occur at an extremely low rate, thus,
the leak may not be detected by gauging alone.

A photo ionization detector (PID) can be used to test oil vapor concentration in a tank foundation, the
sensitivity to ppm levels, which is “fine” leak detection, according to Liu. “The results of the experiments on
both models and actual tanks show that the leakage from tank bottom could be detected in time by testing and
monitoring vapor in the tank foundation.”

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© huyangshu—Shutterstock.com

API TANK STANDARDS UPDATES

The American Petroleum Institute (API), through its various committees, has developed standards and best
practices to help downstream companies safely operate their facilities and pipelines. API standards are
reviewed on a regular basis. API standards for aboveground storage tanks (ASTs) are Standards 620, 625, 650
and 653 (Table 1), and are developed using API procedures and standards development. The AST standards
are reviewed on an 18-month basis. Changes in several AST standards took effect in 2014: API 650 was issued
in September 2014 with participant in the API Monogram Program; the final release was in March 2015. For
API Standards 653, 625 and 620, the revisions were issued in November 2014.

2015 API TANKS, VALVES AND PIPING CONFERENCE & EXPO

The 2015 API Tanks, Valves and Piping Conference and Expo will be held October 12-15, 2015, at the Aria
Hotel in Las Vegas, Nevada. This event will give attendees an opportunity to learn about new and existing
industry codes and standards, and to hear about emerging trends from industry experts. The two-day
conference offers over 65 sessions in three conference tracks, addressing the needs of individuals involved in
production systems, pipelines, terminals, refining and chemical manufacturing, and storage facilities. Each day

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focuses on presentations relevant to upstream, midstream and downstream. For more information, visit
http://www.api.org/tvp. HP

TERMINALS AND STORAGE NEWS/PRODUCTS/EVENTS

CB&I to build refinery storage tanks for Kuwait Clean Fuels Project

CB&I has been awarded a contract valued at approximately $60 MM by JGSK, a JV between JGC Corp., GS
E&C and SK E&C. The project scope includes the engineering, procurement, fabrication and construction of 39
storage tanks and two spheres for the Clean Fuel Project (CFP), a major initiative of Kuwait National
Petroleum Co. (KNPC) to upgrade and expand two existing KNPC refineries.

“This award underlines the confidence our clients have in CB&I’s commitment to safety, reliability and on-time
solutions for complex projects,” said Luke Scorsone, president of CB&I’s fabrication services operating group.
“CB&I has a long history of experience for new construction and reconstruction work in Kuwait, and our
infrastructure and capabilities in the Middle East will allow us to execute the scope of work outlined for the
CFP at the highest quality.”

Wireless technology enables safer and more efficient terminal operations

Honeywell’s OneWireless Terminal Solution combines a portfolio of wireless-enabled products, services and
productivity tools tailored for terminal operators. The new system enables operators of oil and gas terminals to
increase their productivity while also complying with stringent health, safety and environment regulations, all
at significantly lower cost than wired technology.

Unique in the industry, the OneWireless Terminal Solution includes Wireless ISA100 Honeywell Enraf
SmartRadar FlexLine (Fig. 1), the highest-precision wireless radar gauge available. Requiring no external
wireless module, the FlexLine’s integrated radio sends tank level measurements securely and wirelessly to the
central control room. The FlexLine is also used as a data concentrator, collecting data from local tank
instruments and sending the data wirelessly through the same ISA100 Wireless network.

Fig. 1. Honeywell FlexLine Radar Gauge ISA100

Wireless, the latest and most technically advanced
tank gauging system, custody transfer approved.

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Safety and environmental updates for HPI storage tanks | Hydrocarbon Processing | May 2015

The OneWireless Terminal Solution includes additional applications such as Honeywell’s mobile productivity
tools (Field Advisor, Mobile Station and Experion Mobile Access), aiding with the adoption of operator driven
reliability (ODR) programs and enabling operators to complete activities more efficiently and safely. Other
applications include wireless fixed and portable gas detectors and wireless video, including Honeywell’s Digital
Video Manager to enhance plant security. For a mid-size petrochemical facility, ODR and these wireless
applications can generate more than $1 MM in annual cost savings.

Honeywell’s OneWireless Network enables all of these applications, which can be tailored to offer either
ISA100 Wireless-only coverage or ISA100 Wireless and Wi-Fi coverage.

Software addresses API standards for storage tanks

Intergraph’s TANK is a comprehensive, easy-to-use software package for the design, analysis and evaluation of
oil storage tanks. It provides quick and accurate designs for new tanks and evaluation of existing tanks.

Data collection. The menu-driven interface of TANK allows for the quick definition of input and functions
for the accurate analysis of oil storage tanks to API standards. Increased flexibility allows combination of data
for analyses or to desired reports. In addition, unit files are completely user-definable, so engineers are not
bound by program default settings.

Analysis options and codes. TANK performs calculations in accordance with the latest API Standards 650
and 653. Analysis can also take into account wind, seismic and settlement conditions, plus calculate air venting
requirements to API 2000 Section 4.3.

Output and reports. After completing an analysis, you can view the results in a tabular report or as a graphic
diagram with associated data. For convenience in verifying the results, the output reports reference code
sections used where applicable.

Material databases. TANK has many databases integral to the package, which make it easy to select
standard data for accurate analysis. A number of US and international structural steel databases are provided.
API materials are available.

EVENTS

International Liquid Terminals Association (ILTA) 35th Annual International Operating Conference
and Trade Show, Jun. 1–3, George R. Brown Convention Center, Houston, Texas, Phone: +1 (703) 875-2011,
info@ilta.org, www.ilta.org

Active Communications International (ACI) Europe’s European Bulk Liquid Storage 2015 Conference,
Sept. 9–10, Antwerp, Belgium, Phone: 44 (0) 203 141 0623, cwilliams@acieu.net, www.acius.net HP

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