Gas-Freeing and Cleaning of Oil Storage Tank: Manual

MANUAL
GAS-FREEING AND CLEANING OF OIL

STORAGE TANK
PTS 60.038
APRIL 1989
PREFACE
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Table of Contents
FOREWORD
1. SCOPE
2. HAZARDS
2.1 General
2.2 Fire and Explosion
2.2.1 Flammable Vapours
2.2.2 Sources of Ignition
2.2.2.1 Electrical Equipment
2.2.2.2 Lightning
2.2.2.3 Static Electricity
2.2.2.4 Hot Surface Ignition
2.2.2.5 Pyrophoric Deposits
2.2.2.6 Thermite Reactions
2.3 Chemical Hazards
2.3.1 General
2.3.2 Lead Anti-knock Compounds
2.3.2.1 Symptoms of Lead Alkyl Poisoning
2.3.3 Hydrogen Sulphide
2.3.3.1 Symptoms of H2S Poisoning
2.3.4 Polycylic Aromatic Hydrocarbons
2.3.5 Benzene
2.3.6 Miscellaneous Chemicals
2.3.6.1 Tank Cleaning Agents
2.3.6.2 Other Chemicals
2.3.7 Dusts
2.4 Oxygen Deficiency
2.5 Physical Hazards
2.5.1 Temperature Conditions
2.5.2 Noise
2.5.3 Work Conditions
2.6 Radiation Hazards
3. PREPARATORY WORK
3.1 Permits
3.2 Organization and Personnel
3.2.1 Supervisor
3.2.2 Workforce
3.2.2.1 Qualifications
3.2.2.2 Instruction and Training
3.2.3 Medical Aspects
3.3 Pre-Cleaning Inspection
3.3.1 General
3.3.2 Tank Contents
3.3.3 Tank Inspections in General
3.3.4 Roof Inspection
3.3.5 Inspection of Fixed Roofs
3.3.6 Inspection of Floating Roofs
3.3.7 Inspection of Internal Floating Covers
3.3.8 Site Inspection
3.3.9 Weather Conditions
3.4 Work Programme
3.5 Selection of Equipment and Precautions for its Use
3.5.1 Mechanical Equipment
3.5.2 Illumination
3.5.3 Breathing Apparatus
3.5.4 Services
3.5.4.1 Breathing Air
3.5.4.2 Water
3.5.4.3 Electrical Supply and Equipment
3.5.5 Testing Equipment
3.5.5.1 Measurement of Oxygen Level
3.5.5.2 Measurement of Flammable Vapour
3.5.5.3 Measurement of Toxic Substances

3.5.6 Miscellaneous Equipment
3.5.6.1 Wind Indicator
3.5.6.2 Washing and Changing Rooms
3.5.6.3 Protective Clothing
3.5.6.4 Windsail
3.5.6.5 Vapour/Air Eductor
3.5.6.6 Air Blower
3.5.6.7 Ejectors
3.5.6.8 Hoses
3.5.6.9 Sludge Pumps
3.5.6.10 Vacuum Equipment
3.5.6.11 Mechanical Squeegees
3.5.6.12 Scaffolding
3.5.6.13 Aluminium Equipment
3.6 Control of Sludge Disposal
3.6.1 Responsibility
3.6.2 Documentation
3.6.3 Methods of Disposal
3.6.4 Customs Approval
4. TAKING TANKS OUT OF SERVICE
4.1 Emptying and Line Clearing
4.1.1 General
4.1.2 Floating Roof Tanks
4.2 Isolation
4.2.1 General
4.2.2 Isolation from Piping Systems
4.2.3 Thermal Pressure Relief Systems
4.2.4 Drainage Systems
4.2.5 Electrical Isolation

5. GAS-FREEING
5.1 General
5.2 Site Precautions during Gas-freeing
5.3 Gas-Freeing Methods - General
5.4 Gas Freeing Fixed Roof Tanks
5.4.1 Water Displacement
5.4.2 Inert Gas Purging
5.4.3 Steaming Out
5.4.4 Natural Ventilation
5.4.5 Forced Ventilation
5.5 Gas Freeing Floating Roof Tanks
5.6 Gas Freeing Fixed Roof Tanks with Internal Floating Covers
5.7 Gas Freeing Horizontal Tanks
5.8 Special Cases
5.9 Control of Pyrophoric Deposits
5.10 Gas Testing
5.10.1 General Points
5.10.2 Flammable Gas Detection
5.10.2.1 False Readings
5.10.2.2 Testing during Gas-Freeing
5.10.3 Toxic Vapour Monitoring
5.10.3.1 General
5.10.3.2 Leaded Gasoline Tanks
5.10.4 Testing for Oxygen

6. CLEANING PROCEDURES
6.1 Initial Cleaning from Outside the Tank
6.1.1 General
6.1.2 Crude Oil and High Viscosity Oils
6.1.3 Cleaning through Open Manways
6.2 Working Inside the Tanks
6.2.1 General
6.2.2 Conditions for Entry
6.2.3 Access Ways to Tanks
6.2.4 Preparations and Checks for Entry of Personnel
6.2.5 Tank Internal Hazards
6.2.6 Emergency Procedures
6.2.7 Safety Helmets
6.2.8 Floating Roof Supports
6.3 Final Cleaning Procedures
7. PRECAUTIONS SPECIFIC TO PRODUCT GROUPS
7.1 General
7.2 Crude Oils and Condensates
7.3 Sweet Light and Middle Distillates
7.4 Sour Light and Middle Distillates
7.5 Leaded Gasoline
7.6 Aromatic Products
7.7 Residue Fuel Oils
7.8 Bitumen, Cutbacks and Bitumen Emulsions
7.9 Lubricating Oils
7.10 Wax and Waxy Oils
7.11 Ballast Water
7.12 Slops
8. HANDOVER
Appendices
Appendix 1A. Flash Points/Classification of Crude Oils and Products
Appendix 1B. Flammability Data of Air/Vapour Mixtures
Appendix 2. Health Surveillance
Appendix 3. Typical Contents of Work Programme
Appendix 4. Recommissioning Check Points
Appendix 5. References to Related Documents
Appendix 6. Examples of Good Ventilation Arrangements
Index of Subjects
Foreword
The publication 'Recommendations for the Gas-freeing and Cleaning of Oil Storage Tanks' was last
revised January 1975 and continues to serve a useful purpose in the interest of safety during the
cleaning of storage tanks. Nevertheless, accidents during tank cleaning continue to happen Industry-
wide, confirming the hazards associated with this work.
This revision is intended to bring the above publication up to date and in line with latest experience
and trends. It is based on the new IP Tank Cleaning Safety Code and also takes account of the now
widespread use of contractors for tank-cleaning operations.
The objective of this Guide is to give detailed advice on the specific hazards, and the ways of dealing
with them, in cleaning tanks of the types and containing the products described in Chapter 1.
In those countries where statutory requirements or national codes of practice concerning the
activities described in this guide apply, these most be observed and should be read and
interpreted in conjunction with the recommendations made herein.
It is not the purpose of this guide to give detailed information on cleaning techniques as such,
which may be different for similar jobs depending on the locally available resources and
practices.
It is also recommended that each Operating Unit define their own detailed procedures for the tank
cleaning activities and their safety requirements as specifically applicable to their facilities and
operations. The general guidance given in the present Guide can be used as a basis.
It is stressed that these specific, locally applicable tank-cleaning procedures and safety requirements
must be easily accessible for all those involved in this work.
Those responsible for tank cleaning should recognize that every job is different and they must be
prepared to study the circumstances and plan the work accordingly. The present document is,
therefore, intended to be a guide and cannot remove the need for experienced and adequately trained
supervision and a well-trained, disciplined and trustworthy workforce.
It is assumed that the site where the tank to be cleaned is located, can rely on appropriate staff and
expertise capable of effectively supporting the tank-cleaning activity and its safety.
When any doubt exists in this respect, Operating Units are urged to make use of expertise from
outside their organization, as appropriate.
As feedback is essential to sustain our Group-wide expertise, comments on this Guide and
information regarding practical experience and new approaches to the topics covered are invited.
1. SCOPE
1.1 This Guide covers the safety precautions to be observed during the cleaning of fixed
atmospheric pressure type bulk storage tanks of the types commonly encountered in
refineries, installations, depots, terminals and crude oil production facilities.
The Guide does not cover customer tankage and non-fixed tankage like ships, rail and road
tankers. It also excludes underground caverns and storage cells in offshore production areas.
Neither does the Guide apply to pressure storage tanks, or process vessels, where a variety
of different hazards may be present.
1.2 The Guide covers tanks which have been used for the storage of crude oils, intermediate or
refined products, process water, ballast water and slops, which may contain varying amounts
of oil. Refrigerated and pressurized liquefied gas storage is excluded from the Guide in view
of its special design and operational features. Chemicals storage is also excluded from the
Guide. However, the general procedures and precautions herein can be applied in many
cases of chemical storage; see note below.
1.3 Tanks may be cleaned for quality reasons, to remove accumulations which are interfering with
operation, to enable inspection, maintenance and modifications to be carried out or to enable
the tank to be safely demolished. Cleaning may give rise to liquid or solid waste material and
brief guidance is given on its disposal.
1.4 This Guide emphasizes the safety aspects of tank cleaning techniques. It does not attempt to
advise on the efficiency of the various methods or the choice of method for each particular
case. This will be influenced by local conditions and considerations.
1.5 The Guide is concerned with precautions needed for cleaning tanks and it does not deal with
any subsequent work with the tank, such as repairs or modifications, which may include forms
of hot work.
Brief guidance is given, however, about precautions for taking tanks back into service after
cleaning and/or other work.
1.6 In this document the recommendations for a course of action are made with varying degrees
of emphasis. As a rule:
'may" indicates a possible course of action.
'should' indicates a preferred course of action.
'shall' indicates a course of action with a recommended mandatory status within the
Operating Company.
'musts' is used as an alternative for 'shall'.
Note: Whilst strictly, the gas-freeing and cleaning of storage tanks for chemical products is outside the scope of
this Guide, many of the principles and procedures outlined, are valid for chemicals. This applies particularly
to those chemicals having flammability as the sole hazard. However, with chemicals exhibiting specific
toxicity or corrosion hazards, or for those which are oxidizing agents, supplementary advice should be
sought from Chemicals Marketing or Chemicals Manufacturing safety Focal Points in the Service
Companies.
2. HAZARDS
2.1 General
The hazards encountered during tank cleaning operation can be divided into those of fire and
explosion, those resulting from the toxic properties of stored materials, and those associated
with the physical operations in and around the tank. The following sections give guidance on
the nature of these dangers and highlight features of the work which experience shows give
rise to particular safety problems. For more details on certain hazards additional references
are available, see Appendix 5.
2.2 Fire and Explosion
The contents of petroleum storage tanks are flammable to a greater or lesser degree,
depending on the material stored. When embarking on a tank cleaning operation, it is
therefore essential to know the relevant properties of the material stored in the tank. An
important property is the flash point, which is defined as the lowest temperature at which the
liquid gives off sufficient vapour to form a flammable gas mixture near the surface of the
liquid, as measured by standard methods. Appendix 1 lists the ranges of flash points and
flammability of a number of typical petroleum fractions and products.
It is important to recognize that the relationship between the flash point and flammability is not
always straightforward and flammable mixtures sometimes exist in a tank containing a liquid
stored below its flash point.
Furthermore, it is recognized that in certain circumstances the material may be more

hazardous than its flash point would indicate, e.g.
a. it will ignite more readily if evaporating from soaked paper, cloth or insulation;
b. high flash point material may give off flammable vapour if heated by a cutting torch;
c. liquids will ignite more readily if in the form of a mist or fog.
If a flammable mixture of vapour and air exists inside the tank and a source of ignition is also
available, a fire and/or explosion may result. It is the vapours left behind after liquid removal
or those rising from the surface of a flammable liquid which ignite and bum. If a source of
ignition can be excluded or oxygen levels throughout the tank atmosphere can be kept below
8% (this includes a safety margin), a fire or explosion cannot occur.
2.2.1 Flammable Vapours
Mixtures of hydrocarbon vapours and air will ignite only if the hydrocarbon to air ratio is within
certain limits. The lower flammable limit (LFL) and the upper flammable limit (UFL) for most
hydrocarbon mixtures are typically at about 1% and 10% by volume hydrocarbon vapour in air
respectively.
Combustible gas indicators are normally used to measure the presence of flammable
hydrocarbon/air mixtures. See Chapter 5.
Ignition will not occur where the concentration of hydrocarbon vapour is less than the LFL, nor
where it is greater than the UFL. However, 'rich mixtures' (above the UFL) may be locally
diluted to within the flammable limits by air entering the tank at tank openings, such as
manways, hatches, vents, etc. Similarly, lean mixtures may be enriched locally due to a
pocket of hydrocarbons, disturbance of sludge or application of heat. If a source of ignition is
present in such areas, explosion and/or fire is likely to occur. When a volatile hydrocarbon
liquid has been removed from the tank prior to commencement of the cleaning operation, a
'rich mixture' will almost certainly remain in the tank. Ventilating the tank by admitting air to
reduce the vapour concentration will result in the formation of a flammable hydrocarbon/ air
mixture at some point during this operation.
Dilution of vapours to within the flammable range may also occur during rapid emptying of a
fixed roof tank or when liquid is withdrawn from under a 'landed' floating roof or floating cover.
A fire or explosion potential will continue to exist until the concentration of vapour has been
reduced to below the LFL. Even when the tank has been vapour-freed, but a sludge or scale
deposit remains on the tank surfaces, flammable vapours can still be formed when these
deposits are disturbed or heated.
Flammable vapours may also enter a tank from secluded places such as cracked floor plates,
pontoons and tubular leg roof supports (in floating-roof tanks), from internal floating covers,
instrument connections and from scale or liquid deposited on tank roof supports or on the
underside of roof plates. Such hazards may escape detection by combustible gas indicators
and require local investigation.
2.2.2 Sources of Ignition
A source of ignition is any heat source having sufficient energy to ignite a flammable
vapour/air mixture by locally raising it above its self-ignition temperature. The amount of
energy required for ignition varies with the nature of the product and its vapour. Possible
sources of ignition in and around tankage are:
2.2.2.1 Electrical Equipment
Electricity may become a source of ignition by sparks or arcs. During tank cleaning, electrical
ignition sources can be created by, e.g. the use of electrically driven equipment, lighting,
batteries, spark ignition engines or cathodic protection systems. The types and use of such
equipment shall therefore be strictly controlled.
2.2.2.2 Lightning
Electrical ignition may also be caused by lightning. During electrical storms all tank cleaning
activity should therefore be suspended and personnel should leave the vicinity of the tank.
Rapid emptying of fixed roof tanks or pumping out from under a landed floating roof should
also cease.
2.2.2.3 Static Electricity
Generation of electric charge occurs whenever two materials,in contact with each other, move
relative to one another. Such electric charging as a result of the movement of liquid products
and solids relative to each other occurs almost everywhere in petroleum handling and related
activities, including tank cleaning. With fluids, including hydrocarbons, the degree of charge
generation and decay is also a function of the electrical conductivity, which is affected by,
e.g., the concentration of trace compounds such as asphaltenes, oxidation products, acids
etc. The presence of a second phase liquid such as water also has an influence on the
generation of static charges. For a more complete treatise on static electricity reference is
made to the PTS Guide "Static Electricity, Technical and Safety Aspects" of June 1988.
The generation of static electricity in itself does not present a hazard unless the charges
reach a sufficient strength to result in a discharge with sparks of sufficient energy to cause
ignition of a flammable atmosphere. Steam and water jetting are capable of generating static
electricity. Steam issuing from a nozzle at high velocity can cause the formation of a charged
mist. This electrostatic charge is generated at the nozzle and is appreciably higher with wet
steam than with dry. Therefore, steam cleaning in a flammable atmosphere shall not be
applied. An electrostatic charge can be generated when a water jet impinges on the tank shell
and breaks down into fine droplets. The charge generated in this way is usually lower than
obtained with wet steam.
The impingement of solids on solids such as occurs during grit blasting operations, also
results in the generations of an electrostatic charge.
Electrostatic charges may be generated by the use of air-driven lights if anti-static hoses are
not used in conjunction with them.
The best method of preventing the accumulation of electrostatic charges on bodies such as
tank shell and hoses, nozzles etc. is to ensure that they are made of electrically conductive
materials and are properly bonded and earthed. It is essential that an inspection and test of all
bonding and earthing connections is made before any tank cleaning takes place. Earthing and
bonding does not protect againts the accumulation of electrical space or liquid surface chages
which may be created by e.g. fast flowing streams of liquid, jetting etc. Cleaning of tanks
should therefore not be carried out by high pressure jetting with a hydrocarbon oil since this
can result in both the creation of electrostatic charges ( depending on the electrical
conductivity of the oil used ) and additional hydrocarbon vapour. If it is necessary to use this
method, it must be carried out in an inert gas atmosphere or subsurface with sufficient oil still
in the tank to avoid splashing.
2.2.2.4 Hot Surface Ignition
Hot surface can be a source of ignition, because the auto-ignition temperatures of

hydrocarbon can be low as 200°C. Ref. Appendix 1B. Examples of introduction of risk as
regards hot surface include:
- application of a welding torch on the external surface of a tank, igniting hydrocarbon

vapours inside the tank;
- hydrocarbon vapours educted from a tank during gas freeing operations, igniting on hot
pipes outside the tank or on the hot exhausts of mobile equipment located outside the
tank;
- ignition of hydrocarbon vapours on a glowing cigarette end.
All sources of ignition shall be kept clear of the tank and immediate vicinity until the tank and
the area surrounding it is tested and declared gas-free. Any hotwork shall be strictly controlled
by the Permit to Work System. As a general rule the carrying of lighters and matches shall be
prohibited.
2.2.2.5 Pyrophoric Deposit
Pyrophoric deposit may occur when a tank has stored oil, liquid gas or a water bottom which
contained hydrogen sulphide or other sulphur compounds. Reaction between the hydrogen
sulphide and/or the sulphur compounds and rust from the corrosion of steel surface may
produce iron sulphides . The subsequent reaction between the oxygen in the air and the iron
sulphides is exothermic. The heat generated as the reaction proceeds can act as an ignition
source leading to a fire or explosion. In the case of inert gas blanketed tanks where the
inerting gas contains no oxygen or a low level of oxygen, but which is subsequently
consumed or displaced, a build-up of pyrophoric deposit can occur.
2.2.2.6 Thermite Reactions
The impact of aluminium equipment on rusty steel surfaces can be a source of ignition by so-
called thermite reactions.
2.3 Chemical Hazards
2.3.1 General
Chemical hazards can arise from:

a. skin contact with the hydrocarbon liquid stored in the tank, with sludge, or from contact
with certain chemicals;
b. inhalation of hydrocarbon or chemical vapours;
c. accidental swallowing of liquids or solids.
The most hazardous chemicals commonly encountered are dealt with in the following
paragraphs.
Monitoring the tank atmosphere for toxic vapours is a specialized task and must be carried
out by a person who is trained and competent to do so. Such monitoring can be achieved with
specific portable instruments (approved intrinsically safe) or with suitable chemical vapour
detector tubes. It is, unless there are different National/local requirements, recommended that
an action level of half the published Occupational Exposure Limit (OEL) for the substance in
question is adopted, to allow an additional safety margin. Where multiple toxic vapours are
present, the advice of a specialist is essential.
2.3.2 Lead Anti-knock Compounds
Tetraethy lead (TML) and tetra-ethyl lead (TEL) compounds which are blended into gasolines
as anti-knock additives are very toxic compounds. Exposure may occur by accident during the
course of tank cleaning operations. Absorption can occur in order of practical importance as
follows:
1. via the respiratory tract by inhalation of the vapour;
2. through the skin from contact with the liquid;
3. via the mouth by ingestion of the liquid.
Tetraethy lead is more volatile than the tetra-ethyl lead.
The occupational exposure limits are:

