mina HEADQUARTERS OFFICE a 4 HINDUSTAN BHAVAN DGM-O&D (NZ/EZ/W2/SZ/SCZ/NW2/NC2) Ch/Sr/installation Managers Ail Depots & Terminals 16/09/2016 ‘0&D/M&i/BPI SOP for inspection of Internal Floating Roof tanks Recently we have converted many external floating roof tanks to Internal floating roof tanks as a compliance to MBLC recommendations. These tanks are converted to internal floating roof by providing either a MS roof or Aluminium dome. As such these tanks are now commissioned & taken into operations at various locations. ‘As a good operation & maintenance practice, these tanks need to be inspected regularly for its health condition. A detailed SOP has been developed to underline the methodology of accessing the floating roof of these IFR tanks. The SOP is prepared based on the relevant API-RP 2016 & OSHA-1910.146 requirements. The SOP outlines the general guideline/ procedure for inspection of IFR Tanks. The document covers the following points: a) Hazards involved in accessing the floating roof of the IFR b) Procedure for inspection without entering the deck ©) Pre-requisite conditions for entering on the floating roof of IFR d) Periodicity of inspection The detailed SOP for IFR inspection is attached as annexure-1. All are hereby advised to adhere ‘to the SOP during inspection of IFR tanks. > bt" anitparide ED-O&D and E CC: Director (M), HB-4 CC: GM-FPRE, GH-2 CC: GM-Spl Projects, HB-2 CC: Head (Retail) Zones CC: CRM/SRN- All Retail ROsAnnexure-1 ‘SOP FOR INSPECTION OF FLOATING DECK OF INTERNAL FLOATING ROOF TANK ‘Typically, space above the floating deck in the Internal Floating Roof Tanks are “confined spaces” with limited entry through “Inspection Hatch”. The following potential hazards may normally be present, + Topentry can present a falling hazard. * The internal structure of tanks may not be visible clearly from the fixed roof top and at times may cause hazard. * Internal floating roofs may be under operation and may cause tripping * The petroleum products stored in tanks pose flammability and toxicity hazards. : INSPECTION OF DECK WITHOUT ENTERING THE TANK FROM TOP (Applicable to Mild Steel Deck as well as Aluminium Deck) In view of likely presence of hazardous conditions, it is recommenced that the Floating Deck inspection of IFR tank is Gone through inspection hatches provided on the fixed roof without entering the tank. 1. In Typical Internal Floating Roof tank with MS Roof, following appurtenances are provided to enable inspection of floating deck, without the need of entering on fio ng deck from Tank top. 2, Minimum four nos. Circulation cum Inspection Hatch b, Two Manholes Entry Hatch Cover 2. Inspection shall be planned when the product level in tank is near to maximum allowable filling height. Ensure that tank is in DORMANT (No Recefpt/ No Dispatch) mode. 3. Inspection shall be carried out in the presence of supervising officer. 4. Ensure usage of FLP torch for adequate illumination & safety harness to avoid falling/ tripping, Open all the circulation/ Inspection hatch covers. Decision on opening fixed roof Manhole covers shall be taken on need basis. 6. Inspection of the Floating deck top surface/ rim seal condition shall be done through open citeulation cum inspection Hatches. 7. Note all the observations by carefully inspecting the floating deck area from each inspection hatch & manhole covers. 8. Once the Inspection is complete, ensure to close & lock all the inspection hatches as well as the manhole covers, 8. Specific note regarding closing of all the hatch covers & manholes shall be mentioned in the inspection checklist. enAnnexure-1 SOP FOR INSPECTION OF FLOATING DECK OF INTERNAL FLOATING ROOF TANK PART B: INSPECTION OF DECK BY ENTERING ON FLOATING DECK FROM TANK TOP (Applicable to Mild Steel Deck only) ifthe entry on the floating Deck of IFR is unavoidable, following pre-qualifying conditions & SOP shall be ensured. Pre-Qual ing Condition: 1. No accumulation of Product on the Floating Deck. 2. No visibie tilting of the Floating Deck 3. No Damage to the access ladder SOP for access to Floating Deck. 1. All the pen it conditions for confined space entry are complied. 