TDFC (Pvt.) Ltd.

ISO:14001-2004+Cor1:2009
DE-30900020 UM
ISO: 9001:2008
DE-30900020 QM08

TECHNOLOGY DEVELOPMENT & FEBRICATION COMPANY (Pvt.) Ltd.

MAINTENANCE MANUAL FOR ACID STORAGE TANK

Introduction

Tank inspection is required to ensure that tank containing acid are maintained in a safe
condition. The degree and frequency of inspection will depend on how the tank has been
operated and the maintenance done on the tank.

Documentation and Records

Proper documentation and records for each tank should be maintained. These records
should include the following:

 Tank design and construction details including shell thickness, weld details,
dimensions, etc.
 Materials of construction
 Corrosion allowance
 History of tank contents including acid concentration and temperature
 Civil engineering details for foundations and supports
 Record of all maintenance performed on the tank
 Record of all previous inspections
 Details of any incidents the may have occurred to the tank (i.e. leaks)

Routine Inspections

A regular visual inspection of a tank ensures that there has been no obvious damage to the
tank due to deterioration of accident. This is accomplished by walking around and on top of
the tank. This type of inspection is limited to the exterior of the tank. Some of the things to
look for during an inspection are:

 Signs of acid leaks

Base Works: East Paharange Drainage, Millat town, Millat Road, Faisalabad 38000, Pakistan Tel.
+92-41-8766660-62, 8505804 Fax.+92-41-8766662
Email. [email protected] Web www.tdfcpk.com
Page 1 of 4
 TDFC (Pvt.) Ltd.
ISO:14001-2004+Cor1:2009
DE-30900020 UM
ISO: 9001:2008
DE-30900020 QM08

TECHNOLOGY DEVELOPMENT & FEBRICATION COMPANY (Pvt.) Ltd.

 Damage to insulation and cladding

Storage tanks are often located a distance from the main plant and are not visited
frequently during the normal operation of the plant. Tanks should be inspected once a day
if possible with a minimum frequency of once a week.

In-Service Inspections

In-service inspection of the tank involves both a detailed visual examination of the exterior
of the tank as well as ultrasonic thickness measurement of the shell. As the name implies
this inspection is performed while the tank is still in service. The in-service inspection
should include all the inspection points of the routine inspection as well as ultrasonic
thickness measurements of the tank shell and roof.

Ultrasonic thickness measurements should be performed in the following areas:

a) On the side wall on a vertical line through the radius of any top inlet which is less than
2.44 m (8 ft) from the edge of the tank. Testing should be carried out on a 300 mm (1 ft)
grid extending 1.83 m (6 ft) from the centreline on each side.

b) On the side wall on a vertical line through the radius of any top opening at 300 mm (1
ft) intervals on the centreline from top to bottom.

c) On the side wall on a vertical line every 90 degrees around the tank. One or more of
these line may correspond to the area tested in a) and b).

d) All side openings and outlets should be tested thoroughly in the whole area extending
up to 300 mm (1 ft) from the edge of the nozzle and nozzle reinforcement.

e) On each vertical seam weld on each tank course, consisting of a thickness scan of a
125 mm (5 in) length of weld.

f) On the tank roof on a line every 90 degrees from the centre of the tank to the side wall
at 300 mm (1 ft) intervals.

g) On the side wall at an elevation of 25 mm (1 in), 75 mm (3 in), 914 mm (36 in) and
1829 mm (72 in) from the bottom of the tank with a minimum of 4 test points between each
vertical weld seam. A test point will be located within 25 mm (1 in) of each vertical weld
seam.

Base Works: East Paharange Drainage, Millat town, Millat Road, Faisalabad 38000, Pakistan Tel.
+92-41-8766660-62, 8505804 Fax.+92-41-8766662
Email. [email protected] Web www.tdfcpk.com
Page 2 of 4
 TDFC (Pvt.) Ltd.
ISO:14001-2004+Cor1:2009
DE-30900020 UM
ISO: 9001:2008
DE-30900020 QM08

TECHNOLOGY DEVELOPMENT & FEBRICATION COMPANY (Pvt.) Ltd.

h) On the side wall along each horizontal weld seam with a minimum of 4 test points
between each vertical weld seam. A test point will be located within 25 mm (1 in) of each
vertical weld seam.

The readings obtained should be compared to previous data to determine the extent of
corrosion on the tank shell. Where higher than anticipated metal losses are found, more
extensive testing is required to confirm and establish the severity and extent of corrosion.

To obtain good ultrasonic measurements, the following should be noted:

 Ensure that the area to be tested consists of a good sound metal surface, free of paint and corrosion
inhibitors.
 If testing is done on paint an allowance of 3 mils for each mil of paint should be subtracted since the
sound velocity through paint is about 1/3 of the velocity through steel.
 The instrument should be calibrated frequently.
 The inspector should be experienced with performing this type of testing.

Internal Inspections

Internal inspections are required since there are areas of the tank where corrosion can only
be detected by an internal inspection. Internal inspections should be done at least once
every five (5) years. Internal inspections should be done in conjunction with the in-service
inspection where detailed ultrasonic thickness measurements are performed.

Sandblast welds to remove slag and sulphate. Visually inspect welds for undercutting,
excessive porosity, grooving, and other defects. If required, welds should be
radiographed. All defects should be repaired by grinding out the defect and repaired by
welding. The finished weld should be ground flush with the surface of the surrounding
metal.

Ultrasonic thickness measurements shall be performed on the interior surface of the shell
and roof when performing an internal inspection. This replaces the ultrasonic thickness
measurements taken from the outside of the tank during in-service inspections. In
additional to all the measurement points required during and in-service inspection, the
bottom of the tank will be tested. Normally, the bottom is only accessible during an internal
inspection for ultrasonic thickness measurements.

Ultrasonic thickness measurements should be performed in the following areas on the tank:

Base Works: East Paharange Drainage, Millat town, Millat Road, Faisalabad 38000, Pakistan Tel.
+92-41-8766660-62, 8505804 Fax.+92-41-8766662
Email. [email protected] Web www.tdfcpk.com
Page 3 of 4
 TDFC (Pvt.) Ltd.
ISO:14001-2004+Cor1:2009
DE-30900020 UM
ISO: 9001:2008
DE-30900020 QM08

TECHNOLOGY DEVELOPMENT & FEBRICATION COMPANY (Pvt.) Ltd.

a) On a line every 45 degrees from the centre of the tank to the side wall at 300 mm (1 ft)
intervals.

b) If the tank is supported on steel beams, thickness measurement should be taken on

The readings obtained should be compared to previous data to determine the extent of
corrosion on the tank shell, roof and bottom. Where higher than anticipated metal losses
are found, more extensive testing is required to confirm and establish the severity and
extent of corrosion.

Review of Data

The data collected during an inspection should be reviewed and an assessment done to
determine if further testing should be done, the extent of tank repairs or if changes in tank
operation are required. The evaluation of the data should establish the following
parameters for the tank:

 Corrosion allowance remaining

Base Works: East Paharange Drainage, Millat town, Millat Road, Faisalabad 38000, Pakistan Tel.
+92-41-8766660-62, 8505804 Fax.+92-41-8766662
Email. [email protected] Web www.tdfcpk.com
Page 4 of 4