3
TML 0.15 mg/m ) TLV (Threshold Limit Value)
3
TEL 0.10 mg/m ) 8 hour Time-Weighted Averages
(American Conference of Governmental Industrial Hygienists (ACGIH) "Threshold Limit

Values and Biological Exposure Indices for 1988-1989").
When an alkyl lead compound has been blended into gasoline, there is, owing to the dilution,
no longer a significant hazard. However, the hazard recurs when gasoline tank cleaning is
undertaken owing to the build-up of compound in the sludge and scale deposited in the tank.
Therefore, lead alkyls are amongst the most hazardous chemicals that can be met in tank
cleaning activities, and they require extensive and strict precautions. If these are taken,
however, cleaning of leaded gasoline tankage can proceed in safety. References to detailed
publications are given in Appendix 5.
2.3.2.1 Symptoms of Lead Alkyl Poisoning
Symptoms of lead alkyl poisoning may result from one brief severe exposure or from the
accumulated effects of repeated milder exposures. The effects on the central nervous system
predominate. The more severe the exposure, the earlier will the symptoms appear and the
more likelihood there is of severe illness. Depending on the severity of the exposure,
symptoms may arise within six hours to 10 days. Early symptoms and signs include sleep
disturbance, unpleasant dreams, anorexia, nausea and vomiting, metallic taste, mental
irritability, anxiety neurosis, loss of libido, a sense of impending death, pallor, tremor and slow
pulse.
If exposure has been serious or prolonged, later symptoms may include intense anxiety and
nervousness, nightmares, muscular weakness and abnormal physical movements, low
temperature, hypertension, exaggerated reflexes and weight loss and may eventually lead to
death. It is essential that expert medical advice is sought as soon as any degree of lead
poisoning is suspected.
2.3.3 Hydrogen Sulphide
Hydrogen sulphide (H2S) is a highly toxic gas. At low concentrations it has the vapour of
rotten eggs, although this can be masked by the presence of other vapours. H2S quickly
deadens the smell at about 100 ppm and higher and this may lead to a false sense of
security, since the disappearance of the smell after it has been first recognized may be due to
an increase, rather than a decrease in the atmospheric concentration. All petroleum crude oils
contain sulphur in varying amounts, usually combined with hydrogen and/or carbon. Some
crudes contain free sulphur and H2S. Sulphur is an undesirable element in petroleum
products and various processes exist to remove it, whereby H2S is often formed during
intermediate stages. Whilst the H2S is subsequently removed, certain amounts of it may still
be present in product storage tanks. These may be encountered during tank cleaning, e.g in
the vapours left behind after emptying the tank or as a result of releases from remaining liquid
or sludge.
The current occupational exposure limit is 10 ppm (8 hour TVA) with a short-term exposure
limit (15 minutes TWA) of 15 ppm (ACGIH 1988). The odour threshold is obviously
subjective, but generally levels of 0.5 ppm or less can be recognized. It is re-emphasized,
however, that the odour of H2S is not a reliable guide to its presence as with increasing
exposure the sense of smell is very rapidly lost.
Reference is made to the SSC Guide "Hydrogen Sulphide" of 1986.

2.3.3.1 Symptoms of H2S Poisoning
The toxic effects of exposure to H2S are very rapid and death can occur quickly. Brief
exposure to concentrations above 500 ppm may result in rapid unconsciousness without any
warning symptoms. Exposures above 500 ppm for any length of time are considered as
potentially lethal. Death due to respiratory paralysis may follow within a few minutes unless
the victim is removed to a safe atmosphere in time and artificial respiration is applied.
Exposures over 30 minutes to H2S concentrations of 200 ppm or above may cause a delayed
chemical pneumonitis. Concentrations above 10 ppm H2S can have an irritating effect on the
eyes and on the lining of the nose, mouth and lungs. Where there is any chance that H2S
might be present, it is imperative that before any personnel are allowed to enter a tank, tests
for H2S are made and that these are repeated regularly during cleaning. Apart from its
toxicity, H2S is also a flammable gas when mixed with air between approximately 4% and
46% by volume. This, however, generally creates no particular additional hazard for tank
cleaning since these concentrations are far beyond those where toxicity is the governing
factor.
2.3.4 Polycylic Aromatic Hydrocarbons
Some heavy refinery streams or products may contain small amounts of polycylic aromatic
hydrocarbons (PCAS) , sometimes referred to as PAHS. Typical streams are gas oils, fuel
oils, extracts, catalytic cracker recycle oils and vacuum distillation residue. The ability to
cause cancer of these products appears to be associated with the presence of PCAS, having
a 4 to 6 ring structure. The toxicity of PCAs will differ, depending on the structure and no
generally accepted exposure limits can be given. Frequent and prolonged contact with these
heavy oils and sludges accruing from them can lead to a variety of skin disorders such as
dermatitis, oil acne, skin lesions and warts. During the cleaning of tanks which have contained
such products skin contact with oils or sludge should be avoided by wearing impermeable
protective clothing, gloves and boots. A high degree of personal hygiene is also required.
2.3.5 Benzene
Benzene is an aromatic hydrocarbon which can be present in very low concentrations in

some crude oils and is produced in certain refinery processes. It is also manufactured as a
finished product in the petroleum industry. Liquid benzene can be absorbed through intact
skin but only in small quantities. This route of entry is not of great biological importance. In
common with other liquid hydrocarbons benzene defats the skin and may cause local
irritation. Dermatitis may occur from prolonged or repeated contact.
The chief route of entry by benzene into the body is by inhalation of the vapour. Whether as
the pure compound or as part of a mixture such as gasoline, benzene may give rise to the
following health hazards:
- inhalation of high concentrations of benzene vapour (above 700 ppm) can lead to loss of
consciousness and, if allowed to continue, respiratory failure and death will result;
- inhalation of benzene vapour over a prolonged period may cause:
• bone marrow damage, leading to blood disorders of varying severity which are
usually reversible after removal from exposure, and, more rarely,
• leukaemia (cancer of the blood), which may occur long after exposure has ceased.
The cleaning of storage tanks for benzene (petrochemical material) is not covered by the
present manual. However, benzene is also often a minor constituent of gasoline (typically 2-
3% volume) and may occur in higher concentrations in certain gasoline components and
natural gas condensates. It is therefore necessary that with cleaning of tanks which have
contained gasoline, gasoline components (e.g. reformates/ "platformate") and condensates,
the possible presence of relatively high benzene concentrations be assessed together with
the custodian of the tank. Where necessary, the benzene level in the tank vapour should be
tested and monitored. At this time there is a variation in Occupational Exposure Limits (OEL's)
in different countries. Where there is a national OEL, this must be observed.
For information and general reference the following OEL's apply in the countries specified (all
values stated in ppm 8 hours' Time Weighted Averages):
- United Kingdom - 10 ppm
- European Community - 5 ppm (proposed)
- USA - 1 ppm (OSHA, Occupational Safety and Health

Administration)
- Shell Benzene Guide - 10 ppm
Note: There is a tendency for the OEL to be reduced from 10 ppm to 1 ppm.
2.3.6 Miscellaneous Chemicals
2.3.6.1 Tank Cleaning Agents
From time to time various chemicals may be used during the tank cleaning process, e.g.
demulsifiers and degreasing agents. The toxic nature of these chemicals must be ascertained
and the manufacturer's safety data sheet obtained before any arrangements are made to
bring them on site.
Where a toxic risk is identified, efforts must be made to obtain a non-toxic substitute.
Otherwise, procedures, including means of personal protection, means of supervision and
safe means of disposal must be clearly defined. Tank drainings following the use of cleaning
agents with detergent or oil emulsifying properties may cause oil carry-over from interceptors,
with resultant environmental damage. Such agents should not be used if at all possible
Consultation with the manufacturer of the chemical agent is recommended.
2.3.6.2 Other Chemicals
Whilst the cleaning of storage tanks for chemical products is outside the scope of the present
Guide, a variety of chemicals may be present in oil storage tanks as additives, blending
components or as contaminants.
In normal dilution, these additives are generally harmless, but accumulations with higher
concentrations may occur in sediments and scale which are to be removed during tank
cleaning.
It is, therefore, essential to assess whether such conditions could exist and to assess the
degree of hazard before tank cleaning can start. Consultation with the manufacturer of the
additive concerned or with the management of the tank farm (if competent on this subject) is
recommended. Personal protection measures must be taken as directed.
2.3.7 Dusts
Exposure to toxic dusts will normally occur when the tank interior or external shell is
being cleaned or prepared for repainting by grit-or-shot-blasting or other manual cleaning
techniques.
The source of toxic dust can be:
1. the grit or shot-blasting materials;
2. additive deposits, e.g. TML, TEL;
3. paint coating, e.g. lead-based paints.
Where grit-or shot-blasting cleaning techniques are employed, the persons carrying out the
work shall wear air-fed protective hoods. Other personnel should not normally be allowed
inside the tank whilst grit-blasting is in progress. However, when it is considered safe to do
so, such persons should as a minimum wear approved particulate filter masks. Filters should
be changed regularly. In the case of leaded gasoline tanks, air-fed protective hoods shall be
worn by anyone entering the tank.
Note: Sand containing free silica in excess of 1% shall not be used as the abrasive agent.
2.4 Oxygen Deficiency
The concentration of oxygen in normal air is approximately 21% by volume. As this

concentration decreases, breathing becomes increasingly difficult, until a level is reached
where human life cannot be sustained.
In workplace situations, the lowest level for safe working without air-fed respiratory protection
is considered to be 20% oxygen. Analysers or meters are used for determining the oxygen
level in tanks or other confined spaces. Where flammable vapours may also be present in the
atmosphere, such monitoring equipment must be certified for use in these atmospheres.
In tank cleaning situations oxygen deficiency can arise from:
a. inert atmosphere, i.e. where nitrogen or other inert gas mixtures have been used as a
blanket gas above the stored liquid or during gas-freeing of the tank;
b. high concentrations of hydrocarbon vapours. This situation may exist when a drained
tank is opened and until dilution is effected by air circulation and ventilation.
c. internal corrosion in a closed tank. Where a tank has been cleaned and resealed, oxygen
contained in the air within the tank can be consumed by corrosion. Such reactions are
enhanced by heat and high humidity. On reopening the tank, oxygen levels must be
checked before allowing personnel to enter without appropriate respiratory protection,
and at regular intervals thereafter.
On no account shall pure oxygen be used to raise the level of oxygen in the tank atmosphere,
because of the resultant increased flammability.
2.5 Physical Hazards
2.5.1 Temperature Conditions
Extreme temperatures can occur during tank cleaning operations. Temperatures inside the
tank can be greatly influenced by ambient temperatures. The need to wear personal
protective clothing inside the tank can also cause a rapid increase in body temperature,
eventually leading to heat stress. The air temperature inside the tank can be moderated by
circulating either warn or cold air via flexible trunking. Compressors and other equipment
used for this purpose should be located in a 'safe area' outside the tank. The air supplied shall
be of breathing quality.
In extreme low temperature conditions light-weight thermal clothing can be worn under
overalls and the required protective clothing.
To guard against heat stress, a work/rest schedule should be agreed and the rest periods
should be taken in a cooler environment. Workers should be encouraged to drink small
amounts of cool water (10-15°C) at frequent intervals (15-20 minutes). It is preferable to
provide salted water (0.1%) or isotonic drinks.
2.5.2 Noise
Excessive noise may arise from the use of air hoods, certain cleaning equipment, air movers
or generators and compressors operating in the area. In these circumstances, noise
monitoring should be carried out. If the level of continuous equivalent work day noise dose is
85 dBA or above, appropriate hearing protection measures must be taken; ref. also the SSC
Noise Guide. Measures must be taken to ensure that despite the hearing protection the
attention of those involved is still drawn to any alarm condition.
2.5.3 Work Conditions
In addition to personal injury arising out of fires, explosions, exposure to toxic materials or
asphyxiation, incidents may occur from causes such as:
a. structural failure of tank or its components;
b. falling tools or materials;
c. falls through corroded or weakened roof plates or from ladders/scaffolds;
d. tripping over pipes, hoses or tools, or stepping into tank drain sump; accidents during
manhole passage;
e. knocking heads against obstructions;
f. slipping on wet or oily surfaces;
g. discharge of steam, high-pressure air, water or oil into the tank or surrounding work area;
h. use of improper or poorly maintained tools or equipment;
i. electrocution from faulty electrical equipment;
j. failure to isolate electrical power, process and service lines from the tank;
k. inadequate lighting;
l. inadequate scaffolding
m. inadequate securing of movable items, e.g. level floats.
To minimize the risk of many of the above factors it is essential that the workforce is
adequately trained, that there is appropriate and competent supervision at all times and that
correct work methods are applied. The benefit of maintaining strict good housekeeping
standards is stressed.
2.6 Radiation Hazards
Certain crude oils and condensates may contain small amounts of radio-active substances.
This point should be verified with the custodian of the tank and, where appropriate, specialist
advice should be sought.
3. PREPARATORY WORK
3.1 Permits
It is the practice within PETRONAS to require that work which is not of a routine operational
nature must be carried out under the cover of a work permit system. Tank cleaning falls into
this category. A work permit system helps ensure that the strict control of hazards can be
maintained throughout the duration of work.
For guidance about the work permit system reference is made to relevant Group publications.
3.2 Organization and Personnel
Any company involved in tank cleaning of any nature must organize and maintain a system
whereby tank entry and cleaning operations are carried out in a responsible, safe and
controlled manner.
3.2.1 Supervisor
- A supervisor must be appointed to control any tank cleaning. He should be thoroughly

competent and fully conversant with all the general and specific tank cleaning safety
regulations and procedures involved, including the characteristics of the product being
handled prior to and during the period of tank cleaning operations.
- His qualifications should further include a high sense of responsibility, a safety conscious
attitude and high standard of housekeeping.
- He should have the ability to deal immediately and firmly with any laxity on the part of
personnel engaged in the cleaning operation in the relevant working areas.
He should be able to communicate effectively with the cleaning workforce, taking into
account any differences in working languages.
- Whilst safety is a responsibility of all personnel involved, it is the tank cleaning

supervisor's specific responsibility to minimize all recognized hazards before the tank
cleaning operation begins, and to maintain a safe operation until the tank has been
completely cleaned and handed over to the custodian. He will also monitor changes in
conditions and adapt the cleaning activity accordingly. Throughout the cleaning process
his responsibility will cover the control of all cleaning personnel.
- Prior to the commencement of his tasks clear lines of reporting from the supervisor
upward have to be established with the custodian of the tankfarm or facility.
3.2.2 Workforce
3.2.2.1 Qualifications
Despite the sometimes unattractive nature of the work, care must be taken to select
personnel of an appropriate level of intelligence and reliability for the discipline required in
tank cleaning work.
3.2.2.2 Instruction and Training
It is essential that tank cleaning personnel are adequately instructed and trained in the
following subjects, and that this can be verified from records or otherwise:
- The hazards involved;
- The relevant product properties;
- The safety precautions and procedures involved, including basic fire-fighting;
- Emergency procedures, including evacuation plans;
- Work permit system;
- Decontamination of equipment and clothing;
- Personal hygiene;
- The use of breathing apparatus and protective equipment where necessary;
- A complete understanding of the work involved.
3.2.3 Medical Aspects
All personnel involved in tank cleaning activities should have pre-placement and periodic
health assessments to assess their suitability for the work. Fitness certificates should be
available for perusal by management.
The occupational physician should be conversant with the basic requirements of tank
cleaning and of the attendant health implications. He should agree the content and frequency
of the health assessments in conjunction with site management.
Where work is to be carried out in tanks which have contained toxic products (e.g. leaded
gasoline) the occupational physician must be knowledgeable about the specific hazards
involved. In such cases a regular programme of health surveillance (see Appendix 2) must be
carried out.
3.3 Pre-Cleaning Inspection
3.3.1 General
Before a tank is taken out of service for cleaning, a number of preparatory activities should be
undertaken, in close liaison with operations, engineering and safety advisory groups as
appropriate. A concise record should be maintained of all pre-cleaning activities and findings.
3.3.2 Tank Contents
The operational history of the tank as regards the liquids that have been stored in it should be
checked. The physical and chemical properties of these tank contents and any associated
deposits should be assessed for expected behaviour under tank cleaning circumstances, e.g.
at low ambient temperatures. Particular attention should be paid to properties such as
flashpoint, electrical conductivity, lead content, benzene content, other toxic additives,
hydrogen sulphide and to the risk of pyrophoric deposits.
Before taking the tank out of service any sludge and sediment accumulations should be
minimized as far as possible by operational measures, e.g. by dilution, heat, use of tank
mixers or additives (see Chapter 5). Subsequently an estimate should be made of volumes
and profiles of any remaining sludge and sediment with particular reference to levels at entry
manholes and to the possibility of landing a floating roof safely on its supports. A safe and
environmentally acceptable means of disposal must be established, based on
sampling/analysis of the sludge and sediments.
3.3.3 Tank Inspections in General
Technical drawings and inspection records should be checked for relevant construction
details that may influence the tank cleaning process, e.g. the existence of heating coils,
concentric shells, floating suctions, drainage systems, potential oil pockets, unsafe
roofs and railings. These studies should be completed by external inspection of the tank.
Special attention should be paid to the system of tank connections, valves and piping which
should be assessed as regards possibilities for drainage and recirculation during the cleaning
process.
The means to provide positive isolation of the tank from the piping and utility system and from
other tanks should be studied and requirements recorded.
3.3.4 Roof Inspection
A general inspection should be made of the condition of the roof and of any equipment and
connections thereon. Before permission is given to walk on a roof, enough information shall
be obtained about the condition of the roof-plates to ensure that this can be done safely. If
there is any doubt about the integrity of the roof plates to carry a person, special precautions
are required if the inspection would still need to proceed. Inspection of roofs should be done
when the level of the tank contents is static, and only during periods of good weather with no
significant risk of electric storms or high winds.
Roof inspection, because of its non-routine nature, must be executed by a team of at least
two persons, at least one of whom must observe from the top of the tank by the access
stairway. He must have available adequate means of communication, preferably a portable 2-
way radio, appropriately certified, in order to be able to summon help from the tank top.
3.3.5 Inspection of Fixed Roofs
In addition to the points listed in 3.3.4. certain extra precautions should apply in the case of
fixed roofs.
If the contents of the tank give any reason to suspect that the atmosphere above the roof
might be unsafe owing to toxic contaminants expelled by tank breathing, special precautions
shall apply. This may require the use of self-contained breathing apparatus. If breathing
apparatus is used by the roof inspector, the person observing from the tank top shall also
wear such equipment ready for immediate use, after raising the alarm.
Unless the tank handrail is constructed and maintained in such a way that it will prevent a
person slipping down the roof from falling off, any person should be attached to an inertia reel
lifeline. This lifeline should be securely attached to a suitable structural member of the tank
which has been checked for strength and reliability beforehand. Walking on roofs in high
winds, wet or freezing conditions should be avoided.
3.3.6 Inspection of Floating Roofs
Floating roof inspection should especially include:

- all earthing shunts and cables; roof drains (also to be inspected at ground level);
- any water or product collected within pontoons or double decks or on top of the roof;
- proper functioning of roof ladder;
- condition, operability and setting of roof supports and automatic vents;
- condition of roof seals.
Inspection of floating roofs should preferably be done with the roof floating at high level and
with the tank contents being static.
Whatever the roof elevation the atmosphere above the roof shall be assessed as regards its
possible flammability and toxicity before the roof is accessed for inspection. Access to floating
roofs may also be subject to local regulations.
Entry by any person into a pontoon or other enclosed space on a floating roof while it is still
afloat shall be strictly prohibited.
A flammability test at several relevant positions on the roof shall be taken. Where a need is
indicated this should be done by a person using self-contained breathing apparatus. The
result of these tests should determine whether e.g. a lifeline should be worn and/or breathing
apparatus should be used throughout the subsequent roof inspection. The level of the roof in
respect of the tank rim together with the actual wind conditions must also be taken into
account.
If the tank contains material that is liable to produce toxic vapours or gases, e.g. H2S, portable
monitors should be wom as well as a lifeline and breathing apparatus "ready for immediate
use".
Irrespective of whether the person on the tank roof uses breathing apparatus the person(s) on
watch at the tank top should be wearing and "have at the ready" a breathing set ready for
immediate use.
3.3.7 Inspection of Internal Floating Covers
Inspection of fixed roof tanks with internal floating covers should be subject to similar
precautions to those for both fixed roofs and floating roofs.
Because of the limited possibility of visually inspecting the floating cover and the occurrence
of various different type of construction, it is essential that drawings should be studied and
where appropriate the manufacturer should be consulted.
The external condition of the floating cover and its seals should be observed through
manholes on the fixed roof of the tank with special attention to any liquid present on the top of
the floating cover.
Before this visual inspection can proceed a gas test (Oxygen, explosivity and toxicity as
applicable) shall be made through the opened manholes.
Entry into the space between the floating cover and the fixed tank roof shall not be permitted
when the tank still contains hydrocarbons.
3.3.8 Site Inspection
A survey of the tank surroundings should be made, both inside and directly outside the
relevant bund wall area (if applicable), to plan normal access possibilities for tank cleaning
personnel and equipment and to establish possible emergency escape routes.
If required, additional ramps, stairs, ladders etc to cross piping or bund wall should be
considered. The wall of any bunded area should not be breached when any tank within that
area is still operational, unless intermediate bundwalls or the operational condition of the
tanks allow otherwise.
The surroundings of the tank should be surveyed for any ignition sources, vents, combustible
materials and contamination with hydrocarbons.
The tankfarm drainage systems should be checked for proper functioning.
The local fire-fighting resources should be checked and an assessment should be made of
any additional requirements for the tank cleaning period.
The location of any electrical and instrument cables and ducts should be established.
Consideration should be given to any construction or maintenance activities in the area

surrounding the tank that might influence the cleaning operations.
The proximity and contents of any other operational tankage should be taken into
consideration.
3.3.9 Weather Conditions
In locations subject to seasonal cyclones, typhoons, etc. the work should be planned to avoid
such seasons. This is especially important if the work programme would not allow the tank to
be rapidly closed and filled with water (or product) to the required level that would prevent the
tank from being blown off its foundation.
3.4 Work Programme
Based on the job requirements for cleaning each tank and on the findings of the pre- cleaning
inspections, a comprehensive work programme should be established. This work programme
should be made available it written form. It should be agreed by all concerned and particularly
by the person responsible for overall safety in the area and by the cleaning operations
supervisor before decommissioning and cleaning of the tank can commence. Typical contents
of such a work programme are listed in Appendix 3.
3.5 Selection of Equipment and Precautions for its Use
3.5.1 Mechanical Equipment
Owing to the potential hazards which exist when cleaning petroleum storage tanks, it is
recommended that, where possible, any mechanical equipment used (i.e. pumps, blowers,
eductors, etc.) is powered by compressed air or hydraulics.
Where electrically powered equipment is used, see 3.5.4.3.
Where compression ignition engines are to be used, reference should be made to EEMUA
Publication No. 107, previously designated OCA publication No. MEC-1 "Recommendations
for the Protection of Diesel Engines operating in Hazardous Areas".
All engine-driven plant should be kept as far away as possible from any vapour source,
preferably upwind, and must never be used inside a tank. There should be a clearly labelled
emergency stop device.
Spark ignition engines must not be used, unless positioned in a safe location.
3.5.2 Illumination
It is recommended that any fixed lights used in tanks where flammable vapours may be
present, are air powered and certified Exp (Explosion-proof pressurized) for use in hazardous
atmospheres by a recognized testing body (e.g. BASEEFA in the the U.K., PTB in Germany).
Antistatic hoses must be used for the air supply. Any hand lamps or torches used must be
certified Exc. (Explosion-proof, increased safety).
If rechargeable battery type units are used, then the charging units must only be used in a
safe area.
3.5.3 Breathing Apparatus
Protective respiratory equipment should preferably provide a positive air pressure throughout
the breathing cycle. This equipment is normally air line supplied.
Self-contained compressed air breathing apparatus should only be used for short-time
working and where adequate access and egress is available. It must be equipped with
audible low-pressure alarms.
Where air supplied hoods or blouses are used, care must be taken to ensure that there is
sufficient airflow into the blouse or hood such that a negative pressure is not created during
the inhalation cycle, thus inducing toxic gases or vapours into the breathing zone. During
heavy work a flow rate of approximately 250 litre/minute is recommended.
Canister respirators shall not be used inside any tank where toxic levels are above acceptable
exposure limits or where the oxygen level is less than 20%.
Oxygen supplied equipment shall not be allowed inside a tank, except perhaps for emergency
resuscitation purposes, because of the danger of producing an oxygen-enriched atmosphere.
3.5.4 Services
3.5.4.1 Breathing Air
It is recommended that a dedicated air compressor, complete with an air reservoir, is provided
to supply breathing quality air for the breathing equipment.
It is essential that the air reservoir is adequately sized and provided with a low pressure
alarm, to allow personnel using the breathing apparatus time to reach a safe area in the event
of compressor failure. In such an event, it is important that the reservoir does not
automatically vent to atmosphere and that prior arrangements have been made to warn the
persons using breathing apparatus. Consideration may be given to providing back-up air
bottles for escape purposes. Any local regulations on this point should be followed.
The compressor should be fitted with air intake and discharge filters to provide an air supply
meeting the air purity requirements for air line breathing apparatus in BS 4275 or equivalent,
and be sited upwind of the tank on which work is being carried out, in an area free from
flammable or toxic vapours.
The air intake should be upwind and well clear of the compressor engine exhaust, of the
exhausts of any other engine-driven equipment and of any sources of flammable vapour in
the vicinity.
Air hoses for use with breathing apparatus should comply with BS 4667 Part 3 or equivalent.
The hoses should be maintained, cleaned and tested, in accordance with the manufacturer's
instructions. Any sections of hose which are found to be defective, must be replaced
immediately.
The compressor used to supply air for breathing purposes should not be used, at the same
time, to supply air for airdriven equipment.
Hand-operated airblowers are used in some locations. However, these may not always
provide the same continuity or air supply. Therefore their use is not supported.
3.5.4.2 Water
All temporary pipelines, equipment, hoses, etc. which may be required between the water
supply point and the point of use, should be maintained in good condition and free from leaks.
The fire main should not be used without authorization. If its use for water supply is permitted,
the installation of a pressure reducer is a sensible precaution and provision should be made
to shut off if water is required in an emergency. In particular, personnel using the fire main for
cleaning purposes should be instructed to stop using hoses immediately on hearing the fire
alarm and to close the hydrant valve, to prevent injury arising from a pressure surge.
Care should be taken with water supplied from effluent or other process water systems to
avoid contamination.
Where fire or potable water is used for tank cleaning, appropriate measures shall be taken to
avoid contamination of the supply source, for example by installing check valves or break
tanks.
3.5.4.3 Electrical Supply and Equipment
Electrical equipment used where petroleum vapours may be present, shall comply with the
area classification and be appropriately certified for use in hazardous atmospheres.
Clearly labelled start and stop facilities should be provided in the vicinity of the equipment.
Associated equipment shall have a type of protection suitable for the area classification.
Motors and supply cabling shall be protected against short circuits, overloads and earth faults.
Temporary cabling should be installed and protected in such a way that the risk of damage
will be minimized. Cables shall be of the heavy duty type, resistant against oil products and
provided with an earthed metal braiding, with a rubber or PVC sheath overall. The cables
should be adequately sized and connected to the motor terminal box by means of flameproof
certified cable glands.
Electrical equipment shall be securely and effectively earthed and bonded to the shells
of the tanks, see relevant Group guidelines.
The complete installation should be checked by a competent person for conformity with the
appropriate safety rules (electrical safety as well as area classification).
3.5.5 Testing Equipment
Instruments used must be certified for use in flammable atmospheres by the appropriate
certification authority. They should be carefully selected with reference to the usage aspects
given in Section 5.10.
3.5.5.1 Measurement of Oxygen Level
Portable instruments are available to measure the percentage oxygen level in the
atmosphere. These may include audible and visual alarms which indicate when the level of
oxygen falls below a preset level. Group standard is minimum 20% oxygen. It is important to
check the operation of the instrument prior to starting the tank cleaning and, at intervals,
throughout the cleaning operation.
3.5.5.2 Measurement of Flammable Vapour
(i) The level of flammable vapour in an air/vapour mixture can be measured by means of
an intrinsically-safe combustible gas monitor.
Combustible gas monitor scales are graduated from 0-100 percent of the lower
flammable limit of the gas for which the instrument has been calibrated. It is to be
noted that these instruments do not function satisfactorily in oxygen deficient
atmospheres.
(ii) The instrument used for measuring the concentration of this vapour should be of an
approved design, must be tested before each use, calibrated and it should be used
only by a competent person. Where lead alkyl vapours are likely to be present, a
combustible gas indicator of a type which is not affected by such vapours must be
selected.
3.5.5.3 Measurement of Toxic Substances
Historical data concerning the products previously stored in the tank will indicate whether
there is a need for toxic vapour monitoring. Various techniques are commercially available.
These range from gas chromatography through sensitive vapour indicators to calibrated
chemical detector tubes. Manufacturers' operating instructions need to be strictly adhered to
in order to ensure acceptable accuracy.
Toxic substances potentially present are referred to in Chapter 2.
Accurate measurement of toxic vapours is only made possible by personnel entering the tank,
where sludge levels permit, wearing suitable breathing apparatus and protective clothing.
3.5.6 Miscellaneous Equipment
3.5.6.1 Wind Indicator
A wind sock or flag should be provided to assist in the safe positioning of equipment and a
watch kept thereafter for changes in the wind direction.
3.5.6.2 Washing and Changing Rooms
A wash room with washing and showering facilities, including hot and cold water, should be
provided. The wash room should be equipped with a sufficient supply of clean towels, soap,
nail brushes, etc. The wash room should not be used for storing or cleaning contaminated
outer protective clothing, but should have a container for used under-clothing.
A changing room should also be provided adjacent to the wash room, or it may be combined
with, but partitioned from the wash room in a single unit.
If portable washing and changing rooms are used, these should be located in a safe area.
Where necessary, a portable canteen should also be provided. This should be sited remote
from the work site and, for hygiene reasons, restricted to work people who have washed and
changed. The electrical installation shall be protected e.g by earth leakage trips, fuses and
earthing.
For leaded gasoline tank cleaning activities special wash and changing room arrangements
must be provided. See Appendix 5 for applicable documentation by Associated Octel.
3.5.6.3 Protective Clothing
The choice of protective clothing depends on a number of factors, such as climate, and the
nature of the sludge, liquids or vapours present in the tank.
Personal protective clothing would normally include:

(i) A suit manufactured from a material impervious to the vapours and liquids likely to be
encountered in the tank. The suit should be light in colour to highlight contamination
and to render the wearer visible in poor light.
(ii) Protective safety helmets with chin straps to an approved standard.
(iii) Safety boots manufactured from materials impervious to the vapours, liquids and
deposits likely to be encountered in the tank. Where there are substantial sludge
deposits, boots of the chest-high wader type should be worn. The sole pattern should
provide a positive grip against slippery surfaces.
(iv) Gloves of material impervious to the vapours, liquids and deposits likely to be
encountered in the tank and of sufficient length to cover and fit over protective
clothing at the wrists.
(v) Goggles to a recognized chemical splash standard with anti-misting surface.
It should be noted that no material is completely impervious to hydrocarbons. For this reason,
protective clothing must be cleaned, inspected and tested regularly. If there is any doubt
regarding the integrity of a piece of clothing it must be discarded.
The use of protective clothing to prevent exposure to toxic chemicals also presents an
additional barrier to sweat evaporation, thereby significantly increasing the potential for heat
stress in a hot environment. In such circumstances supervision should ensure that the work is
planned to allow for adequate rest periods to prevent heat stress situations arising.
Protective clothing should never be removed in a potentially flammable or toxic situation.
3.5.6.4 Windsail
Windsails may be mounted alongside a roof or shell manhole to assist in natural

ventilation of the tank.
3.5.6.5 Vapour/Air Eductor
Eductors may be used for removing vapours from tanks. They should be of the compressed
air or steam type, and may be used with flexible trunking, to draw vapours from low level in
the tank and discharge to a safe location at high level. They must be electrically bonded to the
tank.
3.5.6.6 Air Blower
Air blowers shall be of a non-sparking, non-static accumulating design. They should be driven
by flameproof electric motors or air motors. Electrical continuity must be ensured between the
air blower and the tank.
To avoid that flammable vapours may be passing through the equipment, a blower should
never run in reverse and work as an extractor unless the tank has been tested and is gas-
free. Electrical connections and rotation should therefore be checked before starting the
blower.
3.5.6.7 Ejectors
Ejectors may be used to remove liquids from tankbottoms. Water operated ejectors are
preferred.
The ejectors must be electrically bonded to earth.

3.5.6.8 Hoses
Hoses used for the transfer of sludge should be suitable for the material being pumped and
for pressure or vacuum service and must be electrically continuous and bonded to the tank
shell. Canvas or other porous hoses should not be used for hydrocarbon sludge. Hoses
should be regularly checked for wear and damage and cleaned after use.
3.5.6.9 Sludge Pumps
These are located inside or outside the tank and are to be powered remotely by hydraulics or
compressed air. Sludge may be pushed manually or mechanically to the open-ended hose
located in a sump or low point in the tank.
Pump selection should take into account the possibility of extraneous items, e.g. rags, bolts,
etc. which may be drawn into the pump if a strainer is not used. Consideration should be
given to the required delivery point of the sludge, i.e. distance to be pumped, fitting of non-
return valves, selection of pipework, hoses and couplings, protection from damage, e.g. at
road crossing, so as to avoid spillage risks. Constant surveillance is essential during this
operation.
3.5.6.10 Vacuum Equipment
This is used to remove heavy residues, sludges and sometimes solids. The method employs
either special, temporarily erected on-site vacuum facilities (with or without facilities for sludge
separation) or vacuum trucks. High efficiency vacuum trucks can be used, where available,
which are able to uplift heavier materials than the conventional type. Where the tanks are
open and sludge is below the manway, hoses, which may vary in diameter from 3" to 8", are
introduced and the sludge is pushed manually or mechanically to the open end. Since the
equipment operates at a high vacuum, care should be taken with the open end of the suction
line which, wherever feasible should be designed such that operator injury cannot occur.
When extracting hydrocarbon products, vacuum pump exhaust emissions to atmosphere
should be controlled and the vehicle positioned at a safe distance from the open manway,
where possible outside the bunded area.
Unloading at the sludge disposal site may require entry of personnel into the tank of the
vacuum truck. This is a hazardous activity which should only be undertaken by well-trained
and experienced personnel, where necessary using breathing equipment.
Spark ignition engine driven vacuum equipment or trucks should not be used.
It is necessary that vacuum equipment is earthed and/or bonded to the tank to be cleaned. In
the case of vacuum trucks a bonding wire shall be connected between the vacuum tank and
the storage tank being cleaned which shall not be disconnected until after the suction hose
has been uncoupled. This bonding wire and its proper attachment to tank and vacuum tank
on bare metal should be regularly inspected and tested.
3.5.6.11 Mechanical Squeegees
Mechanical squeegees are made in several sizes and types and are designed to go through a
450 mm manway and be rebuilt inside the tank. They are hydraulically driven from an outside
power pack. Although they are used mainly in large diameter tanks to reduce man entry time
and numbers, they are also particularly useful in difficult or hazardous conditions, e.g deep
sludge or confined spaces. The equipment can be operated by a driver on the machine or at a
distance by remote control, thus substantially reducing personnel presence in the tank, both
in number of people and in time.
It is essential that the operator has sufficient training and is familiar with the tank, before
operating inside a tank. The tank should be checked for internal obstructions e.g. pipes, coils,
sump etc.
3.5.6.12 Scaffolding
Scaffolds may be required where work is to take place at height.
They must be positioned on a sufficiently clean, firm and secure base. Where mobile
scaffolding is used, special care must be taken that they are securely immobilized while the
scaffold is in use.
Special attention is required when relocating mobile scaffolding on uneven or sloping

surfaces. Personnel shall not remain on scaffolding during relocation of same.
Care shall be taken that any tank internals that are used for added support have sufficient
strength.
For further information about scaffolding reference is made to the PTS publication on the
subject, see Appendix 5.
3.5.6.13 Aluminium Equipment
The use of aluminium equipment, flanges etc. requires special care when fitted directly
against (possibly rusty) steel surfaces. Impact between these surfaces may create sparks
caused by a thermite reaction.
3.6 Control of Sludge Disposal
3.6.1 Responsibility
It is the responsibility of the company operating the tankage to ensure that the sludge
resulting from tank cleaning operations is disposed of in accordance with responsible
environmental practices and relevant statutory regulations.
Particular attention should be paid to long term consequences of the selected disposal
methods. Professional advice may need to be sought in this respect.
3.6.2 Documentation
All permits required by the current national and local regulations must be obtained. Records
must be kept of the character and final location of any sludge.
3.6.3 Methods of Disposal
Possible disposal methods include, but are not limited to:

Reprocessing
Land fill
Land farming
Incineration
Encapsulation
Both land-fill and land-farming must be only at authorized waste disposal sites, even when the
site is inside the confines of the refinery, terminal or depot.
Special consideration may apply to the safe disposal of sludges containing heavy metals such
as lead.
Incineration may be necessary for those sludges which cannot be safely disposed of within
the provisions of a licensed land-fill site.
Access to all disposal sites should be strictly controlled.
3.6.4 Customs Approval
In bonded installations, Customs approval may be required for the removal of sludge.
Certification of disposal may also be required.
4. TAKING TANKS OUT OF SERVICE
4.1 Emptying and Line Clearing
4.1.1 General
Tanks should be emptied to the maximum extent by using the normal operational piping
system.
Where tanks cannot be emptied completely via the normal piping system, special measures
should be considered such as temporary connections to low drains, or introduction of a water
bottom to raise oil level to the normal product suction level.
After the tank has been emptied all relevant tank connections, connecting pipelines and any
internal piping elements (e.g swing arms, air mixing spiders, floating roof drains) should be
emptied, drained and flushed with water as appropriate.
Any instrument connections and permanent foam connections should be checked for possible
presence of hydrocarbons (via burst seals) and flushed and drained when necessary.
Water used for line clearance and flushing of tanks which have contained toxic materials
should be collected for separate treatment or disposal unless its quality is acceptable for the
normal oily water disposal system.
4.1.2 Floating Roof Tanks
In the case of floating roof tanks the roof legs should be lowered and set in their high support
position before emptying the tank. The automatic vent should be set correspondingly. The
bulk of any liquid that may have been found corrected in pontoons of floating roofs must be
removed before landing the root. Floating roofs should be landed slowly and special care
should be exercised to ensure an even landing if at all possible in tanks that contain large
accumulations of bottom sludge or sediment.
It is stressed that floating roofs standing on their legs are very vulnerable. Accumulation of
rain or snow can cause collapse. For this reason arrangements must be made to ensure that
any rainwater is adequately drained.
4.2 Isolation
4.2.1 General
After the tank and its connections have been drained and flushed to the maximum extent,
preparations can be made for gas-freeing and/or opening of the tank. These preparations
comprise the complete physical isolation of the tank from any other tankage and pipelines,
utilities and from electrical systems.
4.2.2 Isolation from Piping Systems
Closed valves, even when sealed and made inoperative, are not acceptable as safe means of
tank isolation. Preferably, relevant piping sections should be disconnected from the tank and
removed and the pipework that remains connected to the system shall be blanked off.
Alternatively slip blinds shall be inserted in all pipelines connected to the tank, including
product connections, drains, steam, condensate, hot oil, air, foam, inert gas and vapour
collecting pipework, as close to the tank shell as possible.
Blinds and blank flanges must be sufficiently strong to withstand the maximum internal
pressure which might be exerted against them. Checks should be made that no liquid-filled
lines are left in a blocked in condition. This includes heating coils inside the tank which should
be isolated, cooled and drained.
Before any flanges can be loosened in the pipework it must be ensured that all valves directly
upstream and downstream are tightly closed. These valves shall then be made inoperative
e.g by locking or removing handwheels and (in the case of motor-operated, remotely-
controlled valves) by isolating and disconnecting the power supply to the valve operator.
To minimize spillage, the pipe section to be opened should be drained if at all possible
through fixed drain points. Where fixed drainage systems cannot be used, spillages should be
collected by using metal funnels, buckets or other suitable means, which must be adequately
earthed. These should be emptied by vacuum trucks or into movable slops drums etc. All
such material should be safely removed from the site as soon as possible and before further
work is done.
As disconnecting and/or blinding of pipelines may still release small amounts of hazardous
liquids and vapours, any source of ignition shall be eliminated from the area and work
methods and tools should be selected accordingly.
Fire extinguishers and/or fire water hoses must be at site and ready for immediate use.
Personal protection equipment, such as breathing apparatus, may have to be used depending
on workplace conditions and toxicity of the product concerned.
4.2.3 Thermal Pressure Relief Systems
Pipeline thermal pressure relief lines connected to the tank shall be disconnected and blinded
off. It should be checked, however, that the proper functioning of the relief system is not
obstructed thereby. In that case the pressure relief fine should be re-routed and connected
temporarily to another point of discharge in compatible duty.
4.2.4 Drainage Systems
Any open or closed drainage systems affected by the tank cleaning operations should be
disconnected and/or closed off from the system. If the tank cleaning procedures will require
the use of drainage systems, appropriate measures must be taken to avoid the risk of
backflow from other sources. Tank bund service drains should be kept operable but normally
closed.
4.2.5 Electrical Isolation
All electrical supply connections to tank mounted equipment shall be isolated and
disconnected by a competent person. Disconnection should be both at the equipment itself
and at the upstream distribution system to avoid the presence of live power cables in the
immediate vicinity of the tank. All cable ends must be properly insulated, secured, protected
and tagged.
The system of bonding and earthing of the tank shall not be disconnected. It should be
inspected to ensure proper earthing.
In the case of cathodic protection of the tank, the relevant power supply should be
disconnected at least 24 hours before any other work can commence. The earthing system
shall then be re-established as appropriate and checked for proper functioning before any
further work is undertaken.
5. GAS-FREEING
5.1 General
Before any personnel are allowed to enter a tank, the composition of the tank atmosphere
shall be verified by using appropriate gas testing equipment and procedures as described in
5.10. If the tank atmosphere is found to be unsafe, the tank must be gas freed or ventilated to
the appropriate level.
Whilst certain products are likely to leave a safe atmosphere after the tank is emptied, it is
nevertheless essential that the atmosphere inside any tank be considered unsafe until tested.
Apart from the testing for reasons of flammability, tank atmospheres which are under
suspicion of containing toxic contaminants, or inert gas, shall be tested additionally for safety
from these materials and for adequate oxygen level before personnel may enter.
Whilst a tank atmopshere may have been safe for entry at a particular moment, this situation
may change with time, e.g. owing to disturbance or removal of scale and sediments during
cleaning, which may release fresh vapours. Other sources of fresh vapour release may be the
clearing of liquid or vapour filled tank internals. It is therefore essential that a good air
ventilation of the tank is maintained and that the tank atmosphere is monitored near the points
of work whilst personnel are working inside.
Tanks which have been standing empty for long periods whilst closed may be unsafe for entry
even when clean, owing to oxygen depletion. Also in these cases the atmosphere shall be
tested to ensure adequate oxygen levels before entry.
In tanks which have been used for the storage of material containing sulphur compounds,
particularly H2S, it is possible that potentially dangerous pyrophoric deposits and scale have
been formed. In such cases special measures may be needed during gas freeing (see 5.9.).
5.2 Site Precautions during Gas-freeing
During the gas-freeing operation the hazardous tank atmosphere is gradually discharged to
the environment outside the tank where it disperses. As a consequence the area around the
tank should be regarded as suspect during the gas-freeing operation and a number of
precautions should be taken. Roads should be closed, areas roped off and warning signs
posted as appropriate. Special consideration should be given to low areas where hydrocarbon
vapours may collect.
Admission of personnel and equipment to the affected area should be minimized and strictly
controlled. It is, however, necessary that regular control and inspection be carried out by a
competent person, who should have the resources and authority for quick intervention.
Potential sources of ignition shall be prohibited in the affected area. Close liaison should be
maintained with neighbouring operational departments. In cases where tanks being gas freed
are located close to a site boundary the required liaison and recommended precautions may
have to extend to third parties.
It is recommended to install a wind sock or other means to check on wind direction and
strength.
During thunderstorms, at very low windspeeds, or during periods of substantial fog in the
area, the gas-freeing operation should be stopped. Where practicable, i.e. time permitting, all
large tank openings should be temporarily covered or closed, except those which are
essential for normal tank breathing.
Consideration should be given to providing lightweight non-metallic covers of the proper size
to allow fast and easy covering of tank openings.
5.3 Gas-Freeing Methods - General
Gas-freeing of storage tanks entails the removal of the hazardous tank atmosphere through
replacement by clean air. Oxygen shall never be used for gas-freeing.
A variety of methods can be applied for gas-freeing depending on local circumstances and
the particulars of the tank concerned. In 5.4. to 5.8. brief descriptions are given of commonly
applied methods, together with specific safety precautions.
During gas-freeing the tank atmosphere may be in the flammable range for a period of time.
To shorten this period rapid gas-freeing rates are generally recommended.
However, depending on the tank environment, the concentration of the vapours and weather
conditions, it may be preferable to decide otherwise and to reduce the rate of vapour
expulsion from the tank by limiting the number of tank openings used or by partially closing
them off. A balanced decision should be taken on each occasion and this may be modified as
circumstances change.
Most hydrocarbon vapours are heavier than air and tend to concentrate near the ground both
inside and around the tank.
It is therefore preferable for the vapours to be discharged at high level, such as the tank roof,
which will promote dispersion to the lowest possible concentration in the area around the
tank.
Low level apertures of the tank, such as shell manholes, should remain closed during the gas-
freeing process if at all possible.
Opening of manholes should be done carefully and only after any possible internal over or
underpressure has been equalized by the opening of smaller apertures, such as dip hatches
or drain nozzles.
If it is necessary that shell manholes or comparable low level apertures are opened
for gasfreeing purposes, it is recommended that roof manholes are opened first, followed by
the cautious opening of smaller shell apertures, before the larger shell manholes are
opened. Provisions must be made to prevent people from entering the tank.
Depending on the product stored, the opening of large low level apertures of non-gas-free
tanks may require the use of breathing apparatus and surveillance from a safe distance by
other staff who have additional breathing equipment, life lines etc. ready for immediate
deployment.
Before any shell manhole is opened the possible presence of high sludge levels should
be checked by sounding from the tank top where possible.
Working on tank roofs should be minimized and shall be subject to the precautions described
in 3.3.4.
5.4 Gas Freeing Fixed Roof Tanks
5.4.1 Water Displacement
With this method the tank vapours are displaced via open manholes or other vent openings
on the roof by filling the tank with water, after which the water is drained so that air can enter.
In general this method is comparatively safe but often less practical for large tanks owing to
the quantities of water required and to be disposed of.
The tank should be filled from a connection near the bottom or via a top connection with an
internal downpipe to near the tank bottom.
To avoid generation of static charges the initial filling rate should be slow until the inlet nozzle
has been completely covered.
Free fall, splashing and jetting must be avoided during the whole filling period.
The water level in the tank must be limited to the cylindrical part and consequently vapours
remaining in the roof space may still cause the tank atmosphere to be unsafe after drainage
of the water.
Before the tank is filled with water the design and condition of the tank and its foundation
must be checked as to their suitability to withstand the forces exerted by the completely
water-filled tank. In certain cases the water level may have to be limited to less than a
completely filled tank. Also the venting capacity must be checked to prevent over
pressurizing.
It should be ensured that the drainage system of the installation can deal with the amount of
potentially contaminated water released from the tank and that the capacity of treating
facilities will not be exceeded. It is essential to check that during drainage, the openings
available for ingress of air are clear and sufficient to prevent the tank being sucked in.
Precautions must be taken to prevent backflow of water from the tank into the supply system
in the event of a reduction in the supply pressure.
Valves or other means must be installed at the tank shell or tank top as applicable
applicable, to enable the flow of water to be stopped and to avoid uncontrolled outflow by
draining or syphoning in case of failure of any flexible hose or pipe etc. used for the water
supply.
5.4.2 Inert Gas Purging
With this method the tank atmosphere is dispersed and displaced via vent openings on the
tank roof by purging with inert gas. After the inert gas has displaced the original vapours, the
operation can be terminated. The inert gas atmosphere is then displaced by air.
The scope for applying inert gas to atmospheric pressure type storage tanks is limited. It may,
however, be applicable in special cases where air, water or steam can have adverse effects
on the tank. Each application will require special study and may require particular
precautions. Some more general precautions are listed below.
Inert gas is hazardous to man and special care is required to avoid exposure of personnel to
inert gas emissions, e.g. from openings in the tank or inert gas supply lines and connections.
Breathing apparatus must be made available and used as required.
Inert gas should be admitted to the tank either via a bottom connection or via a roof
connection provided with a duct to near the tank bottom as described under 5.4.4. To
minimize by-passing effects of the light inert gas, only relatively small apertures on the tank
roof should be opened for venting.
Caution is required in the selection of inert gas to be used. Carbon dioxide, when expanding
from cylinders, will tend to form a mist of particles (ice) which is highly electrically charged
and therefore can be a source of ignition. For this reason inerting with carbon dioxide from
cylinders is not recommended. When flue gas is used, electrical charges can accumulate as a
consequence of small soot particles in the flue gas.
The quality of these types of inert gas must therefore be checked before they are used to inert
a tank of which the atmosphere may be in the explosive range.
Nitrogen is suitable under all circumstances but must be added at a slow rate and at low
nozzle speeds to avoid accumulation of any static charge on insulated tank internals
transmitted via moisture in the tank atmosphere.
Access to a tank roof when inert gas purging is in progress should be prohibited.
5.4.3 Steaming Out
With this method the tank atmosphere is dispersed and displaced by steam. After termination
of steaming the steam is left to condense, thereby allowing fresh air to enter the tank. At least
one roof manhole must always be left open during and after steaming and during any
interruption, in order to avoid any excessive pressure differentials, which might damage the
tank.
Because of the possibility of static charge build-up, gas-freeing by steaming is not normally
recommended for large tanks, where it is also often impractical due to the volumes required.
Reference is made to the SSC Guide on Static Electricity, see Appendix 5.
Where steam purging is used, all fittings and nozzles must be properly earthed and bonded to
the tank. It cannot be assumed that this situation already exists as regards the tank normal
fittings owing to e.g. gaskets.
To minimize the risk of static electricity generation in the tank, the steam must be dry or
superheated at the point of entry into the tank, but kept below 200°C to avoid the risk of auto-
ignition of vapours. Condensed water should be cleared from the line. The line should be
preheated if at all possible to avoid the formation of further condensate and a condensate trap
should be fitted close the nozzle.
To compensate for condensation in the tank, the rate of application should ensure that the
tank temperature is raised to approx. 75°C as fast as possible.
Exposed steam coils or other internal tank heating equipment shall not be used, however, to
help raise the tank temperature.
Steam should be introduced near the bottom of the tank.
Arrangements should be made to drain condensed steam from the tank, which may be
contaminated.
5.4.4 Natural Ventilation
With this method air is allowed to enter the tank directly by natural draught whereby the tank
atmosphere is gradually diluted and displaced until it is safe for entry. See Figure 1.
Multiple roof manholes should preferably be used for natural ventilation. If only one manhole
is available additional top connections (gauging tubes, sampling hatches etc.) should be
opened. To minimize short circuiting the apertures used should, however, be as far apart as
possible.
For better effect an upwind manhole may be fitted with a windsail and a downwind manhole
with suspended flexible ducting reaching down to near the tank bottom or sludge level.
It should be ensured that the flexible ducting is prevented from flattening (e.g. by means of
hoops).
If gas freeing using only tank roof openings is considered insufficiently effective in the
prevailing circumstances, shell manholes or comparable low elevation apertures can
be used in addition. In that case the precautions outlined under 5.3. apply.
5.4.5 Forced Ventilation
This method is similar to natural ventilation but the flow of air is increased by artificial means.
See Figure 1.
For creating a forced draught an air blower can be installed in a roof manhole either forcing
air to the tank bottom through a suspended duct leaving other roof opening(s) open for vapour
release or forcing air into the tank top and providing another roof manhole with a suspended
duct.
A further method is to install an air blower on one of the shell manholes, thereby
forcing vapours out through a roof manhole. In that case all other tank bottom/shell
apertures should be kept closed. The blower can also be placed some distance away from
the tank, preferably upwind and outside the bund wall. In such cases a non-static-
accumulating duct can be used between the blower and the manhole.
Air blowers shall only be started after it has been checked that all connections have been
made properly and that the fan of the blower rotates in the correct direction.
Proper electrical bonding and earthing between the blower, any ducting and the tank
shell shall be ensured.
For creating induced draught a venture type air or steam operated educator can be placed in
one of the roof manholes, with a flexible trunk extended to near the tank bottom. The other
roof apertures are kept open for air entry.
In all cases of forced air ventilation a careful check is required that sufficient shell or
roof openings are used to avoid the build-up of unacceptable over or under pressure in the
tank.
All equipment used such as fans, blowers, eductors, etc. must be in accordance with the
requirements of 3.5. The installation of equipment on opened manholes of a non-gas-free
tank is a hazardous operation which must be done with extreme care, using breathing
apparatus, and wetting by water hose, wet sacks etc. to minimize the risk of accidental
sparking.
5.5 Gas Freeing Floating Roof Tanks
In the case of floating roof tanks three separate but partly interconnected spaces have to be
dealt with, viz. the enclosed tank space under the (landed) roof, the air space above the roof
and the spaces inside the pontoons or double deck.
Gas-freeing efforts should primarily be aimed at the enclosed tank space since it is the main
source for creating vapours above the roof. For gas-freeing of this space, the methods
described for fixed roof tanks may be applicable. If roof manholes connecting to the tank
space under the roof are available these should be opened. The access of personnel onto the
roof shall be subject to the precautions of 3.3.6.
However, owing to the low and wind-protected position of the roof, natural ventilation via roof
manholes only is unlikely to be effective and one or more shell manholes should be
opened additionally for either natural or forced ventilation as described in 5.4. Where no roof
manholes can be used two or more shell manholes should be opened, where
necessary with blowers or eductors on one of these. When eductors or blowers are used it
must be checked that the space under the roof cannot be subjected to too high pressure or to
vacuum by e.g. ensuring that other manholes, roof vents, etc. are open or that roof seals
leave adequate free gaps.
When vapours are to be released in large volumes and at low level it must be ensured that
this can be done safely. Alternatively a duct to lead such vapours to a higher point of
discharge may be needed.
To allow gradual dispersion of any vapours left in roof pontoons or double deck spaces the
manholes of such spaces should be opened after the space under the roof has been gas-
freed. Roof drains must be checked for the presence of vapour.
When the enclosed tank area under the floating roof has been gas-freed it is to be expected
that the space above the roof will become gas-free by natural draughts and air circulation.
However, in certain circumstances e.g. with tall tanks, with particularly low wind speeds or
where time demands, additional ventilation of the space above the roof may be required. In
such cases an eductor or blower mounted at the tank rim with a duct lowered to the roof can
be used to displace vapours over the side of the tank. Alternatively, where roof manholes are
available, ventilation from the space under the roof can be continued for some time by
keeping open one shell manhole, preferably provided with a blower.
Persistent vapour accumulations can be expected under wind protected areas of the floating
roof seal especially when secondary seals are applied. This space should be carefully
monitored and if necessary a number of secondary seal plates or weather shields should be
removed to allow air to circulate through the annular spaces.
5.6 Gas Freeing Fixed Roof Tanks with Internal Floating Covers
In general the tank space above the floating cover and the space under the cover should be
considered separately for gas-freeing, gas testing etc. since it may not be possible to enter
the tank from above for opening any available manholes in the cover unless the space above
the cover is found to be safe for entry. Even if the space above the cover of a non-gas-freed
tank is found to be safe for entry, the use of self- contained breathing apparatus is still
required since the vapour concentration at lower levels can be expected to be higher than that
measured from above through roof top openings. Furthermore, some designs of internal
floating covers may trap product or vapours in their materials of construction. In such cases,
apparently gas-free tanks may still be hazardous.
Gas-freeing of the space under the floating cover, which is the source of any vapours, should
always be done first. The procedures and precautions described for open top floating roofs in
5.5. are also applicable in this case, but are limited to those methods where no use is made of
roof manholes.
A windsail at the manhole may expedite gas-freeing of the space above the floating cover.
Otherwise a forced or induced draught may be applied via the roof manhole, generally as
described in 5.4.
5.7 Gas Freeing Horizontal Tanks
These tanks are usually of relatively small size. Water displacement or steaming, inert gas or
air ventilation may therefore all be applicable methods with procedures and precautions
similar to those described in 5.4.
When no permanent facilities exist for safe access to the tank top and/or for safely carrying
out work at the tank top (e.g removal of manlids and mounting equipment), temporary
facilities must be provided before any other work can commence.
When tanks are partitioned no access should be allowed unless the complete tank has been
emptied and gas-freed.
5.8 Special Cases
For any tanks not clearly falling into the above-mentioned categories, general
recommendations cannot be given. It will be necessary to study each case on its merits and
advice from specialists should be obtained.
Particular care is required in the case of tanks built in enclosures such as rock caverns, since
direct vapour dispersal to the environment may then not always be possible. In such cases
additional ducting for both fresh air supply and discharge of vapours to a safe location may be
necessary.
Other tanks requiring special consideration are those which have a protective wall made of
concrete or brick, thereby creating an annular space around the tank in which hazardous
vapours may accumulate.
5.9 Control of Pyrophoric Deposits
If a tank has been in contact with any material containing hydrogen sulphide or other sulphur
compounds, there is the possibility that pyrophoric scale is present on the roof and walls. Also
the accumulated tank bottom sediment may contain such pyrophoric constituents. This
applies in particular to tanks which have been held under oxygen-depleted atmospheres with
a very low (less than 3-4%) oxygen content.
To avoid the possibility that suspected pyrophoric deposits will heat sufficiently (by rapid
exothermic oxidation) to become a source of ignition in the presence of a flammable
atmosphere, and may ignite other deposits in the tank, gas-freeing must proceed with
particular care.
It is difficult to predict the presence of pyrophoric deposits. However, reference can be made
to any cleaning and corrosion records of tanks in similar service and to those showing the
history of the materials stored in the tank in question.
Wherever the presence of pyrophoric deposits in the tank is suspected, the lower part of the
tank, which normally remained liquid covered whilst in operation, should be emptied very
slowly during decommissioning. During the entire gas- freeing period, water-flooding or water-
spraying of the tank bottom sediments is recommended.
When air ventilation is used for gas-freeing tanks which were inerted in service, natural
draught is preferred. It should proceed at a restricted rate to let the oxygen level in the tank
rise slowly, thus allowing any pyrophoric material in contact with air to re-oxidise at a
harmless rate.
Where tanks have been blanketed with a flammable product, such as methane, gas-freeing
with air is not normally recommended when there is also any risk of pyrophoric material being
present. In such cases other methods such as water-displacement (see 5.4.1) are preferable
or, alternatively, temporary use of a truly inert gas should be considered to reduce the
possibility of an ignition.
After the tank has been entered, the wetting of deposits must continue until they have been
removed from the vicinity of the tank for safe disposal.
5.10 Gas Testing
5.10.1 General Points
Gas testing for both flammable and toxic vapours as well as for oxygen levels must be carried
out at several representative places by an authorized and competent person, before anyone
is allowed to enter a tank which is being prepared for cleaning. This must be repeated
periodically or continuously, depending on the prevailing circumstances, whilst cleaning is in
progress. Results of the tests should be recorded.
It is stressed that flammable or toxic vapours may emerge even in gas-freed tanks when
sludge or scale is disturbed. This may call for high-frequency or even continuous monitoring
of the tank atmosphere until all sludge and other deposits have been removed.
It is to be noted that monitoring equipment can be adversely affected by low temperatures

(e.g. below zero Celsius) and suitable apparatus should be selected to cater for such
circumstances.
5.10.2 Flammable Gas Detection
The combustible gas indicator used must be suitable for use in the type of vapour to be
tested. Where the tank has contained leaded product, the instrument must be designed to
function accurately in leaded gasoline vapour. In addition, the instrument must have been
recently calibrated according to manufacturer's instructions.
5.10.2.1 False Readings
To avoid false readings or misinterpretation of readings when using a flammable gas detector
for assessing the vapour concentration in a storage tank prior to entry for cleaning, the
following points should be borne in mind:
(1) Readings on the instrument are not instantaneous and there is a time lag between
aspirating the sample and a reading appearing on the instrument scale. The delay will
depend to a degree on wind conditions in open air situations and on the length of the
sample probe or tube. It is important that, with respect to sampling probes or tubes, the
manufacturer's instructions are adhered to.
(2) Vapours such as hydrogen sulphide, tetraethyl lead (TEL), tetramethyl lead (TML) and
silicones can poison, totally or partially, the instrument's detection system. Explosimeters
are available which will respond accurately in hydrocabon atmospheres containing such
contaminants.
(3) The instrument will give erroneously low readings in an oxygen-deficient atmosphere, in
high humidity conditions and at ambient temperatures significantly different from that at
which it has been calibrated.
(4) In hydrocarbon-rich atmospheres the meter needle may initially go to full scale but
immediately return to zero. If the scale is not continuously observed, this movement will
go unnoticed, thus giving rise to misinterpretation of the actual vapour concentration in
the tank at the point of test.
(5) Where long sampling lines are found necessary to test tank atmospheres, artificially low
results may be obtained owing to absorption of the hydrocarbons on to the walls of the
sampling tube.
(6) High flash point products contained on the tank wall give off flammable vapours when hot
but these will condense in the instrument without being detected by the measuring circuit.
5.10.2.2 Testing during Gas-Freeing
The manner in which vapour tests are carried out during gas-freeing both in and around tanks
will vary depending on the type of tank, method of ventilation, type of product previously
stored in the tank and many other variable factors. For these reasons it is not possible to
define a rigid procedure but the following guidelines should be considered:
(1) Fixed roof tanks
Where mechanical or natural ventilation techniques are employed, tests for flammable vapour
concentration should be made at the point(s) where the vapours are being discharged to the
atmosphere. In addition, frequent checks should be made at grade level around the tank and
the surrounding area to ascertain if any hydrocarbons are collecting.
(2) Fixed-roof tanks with internal floating covers
Entry into the space between the fixed roof and the floating cover for inspection and testing
purposes shall not be made until the vapours are below 25 % of the LFL and then only by
personnel wearing breathing apparatus and fitted with a life line. Further tests can then be
conducted to ascertain concentration of flammable vapours, toxic substances and oxygen.
(3) Open-top floating roof tanks
When eductors are fitted to the roof manways on the tank and the vapours are ducted to the
rim of the tank shell, tests should be carried out at this point. Where vapours are
discharged onto the roof of the tank (large floating roof tanks it will be necessary to enter onto
the tank roof to carry out the tests. This shall only be done by personnel wearing breathing
apparatus and having effective rescue facilities.
5.10.3 Toxic Vapour Monitoring
5.10.3.1 General
To conduct meaningful tests for the presence of toxic vapour in a tank, it is necessary to have
information concerning the products previously stored in the tank.
Tests for toxic substances conducted at tank manways or hatches are not always satisfactory
and it is therefore necessary for an accurate assessment to be made by personnel entering
the tank when sludge levels permit. Such entry shall only be made by personnel wearing
suitable breathing apparatus, protective clothing and having effective rescue facilities. The
results of these tests must be interpreted by a competent person.
5.10.3.2 Leaded Gasoline Tanks
Tanks that have contained leaded gasoline may contain TEL and/or TML in sufficient
quantities to present a serious health hazard even though the tank may be hydrocarbon
vapour-free and safe from fire, explosion and asphyxiation hazards. Therefore a number of
specific precautions are necessary (See Section 7.5.).
5.10.4 Testing for Oxygen
After a tank has been gas-freed, cleaned or closed for an extended period of time, the
atmosphere shall be checked for oxygen deficiency before entry without breathing apparatus
is permitted. The oxygen level must be at least 20.0% before unprotected personnel may
enter.
6. CLEANING PROCEDURES
6.1 Initial Cleaning from Outside the Tank
6.1.1 General
The general practice in all tank cleaning should be to keep the time spent inside the tank to a
minimum.
After pumping down to minimum level, the tank may be flushed with cold water and the
bottoms pumped out. Alternatively, depending on type, the product may be floated to allow
skimming by suction from an available point or suitably adapted manway. Water must be
introduced slowly, without splashing, to minimize mixing with the hydrocarbons and to avoid
generation of static electricity. Ref SSC Guide on Static Electricity.
6.1.2 Crude Oil and High Viscosity Oils
These products are particularly susceptible to the deposition of large amounts of material on
the tank bottom, the amount of which can be minimized, however, by installing and operating
side-entry propeller type mixers (or other equipment with similar effect) during normal
operation with the tank.
After pumping down to minimum level, the tank may be flushed with hot water, or cold light
product, or a light crude oil type in the case of crude oils.
After flushing or circulating, the tank may be plumped out to achieve the lowest level. If the
tank is fitted with heating coils, they may be used (provided that they remain fully covered) to
improve pumpability. Overheating must be avoided.
Care must be taken when circulating using temporary lines and nozzles, that the discharge
point is kept submerged in the liquid at all times. A jet breaking the surface may produce
static generation problems (see Section 2.2.1.2.).
Despite the above preventive or corrective activities, there may still be substantial volumes of
residue remaining in the tank.
Any method of removing residual material from the tank which reduces the time personnel
must spend in the tank, contributes to the safety of the tank cleaning operation.
Resuspension techniques are commercially available which utilize submerged jet technology
to resuspend the hydrocarbon sludge in its parent product or in a lighter product. Chemicals
may or may not be an integral part of the resuspension process.
Certain techniques claim to resuspend sludge by jetting from above. In this instance it is
imperative that an inert atmosphere is maintained in the vapour space above the sludge for
the duration of the operation (see Section 2.2.2.3. - Static electricity).
Remotely-controlled mechanical equipment is commercially available which can reduce the

time personnel must spend in the tank (see Section 3.5.6.11).
6.1.3 Cleaning through Open Manways
Where conditions allow, it may be possible to work through an open manway to carry out
certain cleaning work before entry is necessary. This method should normally be limited to
tanks which have passed appropriate gas-freeing procedures (see Section 5.1). Appropriate
ventilation should furthermore be maintained during this cleaning activity. If during the
cleaning activity it is found that flammability inside the tanks is increasing about 25% of LFL ,
the operation must be discontinued until safe conditions have been restored.
Liquid and sludge levels may be reduced by placing a pump or vacuum truck suction hose
through the open manway and remotely controlled hydraulically-driven machines may be
introduced to assist the gathering of non-flowing, pumpable sludge.
Small tanks may be cleaned through top manways using a 360° rotating nozzle lowered
inside. Hot water under pressured, in certain cases with chemical addition , is passed
through the machine which produces a cleaning jet and activates the rotating mechanism
(see Section 2.2.1.2 for static electricity hazard).
6.2 Working Inside the Tanks
6.2.1 General
From a safety viewpoint it is desirable to maximise the cleaning of tanks without entry of
personnel , but it is not usually possible to achieve the required degree of cleanliness in this
way. Final internal cleaning, requiring people to work inside the tanks, will be necessary.
The effort and time required and the applicable techniques vary, subject to e.g. the product
concerned, local conditions and the required final standard of cleanliness. The latter may
range from simple clean-out of liquid and sludges to a high grade clean finish for e.g. internal
painting or hot work.
6.2.2 Conditions for Entry
All tank entries must be covered by appropriate work permits.
Permissible levels for lower explosive limits and petroleum vapour concentrations for tank
entry.
Combustible gas indicator

scale reading (scale Conditions of entry and work
graduated 0-100% of LFL)
a) Less than 1 Safe for men to enter 1) and carry out hot or cold work without
breathing apparatus provided oxygen content is not less than 20%
b) Between 1 and 4 Safe for men to enter and carry out inspection and cold work
without breathing apparatus , providing oxygen content is not less
than 20%. Unsafe for hot work.
c) Between 4 and 25 Entry only with breathing apparatus. Inspection and cold work only
permitted.
d) Greater than 25 Entry not permitted except in an emergency. In such circumstances

special authorization is required and breathing apparatus must be
worn.
Under conditions a) and b) above, tests must be carried out for the presence of any airborne
toxic substances , e.g. alkyl lead, benzene, H2S. If the airborne concentrations are greater
than 50% of the published occupational exposure limit for the substance(s) in question ,
appropriate air-supplied respiratory protection must be worn until such time as the tank has
been sufficiently ventilated (See Section 3.5.3. ref. restriction on the use of adsorption type
filter respirators).
1) Note: Breathing apparatus must still be worn when carrying out hot work in leaded gasoline tanks.
6.2.3 Access Ways to Tanks
Usually tanks can only be entered via opened shell manholes and/or similar apertures
created by the removal of large valves or tank mixers.
The minimum permissible number of access ways is two, placed at diametrically opposed
locations on the tank shell or at least as far apart as possible. However, the opening
up of the maximum number of suitable apertures is strongly recommended, both for reasons
of personnel access and escape and for increased ventilation.
Some tanks are provided with removable clean-out doors which will ease the cleaning
operations.
It is not recommended to create temporary clean-out ports by removing plates from the tank,
unless this can be done by methods which do not create sparks, flames or hot surfaces.
If plates are removed, it shall be verified that this is allowed by any national or local
regulations and that the structural integrity of the tank and/or the properties of the tank plate
material are not adversely affected. It is essential to obtain appropriate professional advice
and authorization on this matter.
6.2.4 Preparations and Checks for Entry of Personnel
Before work starts, the interior of the tank must be inspected for any materials which might
fall, such as scale, loose rafters, angle irons or columns and to ensure that swing lines have
been lowered to the tank bottom or that they are properly supported by angle frames. It
should also be ensured as far as possible that any hazardous obstacles projecting into the
tank from the side (such as propeller mixers, instruments etc.) have been removed.
A checklist will assist in confirming once again that the necessary safety measures in
preparation for and during tank entry have been carried out. This checklist should include the
following points:
(1) Ensure that all process and utility fines to and from the tank have been positively
spaded, blanked or disconnected (see Section 4.2.2) and that all manholes have
been opened to provide the maximum number of escape routes.
(2) Confirm that all gas tests (flammables, toxics and oxygen) have been carried out and
that these have been recorded on the work permit. If the results of these tests
indicate that respiratory protective equipment is required, ensure that this is readily
available.
(3) Before any person enters a tank to carry out cleaning, the appropriate work permit,
duly authorized, must be issued. The work permit must specify the relevant safety
measures to be taken, the protective clothing and equipment to be worn or made
readily available and the duration for which the permit is valid.
(4) In the event that an electrical storm prevails or is expected while a tank entry permit is
in operation, the permit should be suspended. No person shall be permitted entry into
or onto the tank.
In areas where very high wind speeds may occur (e.g. in hurricane areas), all tank
cleaning activities must be stopped during the time that such high winds prevail or are
expected, and any relevant work permit issued must be withdrawn. Flooding the tank
bottom and/or partially refilling the tank with water may be required under certain
circumstances to ensure stability. See also Section 3.3.9.
(5) Where personnel entry into non-gas-free tanks has to be undertaken, it must be
ensured that there are always two people on duty outside the tank. One of these
should be stationed at the entrance manway keeping in communication with the
people in the tank. He must be equipped with a means to raise an alarm and obtain
assistance. He must also be provided with an air-supplied respirator for emergency
use and should hold a second unit in readiness. Use of a lifeline should be
considered.
The second person outside the tank is responsible for ensuring a continual and
satisfactory air supply from the compressor unit to the people in the tank.
(6) Even where a vessel is gas-free and well ventilated, it shall be ensured that a safety
observer is in attendance when anyone is working inside the tank.
(7) Ensure that the breathing air compressor unit is located upwind of the tank, that the
air inlet to the compressor is upwind and remote from the engine exhaust (see
Section 3.5.4.1).
(8) Ensure that all pyrophoric sludge or scale is promptly removed from the immediate
area of tank cleaning and kept wet until safely disposed of.
(9) Take measures to monitor the ambient conditions in the tank. It may be necessary to
seek professional advice to avoid the potential for heat stress.
(10) Ensure that only approved lighting is used in the tank (see Section 3.5.2).
(11) Lighting in the tank bund must also be of the approved type (see Section 3.5.4.3).
(12) Ensure that only tools and equipment as specified on the permit are used in tanks
that are not gas-free.
(13) Check that tank cleaning personnel are equipped with the appropriate protective
clothing.
(14) Ensure that fire-fighting equipment as specified on the permit is available at the tank
site before cleaning commences and that all personnel involved are familiar with its
operation.
(15) Before any cleaning work commences, check that all mobile pumping equipment is
located upwind of the tank, and that spark arrestors and overspeed shut-off devices
are fitted. Also check that the area around the equipment is free from flammable
vapours before the equipment is started up. To assist in the maintenance of a gas-
free area in the immediate vicinity of the tank, ensure that all hydrocarbon vapours
from the tank are released at the roof.
(16) Do not allow smoking inside the tank or in the surrounding area at any stage of the
operation.
(17) Check that the power supply to any cathodic protection system to the tank is
disconnected at least 24 hours before any work is permitted.
(18) When a tank is left unattended either during meal breaks or overnight, ensure that
NO ENTRY signs are erected at any open manways. When a tank is left unattended
for longer periods, barriers should be installed to prevent entry by people or animals.
(19) If either steam or water jets are used during the early stages of tank cleaning when
the tank is not gas-free, ensure that all precautions are taken to avoid any static
electricity build-up (see Section 2.2.2.2).
(20) Manual tank cleaning operations during the hours of darkness should be minimised. If
such operations are to be carried out, check that exits are clearly marked and that
emergency lighting is available in case of a power failure.
(21) Showering and washing facilities should be provided nearby where practicable.
6.2.5 Tank Internal Hazards
Despite the preparatory measures that have been recommended earlier in this Guide, the
following general conditions and hazards should continuously be observed and taken care of.
The hazards which may exist are dependent upon the product stored and the physical
characteristics of the tank and the nature of the work to be done. For specific information see
Chapter 7.
The physical characteristics of tanks vary, but generally all tanks present the cleaner or
inspector with slip, trip or fall hazards.
Even when forewarned, orientation inside the tank may be lost and the personnel put at risk.
The hazards fall into the following groups:
- Sumps
These may be at the side or in the centre of a tank. Centre sumps are not normally of
major concern but all operatives should be informed of their existence. When covered, in
sludge or liquid, they can cause serious injury.
After studying information on the tank interior, the first person to enter should be issued
with a rod or squeegee and be sent to locate the sumps.
Once located, the sump may be marked out either by bunting around the nearest legs to
the sump or by cones if practicable.
- Pipework and heating coils
These are usually more apparent but all operatives should be informed of their existence.
- Floating roof landing height
The landing height of the roof plays a major role in the cleaning operation, both in terms
of time and in operatives' safety and welfare. Landing of the roof below maintenance
height is not generally acceptable for tank cleaning activities. In the extreme cases when
this is necessary, special precautions should be taken.
- Internal covers
When access to the top of an internal floating cover is required, it should be protected by
planks. It is essential to check the design of the cover to ensure that it is capable of
carrying personnel.
All personnel must furthermore continuously be protected against the known risks, which
include, but are not limited to, the following:
- Ingestion
Personal hygiene measures.

- Inhalation
Breathing apparatus appropriate to the task.
- Absorption
Protective clothing (including goggles) and personal hygiene measures.
- Explosion risk
Appropriate equipment and lighting, and testing of the atmosphere.
- Hearing
Ear defenders, particularly when grit blasting.
- Slipping
Special attention to avoid slipping should be taken particularly in lined tanks. Boards etc.
may be laid on the tank floor in certain cases to minimize this hazard.
- Falling
When work is necessary at height, properly designed and erected scaffolding shall be
used, ref SCC Guide on scaffolding. In certain circumstances it may be necessary also to
use harness and lifeline.
- Retained Liquid
Examples of locations where flammable liquid may be retained and when released cause
gas-free conditions to be negated (see Section 2.2.1) are:
∗ under sludge
∗ inside legs of floating roofs (see 6.2.8)
∗ in shaft housings of agitators
∗ in hollow or concave structural sections of roof trusses
∗ under the tankfloor due to leaks or residue from previous leaks
∗ in hot oil coils.
All personnel working inside the tank should be detailed their specific tasks by the supervisor
and should operate within sight of one another and of the safety observer.
Where entry to pontoons is necessary, a harness and lifeline may have to be wom in addition
to the protective clothing and equipment specified.
It should be noted that the use of lifelines in large diameter tanks is not normal practice.
Although technically possible, in practice lifelines, trailing air lines and hydraulic or pump hose
can become tangled, thus reducing the ease of rapid escape in an emergency, particularly
when roof support legs or columns are numerous.
6.2.6 Emergency Procedures
It is recommended that cleaning crew demonstrate their escape procedures before starting
the cleaning operations.
As a minimum, the safety observer (ref 6.2.4, point 5) must have an air horn plus a spare
charged air cylinder to raise the alarm should compressor failure occur or a nearby alarm be
raised.
Methods of signalling such as tugging air lines or lifelines can easily be mistaken due to the
frequency of false alarms triggered by normal movement.
The preferred method is of teams working in sight of each other. The tank custodian must
satisfy himself that a practicable system of alarming is in operation.
6.2.7 Safety Helmets
Safety helmets should normally be used at all; times. However, in exceptional circumstances,
e.g. where breathing apparatus and full protective clothing including hoods are wom, special
measures will need to be taken to provide effective head protection.
Full air-supplied suits have a built-in head protector, but these suits should be limited only to
the most extreme conditions, owing to their inflexibility which restricts the wearer's movement
and necessitates full body tums for vision to the sides or rear.
6.2.8 Floating Roof Supports
In all cases roof legs should be cleaned by hydrojetting through the drainage hole at the foot
of the leg.
If the drainage hole or rodding points are not available, it may be necessary to jack up the
legs to facilitate internal cleaning.
This operation should be carried out in a methodical manner where each leg is jacked
individually after proprietary props have been placed, if necessary, next to the leg to be
jacked. Baulks of timber should be placed at the top and bottom of each prop. This will not
only avoid damage to the tank floor and roof but, if done correctly, obviate any collapse which
may result in the prop puncturing the relatively thin gauge roof plates.
Care should be taken, when props are placed, that the roof remains level and is not itself
jacked out of position as this could conceivably cause 'Domino' style collapse of other legs
and bring the roof down.
In all cases a thorough inspection of all other internals must be made and they should be
cleaned where required, e.g roof drains, coils, suction and discharge lines.
6.3 Final Cleaning Procedures
When a tank has been cleaned by removing all liquid, residues and sludges, it may still be
necessary to continue with more intensive internal cleaning techniques.
Apart from manual scrubbing of e.g. welds and plate laps and the removal of the last
remainders in tank internals and secluded spots, this final cleaning may be required to
remove the last remaining greasy or sticky contaminations on tank walls and bottom so that
e.g. subsequent hot work can be safely carried out.
For this degree of cleaning several methods are employed:
- hot water washing
- cold water spraying or jetting under high pressure
- steam jetting
- gas oil washing
- chemical wash or wipe, using detergents
- manual wiping with e.g. rags.
The method of cleaning used will depend on the product previously stored in the tank, the
degree of cleanliness already achieved and the local means available.
The hazards and precautions to be taken can be derived from other chapters in this Guide.
However, some additional remarks follow:
- When water is used as a cleaning medium, it shall not be recirculated and used again in
the case of spraying or jetting due to the increased hazard of static charge accumulation
caused by the oily contaminant.
- Steam jetting is not normally recommended when there is any risk of flammability above
1% of LFL remaining anywhere in the tank. Steam must be dry or superheated but below
auto-ignition temperature of the hydrocarbons to be removed. Before steam jetting is
started, all steam lines, hoses etc must be carefully drained free of condensed water.
Steam nozzles must be properly earthed.
- When gas oil is to be used for tank cleaning purposes, its flash point must be checked to
be at a sufficiently high level to preclude any risk of generation of dangerous vapours
produced during its use. Any gas oil washing and/or spraying should only be applied
mildly, under carefully controlled conditions, including continuous monitoring of the
atmosphere in the tank for flammability. Any gas oil remaining on the tank surfaces
should be washed away with water. Spraying of gas oil under high pressure or jetting may
produce a flammable mist and must therefore be avoided. Gas oil must not be heated
and not be recirculated.
- WASHING, SPRAYING OR JETTING WITH A HYDROCARBON LIQUID OF HIGHER
VOLATILITY THAN GAS OIL SHALL NOT BE APPLIED UNDER ANY
CIRCUMSTANCES.
- When chemical detergents are used, either in pure form or diluted in other liquids, a
continuous monitoring of the tank atmosphere may have to be maintained depending on
the flammable and/or toxic properties of vapours generated. A thorough familiarization
with the chemicals and their properties is therefore required, which may also identify the
use of any special clothing.
- Wash water containing chemicals, detergents or emulsified oils may impair the efficiency
of interceptors and separators, and therefore be unsuitable to go to site drainage
systems. It may have to be treated on site or removed for safe disposal in accordance
with national or local legislation.
- Where descaling is required it may be necessary to gritblast, e.g. as a surface preparation

for tank internal painting. As this may produce incendive sparks appropriate precautions
must be applied.
7. PRECAUTIONS SPECIFIC TO PRODUCT GROUPS
7.1 General
This chapter aims to provide a summary of cleaning problems and specific hazards that may
be encountered during the cleaning of tanks used for different classes of products within the
scope of this code. It is to be seen as complementary to the preceding chapters to which
references are made as appropriate.
The products that are stored in tanks and the sediments and residues that may be left behind
can vary widely as regards composition, toxicity etc., especially when taking into account the
increasing use of additives. It is also clear that not all products can be specifically mentioned
in this Guide.
Beyond the general information given in the this Guide, it is therefore essential for the
custodian of a tank to be cleaned, to inform the tank cleaning supervisor about any significant
physical or chemical property of products and additives in the tank. It is the responsibility of
the tank cleaning supervisor that such information is obtained and assessed before tank
cleaning can start and in case of any doubts, to err on the safe side in taking precautionary
measures.
Special attention should be given to tanks which, whilst in non-leaded product service, may
have contained leaded material in the past, see Section 7.5.
7.2 Crude Oils and Condensates
7.2.1 Depending on their origin, crude oils may have widely differing properties which will determine
the way in which they are stored and handled. Certain heavy and/or waxy types of crude oils
are heated during storage.
Usually crude oils are stored in floating roof tanks. However, fixed roof storage is sometimes
in use for heavy crude oils.
7.2.2 A considerable number of crude oils can contain H2S in various amounts. Therefore the
presence of pyrophoric iron sulphide deposits is possible, particularly with crude high in H2S
and precautions should be taken accordingly.
In addition, certain types of crude oil can contain significant amounts of benzene or,
occasionally, they toxic compounds e.g. mercury. This must always be checked before
cleaning a tank in that service.
7.2.3 Many crude oils have a tendency to precipitate sludge on the tank bottom. The composition of
the sludge varies, but it often contains a high percentage of hydrocarbons (e.g. waxy
deposits), together with smaller amounts of inorganic matter such as sand. Good operating
practices aim at minimizing the sludge deposition, e.g. by means of heating and/or various
tank mixing and circulation methods, but nevertheless sludge deposition can be considerable,
forming the major significant aspect of crude oil tank cleaning. The sludge can sometimes be
physically very unstable and inhomogeneous and unequally built up on the tank bottom. This
requires special precautions in cleaning and handling; see also Section 7.7.3. It is essential
before a cleaning operation to assess as accurately as possible the sludge profile and to take
a number of samples at different places.
7.2.4 Crude oils may have a high flammability requiring special attention to gas freeing. The
disturbance of sludge by the cleaning action may release flammable vapours which makes it
essential to monitor the tank atmosphere continuously during cleaning as gas concentrations
may well rise again to dangerous levels. This monitoring should continue until all sludge has
been removed.
7.3 Sweet Light and Middle Distillates
7.3.1 This group includes unleaded gasoline, naphtha kerosine, jet fuels, gas oil and diesel oil (or
their component fractions) which contain insignificant amounts, if any, of sulphur compounds
(mercaptans and H2S).
The presence of special additives is common, however. Both fixed roof and floating roof tanks
are used for these products but the more volatile products (e.g. gasoline or naphtha) are
usually stored in floating roof tanks or in fixed roof tanks with internal floating covers.
7.3.2 Particular hazards related to some or all products in this group include:
- flammability, requiring particular attention to gas freeing and to the monitoring of the
atmosphere during cleaning;
- corrosivity, leading to large amounts of (possibly contaminated) rust in the tank bottom
and a risk of lumps of rust falling from roof trusses;
- biological activity in any water/product bottom layers can sometimes leave a slimy and
slippery layer in the tank bottom. These substances, if becoming airborne e.g. as a mist
during cleaning can have health effects when inhaled;
- certain additives and/or product components (caustic entrainments, benzene, methanol

etc.) are harmless in normal dilution but may be concentrated in the bottom water phase
or bottom residue and become hazardous in such concentration;
- carry-over of processing catalyst from refinery processes can lead to substantial sediment
layers in certain dedicated tanks;
- some products have a low electrical conductivity (e.g less than 50 pS/m), requiring
special precautions with e.g. recirculation during cleaning, water jetting etc. Whilst the risk
of spark generation is still low, such activity must only be undertaken when the vapour
concentration is well below LFL, e.g. less than 10% of LFL.
7.4 Sour Light and Middle Distillates
7.4.1 This group is similar to the previous one but the presence of H2S, mercaptans or other acidic
constituents is a factor of significance.
7.4.2 The hazards are generally similar to those listed in Section 7.3.2, but the presence of H2S can
give rise to the formation and accumulation of pyrophoric iron sulphide deposits, particularly
when the product has been stored under oxygen deficient atmospheres. This requires special
precautions during gas freeing (see Section 5.9) and the need for keeping bottom deposits
wet by spraying or covering with a water layer until removed to a safe location.
7.5 Leaded Gasoline
7.5.1 Leaded gasoline belongs to the product group mentioned in Section 7.3 and consequently the
hazards and precautions mentioned for that group also apply to leaded gasoline tank
cleaning. However, additionally, leaded gasoline contains small amounts of very toxic organic
lead compounds in the form of tetra-ethyl lead (TEL), tetra-methyl lead (TML) or a mixture
thereof.
7.5.2 In normal dilution in the products these additives are not hazardous. However, they tend to
concentrate in tank scale and bottom deposits, making the cleaning of leaded gasoline tanks
particularly hazardous.
Apart from the hazard of contact with these lead compounds during sludge or scale removal
and handling, toxic vapours are also generated from the sludge or scale.
7.5.3 A high degree of attention shall therefore be given to health protection and control of
personnel engaged in cleaning leaded gasoline tanks, to the working conditions in and around
the tank, and to decontamination of any materials, equipment and clothing used.
7.5.4 It is necessary that leaded gasoline tanks are clearly marked with permanently fitted or
painted warning notices adjacent to all manholes.
7.5.5 The meticulous control and careful handling of lead contaminated scale and sludge from the
tank is essential. No spillage is allowed and the disposal of the scale and sludge removed
needs to be specially organized.
7.5.6 Detailed tank cleaning and sludge handling instructions for leaded gasoline tanks have been
published by the major manufacturers of lead alkyls (see Appendix 5). It is essential, when a
leaded tank cleaning operation is contemplated, that the relevant publications of these
manufacturers are studied and that the recommended equipment, materials etc. are obtained
well before cleaning starts. During cleaning the recommended procedures must be
meticulously followed.
7.5.7 Tanks which have contained leaded gasoline but have been transferred to other, non-leaded
product service, or have been taken out of service can, even after thorough cleaning and
many years of non-leaded service still pose a hazard. This is caused by a possible residual
lead alkyl presence e.g. in scale on roof plates or roof trusses and in any paint layers.
It is therefore essential that warning notices (ref. Section 7.5.4) are retained and that all
personal protective measures continue to be applied as if the tank were still in leaded product
service.
These precautions must continue until the tank has been proved free from any lead
contamination. This must be determined by a competent and authorized staff member or a
specialist of the lead alkyl manufacturers on the basis of the results of lead-in-air tests before
and during work inside the tank and of the type of work to be executed.
7.6 Aromatic Products
7.6.1 This group comprises gas oils, cycle oils, aromatic luboil distillates as well as solvents, white
spirits, reformates/platformates and certain special boiling point products, which contain
relatively high amounts (up to 80% in certain cases) of aromatic hydrocarbons including
polycyclic aromatic compounds. They are stored in either fixed roof or floating roof tanks.
7.6.2 General hazards and precautions are similar to those described in Section 7.3.
An additional hazard is the toxic nature of aromatic constituents, particularly benzene, see
Chapter 2.
7.7 Residue Fuel Oils
7.7.1 This group comprises all straight run or converted petroleum residues and the products in
which such residues form the major component. Residual fuel oils are usually stored in fixed
roof tanks.
7.7.2 Depending on origin and/or processing routes residual fuel oils can contain relatively high
levels of toxic contaminants e.g. H2S, polycyclic aromatics (see Chapter 2), traces of metal
(e.g. vanadium, nickel) and additives. The legitimate addition slops/waste oil in certain parts
of the world can further add traces of heavy metal compounds, polychlorinated biphenyls etc.
In normal dilution these additives/contaminants are not hazardous but they may tend to
accumulate in tank deposits and sludge. Some may also be released as vapours during
sludge handling.
It is therefore particularly important that before cleaning, the product history of the tank and
the possible presence of harmful substances are discussed with the tank custodian and
operational staff concerned and that samples of bottom sludge are taken and analysed.
Precautions during cleaning should then be taken accordingly.
7.7.3 Residual fuel oils have a tendency to form heavy and/or sticky sludge deposits on the tank
bottom, tank internals etc., whereas the tank wall may be coated with a thin layer of highly
viscous residue after the tank has been emptied. Sometimes the accumulated sludge displays
a physically unstable nature and unpredictable behaviour, requiring very careful working and
the ability to render immediate mutual assistance.
7.7.4 A specific aspect of residual fuel oils is the usually high storage temperature which may be
well beyond 100°C.
Because of this high temperature operation residual fuel oil tanks are often externally
insulated. During tank operation the insulation material may become contaminated/soaked
with fuel oil (e.g. from spillages) or condensates, e.g. from leaking vent pipes. This situation
constitutes a hazard also during tank cleaning since hydrocarbons absorbed in insulation
material may ignite at temperatures substantially below the normal oil auto-ignition
temperature.
It is therefore recommended that the tank insulation around roof and shell manholes
and any other areas likely to be affected by tank cleaning activities should be inspected
before the tank is opened. If necessary certain sections of the insulation around tank cleaning
work areas may have to be removed.
7.7.5 Because of the nature of the product, residual fuel oil tanks after emptying often leave an
atmosphere inside the tank which is sufficiently below LFL to permit entry of personnel
without special gas freeing being required. However, the presence of toxic gases, such as
H2S, should not be overlooked.
Therefore, safe conditions should never be assumed to exist and appropriate gas tests,
including flammability tests, must always be taken and repeated as necessary (see
Section 5.10.1).
7.7.6 If, during the internal pre-cleaning of residual fuel oil tanks, lighter hydrocarbons have been
used for flushing or dilution, the tank should be classified and handled accordingly, e.g. as
regards gas freeing, and gas testing.
7.7.7 Residual fuel oil tanks may have various internal constructions. Heating coils (steam, oil or hot
water) or other internal heating elements are often installed. These internal heating facilities
hinder manual and mechanical internal tank cleaning.
7.8 Bitumen, Cutbacks and Bitumen Emulsions
7.8.1 Bitumens are heavy viscous liquids which are substantially non-volatile. They are found in
natural deposits but more usually are produced in refineries. They are made in a large variety
of grades which differ widely in viscosity and other properties, the lighter of these being
essentially similar to heavy fuel oils (see Section 7.7). Cutbacks are bitumen of which the
viscosity has been reduced by blending with a diluent such as kerosine. Bitumen emulsions
are dispersions of bitumen in water. Bitumens, cutbacks and emulsions are normally stored in
fixed roof tanks.
7.8.2 Depending on the grade, bitumen tanks are heated to high temperatures (often above 200°C)
and are insulated. Upon cooling down of the tank for cleaning, a bottom layer of solidified
unpumpable product is often formed. Care should be taken to check for possible hot layers of
bitumen below the solidified top crust. In the case of hard grades removal can be difficult but it
is normally dug out by hand using air driven tools, high-pressure water jetting or a special
hydraulically-driven mechanical digger.
Special attention should be given to the heavy layers of solid or seemingly solid bitumen that
may sometimes be present on the inner walls of (uninsulated) bitumen tanks. These layers
are liable to sudden shifts or collapse endangering personnel and equipment in the tanks. In
each case it is essential to carefully assess the nature of the remaining bitumen layers before
cleaning personnel are allowed to enter the tank.
7.8.3 Other hazards related to bitumen tank cleaning are similar to those mentioned for residual
fuel oils in Sections 7.7.2 to 7.7.7. As H2S is often present, the formation of pyrophoric iron
sulphides is likely to occur, particularly when the tank has operated under an oxygen deficient
atmosphere, such as inert gas or steam blanketing.
Additionally bitumens form heavy, sticky carbonaceous deposits on the walls of the tank and
on the underside of roof plates and trusses. As for pyrophoric iron deposits these
carbonaceous deposits react exothermically with oxygen and can attain pyrophoric properties
at high temperatures and when exposed to fresh air. During this process small amounts of
volatile hydrocarbons can be released which render the atmosphere locally flammable and
which can be ignited by glowing pyrophoric deposits.
Usually pyrophoric iron sulphides and carbonaceous deposits are found together.
Whilst the deposits are unlikely to be hazardous from a pyrophoric point of view during tank-
cleaning, they tend to dry out when tanks are taken out of service and form a hazard to
personnel in the tank when large size lumps may fall from the roof area.
7.8.4 Tanks which have held cutbacks may contain volatile residues and condensate which require
precautions as outlined in Section 7.3.
7.9 Lubricating Oils
7.9.1 Lubricating oils exist in a great variety of grades having very different properties, especially as
regards viscosity. They may be products from refinery processes or complex blends. Usually
lubricating oils are stored in fixed roof tanks.
7.9.2 Blended lubricating oils usually contain a number of special additives. These may have toxic
properties. Whilst in dilution in the oil they are normally not hazardous, this should be verified
with the custodian of the tank (see Section 7.1).
7.9.3 The amount of sludge left behind on the walls and bottom of lubricating oil tanks is usually
small. However, it can be very slippery and may contain toxic material.
7.10 Wax and Waxy Oils
7.10.1 Waxy oils contain large amounts of paraffinic compounds having high pourpoints, whilst in its
extreme form the product is completely of that nature. They are usually stored in fixed roof
tanks.
7.10.2 The oils and deposits do not normally have toxic or other hazardous properties. However,
very large amounts of waxy deposit may be left behind on the walls and the bottom of the
tank; see also Section 6.1.2. During tank cleaning lumps or slabs of this material may fall from
the tank walls. Furthermore, the deposits are slippery.
As for bitumen, the presence of residual hot material under a solidified top crust should be
checked.
7.10.3 The removal of waxy deposits often requires the application of heat, e.g. by using steaming in
order to avoid auto-ignition of the deposits, their auto-ignition temperature must be
determined beforehand and the steam temperature controlled accordingly with a wide margin
of safety.
7.10.4 Tankage in this category is usually heated, causing potential hazards referred to in Sections
7.7.4. and 7.7.7.
7.11 Ballast Water
7.11.1 Ballast water carried by tankers is often contaminated with oily residues and must be pumped
ashore for treatment and cleaning before release to sea or river. The water can range
between fully fresh and sea water.
Ballast water tanks include floating roof and fixed roof designs. In some cases the tanks may
have open tops.
7.11.2 The greatest hazard during the cleaning of ballast water tanks is the complete unpredictability
of the residues and sediments left in the tank.
These may contain various types of flammable oil residues, unknown additives and
chemicals, including cleaning agents, having toxic properties.
The silt may release gases (such as H2S, methane, etc. as well as airborne contaminants) as
a result of anaerobic bacterial activity in the tank.
It is therefore essential to obtain representative samples of the tank sediment which should be
carefully analysed to determine tank cleaning precautions.
Ballast water tanks often contain heating coils as well as unusual internal constructions to
improve water/oil separation.
These constructions hinder tank cleaning and may contain numerous locations where
hazardous material may remain trapped after the tank has been emptied.
The tank internals may contain sand or other filtering material, which must be removed during
tank cleaning. Such materials may be as hazardous as the bottom sediments mentioned
above, requiring similar precautions.
7.12 Slops
7.12.1 Slops is the common designation of any liquid product that is collected from drainage,
spillages, ballast water tanks or off-grade product.
7.12.2 The greatest hazard in cleaning slops tanks is the variable nature and composition of the
slops and any deposits formed in the tank. It is therefore essential that, before cleaning starts,
samples of the slops and of any bottom deposits be analysed to assess their composition
including the possibility that they may contain lead compounds. Depending on the outcome
precautions should be taken in accordance with the various chapters of this code.
8. HANDOVER
After a tank has been cleaned, it may, depending on the purpose of the cleaning, remain out
of commission for any length of time or it may be recommissioned directly back to service. In
either case the termination of cleaning should be accompanied by a formal handover
procedure involving the cleaning supervisor, authorized representatives of the subsequent
party (e.g. inspection/maintenance), as well as the site management. It is recommended that
this handover procedure includes checklists as appropriate. In addition, documentation on
any abnormal situations encountered should be prepared and handed over to allow updating
of tank history records.
Recommissioning of the tank will normally be executed under the responsibility of the tank
custodian but it may (particularly in case of recommissioning directly after cleaning) also
involve the tank cleaning supervisor and cleaning personnel. The work concerned is not
strictly included within the scope of the present Guide. However, it is considered useful to
present a review of the most important checks that should be carried out to ensure that
recommissioning can be done safely. (see Appendix 4).
APPENDIX 1A - FLASH POINTS
CLASSIFICATION OF CRUDE OILS AND PRODUCTS
The Institute of Petroleum in the UK and the European Model Code of Safe Practices classifies crude
oil and petroleum products according to their closed cup flash points as follows:
Class 0 Liquefied gases.

Class I Liquids which have flash points below 21°C.
Class II(1) Liquids which have flash points from 21°C up to and including 55°C, handled
below flash point.
Class II(2) Liquids which have flash points from 21°C up to and including 55°C handled at
or above flash point.
Class III(1) Liquids which have flash points above 55°C up to and including 100°C,
handled below flash point.
Class III(2) Liquids which have flash points above 55°C up to and including 100°C,
handled at or above flash point.
Unclassified Liquids which have flash points above 100°C.
It will be noted that Class II and Class III petroleum may subdivided in accordance with the
circumstances in which they are handled.
Unclassified petroleum liquids should be considered as Class III(2) when handled at or above their
flash points.
For countries where ambient temperatures are high enough for the handling temperatures of
petroleum products to rise above 21°C, or in circumstances where products are handled artificially
heated, then liquids which as a consequence fall into Class II(2) or III(2), should be treated as though
they were in Class I.
It is noted that in some countries different classifications may apply.
In Appendix 1B a number of hydrocarbons and oil products are listed, with their flammability
properties, which can be used as markers for each particular case.
APPENDIX 1B - FLAMMABILITY DATA OF AIR/VAPOUR MIXTURES
Table 1: Flammability Data of Air/Vapour Mixtures
* In the source document this is quoted as 1%-6.0%. However, other tests have shown that
UFL may be substantially higher depending on the type, nature and degree of weathering of
the crude oil. For practical purpose it is reasonable to assume that the range is 1%-10%.
** This is not a precise property. It may vary with :

- temperature and nature of surfaces in contact;
- contact times;
- contaminants.
APPENDIX 2 - HEALTH SURVEILLANCE
1.1 Health standards and surveillance
Work in and near tanks can result not only in exposure to potential chemical hazards (e.g.
organic lead compounds, hydrogen sulphide, polycyclic aromatics, benzene, tank cleaning
agents and other chemicals) and physical hazards (e.g. dust, heat and noise) but can also
involve strenuous physical activity due to hard physical labour whilst wearing protective
clothing and breathing apparatus. A certain standard of fitness and health surveillance is
necessary for PETRONAS as well as contractor employed personnel engaged in this type of
work.
1.2 Pre-placement health assessment
Before taking part in tank cleaning activities, personnel should be medically examined to meet
Group standard of fitness. Such standard should include:
(a) A general physical fitness meeting physical demands for the job;
(b) Absence of any disease, ailment or condition which could interfere with the safety of the
employee himself or any other persons (e.g. insulin-dependent diabetes, epilepsy, mental
instability);
(c) Absence of any disease, ailment or condition which could interfere with an adequate use
of personal protective equipment (e.g. cardiovascular or respiratory disease,
claustrophobia);
(d) Absence of any disease, ailment or condition which could make a person more
susceptible to any of the potential chemical physical hazards which he may encounter in
the course of his work (e.g. age, physical condition).
(e) A urinary lead level within the normal range
1.3 Periodic Health Assessment
The type and frequency of periodic health surveillance required will be indicated by the
potential hazards people are to be exposed to.
Any person who has been absent from work with any ailment or disease other than " coughs
or colds" should be cleared by the Occupational Health staff before being allowed to resume
tank deaning activities.
Any person who is involved or has recently been involved in tank cleaning, and who falls ill or
shows unusual symptoms or behaviour should report to his supervisor and consult the
Occupational Health physician so as to identify any possible relationship between his
symptoms and his work.
APPENDIX 3 - TYPICAL CONTENTS OF WORK PROGRAMME
1. Subjects which may be included

- a site plan, specifying the exact location of the tank, its identification, the boundary limits
of the working area and designated access routes;
- a clear description of the responsibilities of each party involved, including both company
and contractor personnel, with telephone numbers, office location etc as appropriate;
- a detailed description of the tank decommissioning procedures;
- a specific list of all items of mechanical and electrical isolation identified by tag numbers;
- a detailed description of the cleaning process envisaged and safety procedures to be
followed;
- any special points resulting from the pre-cleaning inspections and studies;
- handling and disposal requirements of tank sludge, sediments and any other
contaminated materials and equipment;
- a time schedule taking into account the interaction of various activities;
- a list of all equipment and services required throughout the process for cleaning and
support (the latter including lighting, ventilation, tool air and electricity etc.) together with
their capacities, and applicable safety standards;
- a separate list of all safety equipment required, together with quantities, capacities and
testing and cleaning requirements.
2. Check list
It is recommended that a check list be established, having a fixed format, to be used for daily
checks and spot checks throughout the cleaning period. The check list should cover the
following items as applicable:
- operations involving neighbouring tanks in the same compound as, or in the vicinity of,
the tank being cleaned;
- maintenance and construction activities in the vicinity of the tank;
- wind direction and equipment siting;
- weather forecasts as regards heavy rains, high winds and electrical storms;
- results of gas testing for both flammable and toxic gases in and around the tank;
- check that roof drain valves of floating roofs are open, drains are clean and there is no
excessive accumulation of water on the roof;
- inspection of operability of tank farm drainage and sewers;
- pollution and cleanliness around the tank, including sludge disposal;
- cleanliness of special clothing used, site lavatory, washing and eating facilities as
applicable;
- compliance with work permit conditions;
- presence and good working order of fire-fighting, safety and personal protection
equipment, including breathing apparatus and lifelines;
- confirmation of electrical and mechanical isolation;
- inspection of earthing of tank;
- condition of all equipment, including electrical equipment and leads, airhoses etc.;
- adequate records being maintained of work progress and of personnel employed;
- location of equipment, e.g. compressors, air supply inlets;
- emergency plans and provisions, e.g. alarms, evacuation procedure.
APPENDIX 4 - RECOMMISSIONING CHECK POINTS
Immediately prior to replacing the shell manhole covers in preparation for hydraulic testing
and/or recommissioning of the tank, confirmation of the following points should be obtained:
1. Civil Works
1.1. The tank foundations have been inspected and confirmed to be in satisfactory condition.
1.2. The bundwalls have been reinstated according to design.
1.3. The bund drainage system is clean and serviceable.
1.4. All necessary tank repairs have been carried out.
2. Electrical and Instruments

2.1. The tank shell is properly earthed.
2.2. Any earthing cables and seal earthing shunts associated with floating roof (or internal floating
cover) are securely connected.
2.3. Any tank or associated piping cathodic protection system has been reinstated.
2.4. The electrical fittings associated with side entry mixers have been correctly installed.
2.5. All tank instrumentation, like level instruments, including that for auxiliaries such as heating
systems has been reinstalled and has been checked for proper functioning where at all
possible.
3. Fire Protection
3.1. Any foam lines, drencher or sprinkler system and their associated fittings have been correctly
reinstalled.
3.2. Any halon fire-fighting facilities installed for the seal area of a floating roof tank have been
correctly reinstated in working order.
4. Mechanical
4.1. All materials and debris arising from the tank cleaning operation and subsequent inspection
and any repair work have been removed from inside the tank, from the roof of the tank, from
any internal floating cover and from the vicinity of the tank, for appropriate disposal outside
the bunded area.
4.2. Any internal floating cover has been reinstalled in accordance with the manufacturer's
requirements.
4.3. Any side-entry mixers have been correctly reinstalled.
4.4. Handrailings on stairways and around the tank roof or wind girder are intact and secure.
4.5. The roof ladder is correctly positioned and intact.
4.6. The roof legs are all in position and correctly set.
4.7. The automatic vent legs are all in position and correctly set.
4.8. The roof drains are correctly installed and have been tested.
4.9. The roof drain sumps are clear of debris and all non-return valves are operational.
4.10. All pontoons are clean internally and all pontoon manway covers have been replaced.
4.11. Any free vents, at the top of the shell or on the tank roof, have the correct "free area"
mesh installed, here a mesh is fitted, and are clear from blockage.
4.12. The pressure and vacuum relief valves have been tested, are in position, have the correct
"free area" mesh fitted (if any) and are clear from blockage.
4.13. All roof manway covers and other roof fitting covers are closed.
4.14. The heating coils (if installed) have been tested.
5. Operational
5.1. The tank has been inspected internally and found to be acceptable for service.
5.2. The tank has been inspected externally, including the roof and any internal floating cover, and
found to be acceptable for service.
5.3. All roof drain, water draw-off, suction and discharge valves are serviceable and properly
identified.
5.4. All emergency roof drains on single deck roofs have been primed with water.
5.5. The tank drain valves are closed.
5.6. The roof drain valve is either open or closed in accordance with local policy.
Only after confirmation has been obtained that all of the relevant actions on the above list have been
completed and a final check has been carried out to ensure that no person or animal is in the tank,
should the shell manway covers be replaced and the entry permit be cancelled.
After the shell manway covers have been replaced and properly tightened, the suction
discharge and any other process piping, fittings and valves can be reconnected and made
operational.
However, if there is to be either a full or partial water test of the tank, it should remain isolated from
the process pipework system until the successful completion of the water test.
APPENDIX 5 - REFERENCES TO RELATED DOCUMENTS
1. The following PETRONAS PTS Guides are considered relevant to Tank Cleaning Operations:
Asphyxiation - The Hidden Danger (1979)
Personal Protection Equipment Guide (1988)
Safety Sign and Colour Coding (1981)
Work Permits (1981)
Safe Handling of Benzene (revised March 1980)
Noise Guide (1981) with Addendum (1984)
Hand Tools and Sparking Hazards (re-issued-1982)
Oxygen - A Hazard (1982)
Electrical Safety (1986)
Asbestos (1986)
Hydrogen Sulphide (1986)
Contractor Safety (1987)
Scaffolding Safety (1987)
Static Electricity - Technical and Safety Aspects (1988)
Man-Made Mineral Fibres (1988)
2. Leaded Gasoline Tank Cleaning
The Associated Octel Company Ltd Booklet OIP/5 (superseding booklet 27/80): "Leaded gasoline
tank cleaning and disposal of Sludge".
The Associated Octel Company Ltd.: "Lead Alkyl Antiknock Compounds. A review for the Use of
Medical Consultants". (1984).
APPENDIX 6 - EXAMPLES OF GOOD VENTILATION ARRANGEMENTS
Index of Subjects
Air Blowers see Ventilation

Aromatic Hydrocarbons see polycyclic and Benzene
Aromatic products
Definition 7.6
Ballast water
Hazards in tanks containing 7.11
Benzene
Hazards of 2.3.5
Biological activity
Hazards from 7.3.2
Ballast water, in tanks containing 7.11.2
Bitumen
Hazards of tanks containing 7.8
Breathing apparatus
Air hose specification 3.5.4.1
Air purity specification 3.5.4.1
Air supply to 3.5.4.1
Selection of 3.5.3
Carbon dioxide
Inert gas purge, for 5.4.2
Cathodic protection
Isolation of 4.2.5, 6.2.4(17)
Central Office
Advice from Foreword
Feedback to Foreword
Cleaning
Detergents, with 6.3(5), 6.3(6)
General 6.1
Final 6.3
Gasoil, with 6.3(3)
Hot water flushing, for 6.1.2
Roof supports, of 6.2.8
Submerged jets for 6.1.2
Through open manways 6.1.3
Water, with 6.3(1)
Chemicals
General 1.2
Hazards of, general 2.3.1
Miscellaneous, hazards of 2.3.6
Occupational exposure limit for 2.3.1
Protective clothing 3.5.6.3
Toxic, monitoring of vapours 2.3.1
Corrosion
Hazards from 7.3.2
Crude oil
Diesel engines
Protection standards 3.5.1
Distillates
Sour light/middle, hazards of 7.4
Sweet light/middle, hazards of 7.3
Earthing
To prevent static electricity 2.2.2.3
Vacuum trucks/hoses, of 3.5.6.10
Eductors See Ventilation
Ejectors
For liquid removal 3.5.6.7
Emergency procedures
General 6.2.6
Entry
Checks and preparations prior to 6.2.4
Conditions for 6.2.2
Floating roof, to space above 3.3.6, 5.10.2.2(3)
Internal floating covers, to space over 3.3.7, 5.10.2.2(2)
Internal hazards, general 6.2.5
Non-gas-free tank, into 6.2.4(5)
Number of access ways 6.2.3
Oxygen tests prior to 5.10.4
Plate removal for 6.2.3
Pontoons, to 6.2.5
Prevention when site unattended 6.2.4(18)
Tank containing toxic material, into 5.10.3.1
Electrical equipment safety requirements for
Air blowers 3.5.6.6
Gas testing equipment 3.5.5
General 3.5.4.3
Isolation during tank cleaning 4.2.5
Lights 3.5.2
Equipment
Diesel engines 3.5.1
Ejectors 3.5.6.7
Electrical 3.5.4
Fire-fighting 6.2.4(14)
Hoses 3.5.6.8
Lights 3.5.2
Mechanical, selection of 3.5.1
Mechanical squeegees 3.5.6.11
Pumps, for sludge 3.5.6.9
Vacuum trucks 3.5.6.10
Fire main
Use of 3.5.4.2
Fixed roof tanks Emptying 4.1.1
Gas freeing 5.4
Gas testing in 5.10.2.2
Inspect on of roofs 3.3.5
Flammable vapours
Measurement of 3.5.5.2, 5.10.2
Occurrence of in tanks 2.2.1
Flammability
Limits, typical 2.2.1
Table of, selected substances Appendix 1B
Flashpoint
Classification of Appendix 1A
Definition of 2.2.1
Floating roof tanks
Emptying 4.1.2
Gas freeing of 5.5
Gas testing in 5.10.2.2
Inspection of roof 3.3.6
Gas freeing
Floating roof tanks, of 5.5
Forced ventilation, by 5.4.5
Gas testing during 5.1, 5.10.2.2
Horizontal tanks, of 5.7
Inert gas purging, by 5.4.2
Methods, general 5.3
Natural ventilation, by 5.4.4
Site precautions during 5.2
Steaming out, by 5.4.3
Tanks with internal floating cover, of 5.6
Water displacement, by 5.4.1
Gas testing
Conditions for entry 6.2.2
During gas freeing, general 5.1, 5.10.2.2
During gas freeing, fixed roof 5.10.2.2(1)
During gas freeing, floating roof 5.10.2.2(2)
During gas freeing, internal covers 5.10.2.2(2)
False readings during 5.10.2.1
Flammable vapours see flammable vapours
General 5.10
Lead compounds, for 5.10.3.2
Oxygen level, for 5.10.4
Results, recording on work permit of 6.2.4(2)
Toxic vapours, methods for 3.5.5.3, 5.10.3
Toxic vapours, information required for 5.10.3.1
Grit blasting
Grit quality 2.3.7
Ignition risk from 2.2.2.3, 2.2.2.6
Personal protective equipment for 2.3.7
Heat stress 3.5.6.3, 6.2.4(9)
Heating coils
Use of to aid emptying 6.1.2
Hot surfaces
Ignition hazard of 2.2.2.4
Hydrogen sulphide
Flammable limits 2.3.3.1
Hazards of, general 2.3.3
Odour threshold of 2.3.3
TILV Of 2.3.3
Symptoms of exposure to 2.3.3.1
Ignition source
Definition of 2.2.2
Electrical equipment as 2.2.2.1
Gritblasting as 2.2.2.6, 2.2.2.3
Lightning as 2.2.2.2
Static electricity as 2.2.2.3
Thermite reaction as 2.2.2.6
Inspection
Floating covers, of 3.3.7
Insulated tanks, of 7.7.4
Precleaning, general 3.3
Pre-entry checks 6.2.4
Roofs general, of 3.3.4
Site, of 3.3.8
Internal floating covers
Gas freeing of tanks with 5.6
Inspection of 3.3.7
Isolation of
Cathodic protection 4.2.5, 6.2.4(17)
Drainage systems from tanks 4.2.4
Earthing systems 4.2.5
Electrical systems 4.2.5
Piping systems from tanks 4.2.2
Thermal relief lines from tanks 4.2.3
Jetting
Hydrocarbon, with 2.2.2.3, 6.3
Gasoil, with 6.3(3)
Steam, Static hazard of 2.2.2.3, 6.3
Steam, auto-ignotion hazard of 7.10.3
Submerged 6.1.2
Water, Static hazard of 2.2.2.3
Water, recirculation of 6.3(1)
Lead compounds
Declassification of tanks containing 7.5.7
Hazard from, general 2.3.2, 7.5
Procedures for tanks containing 7.5.6
Sludge containing, disposal of 7.5.5
Symptoms of exposure to 2.3.2.1
Testing for 5.10.3.2
TLV of 2.3.2
Lifelines
Used of 6.2.5
Lubricating oil
Matches and lighters
Regulations for 2.2.2.4
Medical
Examinations, type and frequency 3.2.3
Nitrogen
Inert gas purging, for 5.4.2
Noise
Limit for 2.5.2
Hazard from 2.5.2
Oxygen
Deficiency, causes of 2.4
Deficiency, hazards of 2.4
Measurement of 3.5.5.1
Minimum safe working level of 2.4
Use of in tanks 3.5.3
Permit to work
General 3.1
Hotwork, for control of 2.2.2.4
Tank entry, for 6.2.4
Protective clothing
Cleaning of 3.5.6.3
Safety helmets, wearing of 6.2.7
Selection of 3.5.6.3
Pumps See Equipment
Pyrophoric deposit
Bitumen tanks, in 7.8.3
Control of 5.9
Crude oil tanks, in 7.2.2
Hazards of 2.2.2.5
Removal of 6.2.4(8)
Qualifications
Cleaning staff, of 3.2.2.1
Medical fitness see Medical
Supervisor, of 3.2.1
Training see Training
Radiation
Hazards of 2.6
Recommissioning See Work, handover after
Refrigerated liquids
General 1.2
Regulations
IP Code Foreword
Leaded gasoline tanks, for 7.5.6
Local / National Foreword
Residual fuel oil
Hazards of tanks containing 7.7
Scaffolding
General 3.5.6.12
Scope
Exclusions, general 1.1, 1.5, 2.3.5
Special cases 5.8
Side entry mixers; Sludge minimization with 6.1.2
Slops
Sludge
Bitumen, characteristics of 7.8.2
Crude oil, characteristics of 7.2.3
Check prior to manhole removal 5.3
Customs approval for disposal 3.6.4
Disposal, general 3.3.2, 3.6
Disposal methods 3.6.3
Documentation 3.6.2
Estimation of quantities 3.3.2
Lead containing 7.5.5, 7.5.6
Removal of 6.1
Residual fuel oil, characteristics of 7.7.3
Sampling 3.3.2
Waxy 7.10
Smoking
Ban on 6.2.4(16)
Squeegees see Equipment
Static Electricity
Air driven lights as cause of 2.2.2.3
Grit blasting as cause of 2.2.2.3
Hoses, antistatic, use of 2.2.2.3
Inert gas purge as cause of 5.4.2
Prevention of 2.2.2.3
Steaming out as cause of 5.4.3
Steam jetting as cause of 2.2.2.3
Water displacement, during 5.4.1
Water jetting as cause of 2.2.2.3
Supervisor
Qualifications of, for tank cleaning 3.2.1
Tank roofs
Inspection of 3.3.4, 3.3.5, 3.3.6
Tetra ethyl lead see Lead compounds
Tetra methyl lead see Lead compounds
Thermite reactions 2.2.2.6
Vacuum trucks see Equipment
Ventilation
Air blowers, use of 3.5.6.6, 5.4.4
Eductors, use of 3.5.6.5, 5.4.4
Wind sails, use of 3.5.6.4, 5.4.4
Waste disposal
General 1.3
Water washings, of 6.3(6)
Water
Ballast tanks 7.11
Gas freeing, by displacement with 5.4.1
Jetting see ignition sources, jetting
Recirculation of cleaning 6.3(1)
Source for cleaning 3.5.4.2
Wax and waxy oil
Weather
Restrictions when bad 3.3.9, 5.2, 6.2.4(4)
Wind indicators, use of 3.5.6.1
Windsails see Ventilation
Work
Checklist for Appendix 3
Handover after 8.
Programme for 3.4
Recommissioning checklist Appendix 4
Working conditions
General hazards in tanks 2.5.1
Noise levels see Noise
Temperature extremes 2.5.1
Temperature monitoring 6.2.4 (9)
Washing and changing rooms 3.5.6.2,6.2.4(21)

Gas-Freeing and Cleaning of Oil Storage Tank: Manual

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MANUAL

GAS-FREEING AND CLEANING OF OIL

The right to use PTS rests with three categories of users :

1) PETRONAS and its affiliates.

3.2 Organization and Personnel

3.2.2.2 Instruction and Training

3.2.3 Medical Aspects

3.3 Pre-Cleaning Inspection

3.3.2 Tank Contents

3.3.3 Tank Inspections in General

3.3.4 Roof Inspection

3.3.5 Inspection of Fixed Roofs

3.3.6 Inspection of Floating Roofs

3.3.7 Inspection of Internal Floating Covers

3.3.8 Site Inspection

3.3.9 Weather Conditions

3.4 Work Programme

3.5 Selection of Equipment and Precautions for its Use

3.5.1 Mechanical Equipment

3.5.3 Breathing Apparatus

3.5.4.1 Breathing Air

3.5.4.3 Electrical Supply and Equipment

3.5.5 Testing Equipment

3.5.5.1 Measurement of Oxygen Level

3.5.5.2 Measurement of Flammable Vapour

3.5.5.3 Measurement of Toxic Substances

3.5.6.1 Wind Indicator

3.5.6.2 Washing and Changing Rooms

3.5.6.3 Protective Clothing

3.5.6.5 Vapour/Air Eductor

3.5.6.6 Air Blower

3.5.6.9 Sludge Pumps

3.5.6.10 Vacuum Equipment

3.5.6.11 Mechanical Squeegees

3.5.6.13 Aluminium Equipment

3.6 Control of Sludge Disposal

3.6.3 Methods of Disposal

3.6.4 Customs Approval

4. TAKING TANKS OUT OF SERVICE

4.1 Emptying and Line Clearing

4.1.2 Floating Roof Tanks

4.2.2 Isolation from Piping Systems

4.2.3 Thermal Pressure Relief Systems

4.2.4 Drainage Systems

4.2.5 Electrical Isolation

5.2 Site Precautions during Gas-freeing

5.3 Gas-Freeing Methods - General

5.4 Gas Freeing Fixed Roof Tanks

5.4.1 Water Displacement

5.4.2 Inert Gas Purging

5.4.3 Steaming Out

5.4.4 Natural Ventilation

5.4.5 Forced Ventilation

5.5 Gas Freeing Floating Roof Tanks

5.7 Gas Freeing Horizontal Tanks

5.8 Special Cases

5.9 Control of Pyrophoric Deposits

5.10 Gas Testing

5.10.1 General Points

5.10.2 Flammable Gas Detection

5.10.2.1 False Readings

5.10.2.2 Testing during Gas-Freeing

5.10.3 Toxic Vapour Monitoring