2. Confined space atmosphere shall be tested using properly calibrated equipment. @. Oxygen less than 18.5% can cause asphy) n b, Use proper ventilation. Ventilate with air flow away from workers to maintain oxygen ‘content between 19.5-23.5%. «Ensure that Hydrocarbon contents are checked using Explosive meter & it should be below the LEL. d. Though presence of CO and HS is not envisaged, its maximum allowable limit is 35 Rm and 10 ppm respectively. 3. Plan inspection when the product dip level in tank is near to maximum allowed filing height. 4, Put the Tank under inspection in DORMANT mode throughout the inspection, til all the inspection personnel are out of the tank & clearance given by supervisor in writing, 5. Inspection shall be cartied out in the presence of supervising officer, who wil! be on the top of the fixed raof. Always inspect the deck with two medically fit personnel, 6. Open all the Inspection hatch covers including those mounted on the Circulation vents, manhole covers at least two hours before the planned inspection to ensure enough ventilation of fresh air in the tank, 7. Secure the full body safety harness line of the person entering the Tank from top. 8. Ensure to wear all the necessary PPEs viz, Full body safety harness with twe life lines, safety shoes, safety helmet, SCBA and other es applicable. 9. Carry Flame-proof torch for proper inspection. 10. Gradually enter the tank using the access ladder. 11. Inspect the Floating deck areas as per items prescribed in the attached IFR Tank Quarterly checklist no. 00/e1/048/00. AAnnexure-1 SOP FOR INSPECTION OF FLOATING DECK OF iNTERNAL FLOATING ROOF TANK 12. Maintain two-way communication through an intrinsically safe VHF set between entrants and supervisor (on Fixed roof Top). 13. Supervisor shall monitor the oxygen level inside the confined space for adequacy. 14, Complete the planned inspection. 15. Inspecting Persons shall come out from the access ladder carefully. 16. Remove all inspection tools. 17. Once the Inspection is complete, ensure to close & lock all the inspection hatches as well as the manhole covers. 18. Specific note regarding closing of all the hatch covers & manholes shall be mentioned in the inspection checklist. \RT C: INSPECTION OF ALUMINIUM FLOATING DECK 1. During In service condition of tank, it is not recommended to inspect aluminium deck by entering on the deck. 2. if any problem is observed on the deck while carrying out inspection from top of Fixed roof, the tank shall be taken out of service, in consultation with M&i department, for carrying out repairs. ART D: MAINTENANCE & INSPECTION OF INTERNAL FLOATING ROOF TANK sriodic Maintenance of the IFR Tanks (M$ Roof/ Aluminiurn Dome} shall be as follows 1. Quarterly / Yearly Inspection as per Checklist No. OD/E1/048/00 a. Routine inspection of Shell, Roof, Deck, Annular plate, Nozzles, Sprinklers, Foam pourers etc. shall be done as per M& Checklist no. OD/EI/048/00. 2. Internal inspection once in 5 years a. Tank shall be completely emptied, de-sludged, de-gassed once in five years for comprehensive inspection. This comprehensive inspection shall be carried out as prescribed in O1SD-129. :Format : 0D/E\/005A/00 HINDUSTAN PETROLEUM CORPORATION LIMITED QUARTERLY INSPECTION CHECKLIST FOR IER TANKS [FenkNo = Product = Location Name: Item Detailed Observation No | 1 | Check the condition of rolling ladder hinge asi z connection and connecting bolt/pins for oK NOT OK wear/tear and corrosion, Check the joint/connection of Rolling shat | i z | assembly to Ladder for any corrosion, Check ox || notox | for greasing of the bress bush. Nt 3 | Check the ladder for wear, distortion, | E | lubrication and freedom of movement. oK NOT OK @| Check the alignment between wheels and track. 0K NOT OK 5 Checkfor corresion/thinning of deck plates underneath vertical support legs of ladder oK NOT OK track. Seat Gheck for free movernent of roof periodically = during product receipt/withdrawal ok NoTOK 7 | To check condition of roof legs and pipe sleeves for corrosion and damages. | B | To check for signs of leakage through weld SS joints/plates at roof deck oK NOT OK 3 To cheek for electrical continuity between st shell and rolling ladder, rolling ladder and roof || OK |), NOTOK | deck, shell to deck ! WO | To check pontoon boxes for any leakage or = mechanical damage/liquid tightness, neoprene | | OK NOT OK beading over pontoon neck | “Ti | To check gauge well pipes for any ruboing A ageinst gauge well sleeve pipes, mechanical oK NOT OK | damage/wear & tearofneoprene sheets. | | 42 | Te check that water seal is intact in Emergency | i; drains all the time, wire mesh provided around | | OK NOT OK EDs are unchoked and no oil traces, | teB inlets to primary roof drains shail have ] guarded trash stops ot screens to stop debris from entering and obstructing the drain system, To ensure that holes provided on central roof drain cover are not choked and allow smooth flow of water from the deck surface. OK NOT OK 74 To ensure that the roof drain inlet nozzle pipe is checked for corrosion and NRV observed for smooth functioning, RD sump is kept clean and free from any debris. OK NOT OK is To check roof for undulations and depressions as water tends to accumulate in these areas and causes corrosion. Check for painting in the | undulated pockets. OK NOT OK 16 To ensure that the deck is free from water and paint condition is good. OK NOT OK 7 ‘To check condition of mechanical shoe seal, gap between shoe plate and shell, gap between wiper tip and shell and corrosion of compression plate. | oK NOT OK 18 To check condition of neoprene sheet cover of primary seal for any damage and foam shall be checked for any dampness, where ‘octagonal foam is used. OK NOT OK 19 Check that the calibration of PV valve/rim | vents fitted on the deck have been done as per periodicity. 0K NOTOK 20 To ensure that auto bleeder vent leg is set to match high or low position of roof leg supports. Neoprene sheet provided under the ‘ABV top cover shall be checked for any ‘mechanical damage/wear/tear. oK NOTOK 2a To check and ensure that there are no missing | bolts on deck manhole cover. ok NOTOK 2D “To check and ensure that condition of neoprene sheet around gauge well at deck level is not damaged. = NOT OK23 | To check and ensure that roof drain nozzle is in ‘open condition especially ifthe roof drain is of flexible hose type (Co-flexip/Mesa) and in other cases viz swivel jointed roof drain, the rain water is routed to tank thru a NRV and | regularly drained under supervision of an | officer. The regular observation shall continue even for flexible roof drains. NOT OK To check circulation vent for ease of opening and SS wire mesh condition including its choking due to dust/debris ete NOTOK To check if wire mesh of free vert is not choked, not rusted. NoTOK |) 26 | To check if paint condition of roof plates is g00d, free from undulation and no marks of ‘water stagnation, no corrosion marks. NOTOK 7 Fo check if joints of Al dome members are sound including its connection with shel | members and sealing intact. NOT OK 2B | To check integrity of hand rails are sound, | corrosion free and paint condition good. ROTO |} 25 | To check if opening of inspection hatch is trouble free, no water ingress through hatch, mechanically sound. NOT OK corrosion free and rung ladder steps are 30 | To check if fire water sprinkler lines are corrosion free, properly painted, structural support integrity, spray nozzles not choked, ae NOTOK record available for strainer cleaning and drain as point available at lowest point in tank farm. BI | To check if foam lines are supported properly, | corrosion free, deflector outlet isnot blocked || oy Vl notoK | and testing provision provided. To check ifair | strainer mesh on foam maker is not blocked. _| 3D To check the shell nozzles visually for any leaks, gasket condition, connection pointsof [ox || NoToK wavaimessure reliet lines are sound and free ||_O* from leaks. \ 33 | To check shell plate condition including wind | girders, curb angles for corrosion, painting, = [Oy ROToe ‘weld soundness. 1 “34 | To check for condition of annular plate/bottom | | plates extending beyond shel, any depression, |[ Oy] NoTOK || | (whether bottom plate has sunk below foundation apron. | e35 | To check condition of tank foundation, tank settlement whether uniform or differential, condition of rec apron and whether water | accumulates on projected bottom plate. “36 | To check condition of earth connection to | tank, its soundness, condition of earth pit and | its resistance value. a oK | NOTOK | ox NoT OK Inspected By: Date of Inspe witnessed by (M&R Officer): Date of Inspection: