Above ground storage tank inspection checks a tank's floor, shell, roof and welds against API 653, to decide whether it can stay in service. TCR Engineering, TCR Advanced Engineering and TCR Arabia inspect tanks in India and Saudi Arabia, with external partners and associate firms, using acoustic emission testing, magnetic flux leakage floor scanning and robotic inspection.
- Floor, in service: acoustic emission screening and robotic ultrasonic thickness, with no draining
- Floor, out of service: magnetic flux leakage scanning, with ultrasonic prove-up
- Shell and roof welds: phased array UT and radiography; bottom welds by vacuum box
- People: NDT personnel certified Level II to SNT-TC-1A; API 653 inspectors compile the findings
Storage tanks are critical assets in the oil & gas, petrochemical, and power industries, serving as reservoirs for hydrocarbons, chemicals, and water. Ensuring their structural integrity is essential to prevent leaks, reduce operational risks, and maximise asset lifespan.
TCR specialises in comprehensive tank integrity inspections in India and Saudi Arabia, offering advanced non-destructive testing (NDT) solutions to detect corrosion, structural defects, and potential failure points. A well-planned inspection strategy improves safety, lets maintenance be planned and can support longer inspection intervals.
TCR's work spans multiple current-generation techniques, including:
- Acoustic Emission (AE) Testing: early-stage detection of structural weaknesses in tank bottoms.
- Magnetic Flux Leakage (MFL) Testing: high-sensitivity corrosion detection for tank floor plates.
- Phased Array Ultrasonic Testing (PAUT): weld inspection of tank shells and roofs.
- Radiographic Testing (RT): high-resolution imaging for tee joints and horizontal welds.
- Vacuum Box Testing: leak detection for tank bottom plate welds.
- Robotic Inspection: ATEX-certified robotic solutions for in-service hydrocarbon and firewater tank inspections.
- API 653 Inspections: evaluations by API 653 inspectors against the standard.
By integrating modern inspection technologies with global best practices such as EEMUA 159 and API 653, TCR helps tank owners develop proactive maintenance strategies that minimise downtime and optimise asset performance. Real-time data analysis, defect detection and automated inspection give the owner findings to act on.
With growing advancements in NDT, selecting the right combination of inspection techniques is crucial. At TCR, we tailor our solutions to meet the specific needs of each client, for a complete storage tank integrity assessment.
Acoustic Emission for Tank Bottom Inspection
TCR undertakes Acoustic Emission Testing (AET), an NDT technique that reads the sound waves emitted by materials under stress. This technique offers:
- Early-Stage Damage Detection: Identifies fibre breakages, impacts, cracking, delamination, and corrosion in their initial stages.
- In-Service Monitoring: Examines the floor with the tank in service, filled, settled and isolated for the test, with no draining or cleaning.
- Real-Time Data Analysis: Provides instant insights for proactive decision-making.
- Comprehensive Coverage: Utilises a sensor network to inspect large areas simultaneously.
- Hazardous Environment Capability: Can be deployed in high-temperature, high-pressure, or corrosive environments.
- Remote and Non-Invasive Inspection: Reduces equipment downtime and access constraints.
- Planned Maintenance: Finds active damage early, so repairs can be planned into a scheduled outage.
Magnetic Flux Leakage (MFL) for Tank Floor Plate Corrosion Detection
TCR uses MFL in India and the GCC for tank bottom plate inspection due to its:
- High sensitivity to corrosion pitting
- Defect sizing by Phased Array Ultrasonics (PAUT) where the scan finds an indication
Phased Array UT (PAUT) for Tank Shell and Roof Weld Inspection
TCR undertakes Phased Array Ultrasonic Testing (PAUT) to inspect welds on tank shells and roofs. PAUT enhances defect detection by utilising multiple ultrasonic beams at different angles, offering a complete volumetric assessment of weld integrity.
Key Advantages of PAUT:
- Weld Defect Detection:
- Identifies cracks, porosity, and lack of fusion in welds, with each beam angle recorded.
- Corrosion Mapping for Preventive Maintenance:
- Provides high-resolution corrosion mapping to detect thinning areas on tank shells before they leak.
- Automated Inspection with Data Recording:
- Modern PAUT scanners can be integrated with automated crawlers, recording thickness and weld defect data for traceability and audit.
Robotic Inspection for Hydrocarbon & Firewater Tanks
TCR employs custom-developed robots from a partner in which the TCR Group has invested; the robots are ATEX-certified and PESO-approved, and capable of operating in explosive and hazardous environments.
The robotic tank inspections are run for oil refineries, LNG terminals, petrochemical complexes, and power plants, checking regulatory compliance with API 653 and RP 575.
Vacuum Box Test for Tank Bottom Integrity
TCR undertakes conventional Vacuum Box Test for detecting leaks in tank bottom plate welds and shell-to-bottom welds, checking compliance with API and international standards.
API 653 Inspectors for Compliance & Structural Assessments
TCR's certified API 653 inspectors specialise in the examination and repair of aboveground storage tanks, checking compliance with regulatory and safety standards.
TCR's Inspectors Role:
- Visual Inspection: Assessment of tank exterior, roof, shell, nozzles, and structural integrity
- Supervise Non-Destructive Testing (NDT): Use of Ultrasonic Thickness Testing (UTT) and Magnetic Particle Testing (MPT), PAUT, AE, MFL
- Documentation Review: Analysis of maintenance records and inspection history
- Final Report & Recommendations: A structured action plan for repairs, maintenance, and compliance
Why Choose TCR for Storage Tank Integrity Inspections?
TCR provides advanced NDT solutions for industrial assets, supporting the safety, compliance, and longevity of critical infrastructure. Our work in robotic inspections, ultrasonic testing, and API compliance enables safer tank integrity management, with less work at height and confined space entry.
Key Benefits of Partnering with TCR:
- Robotic & Automated NDT Solutions
- Enhanced Probability of Detection (PoD) with Advanced PAUT & MFL
- API 653 Certified Inspectors Checking Compliance & Reliability
- Asset Integrity Management & Predictive Maintenance Strategies
- Reduction of Downtime, Work-at-Height, and Confined Space Entry Hazards
By leveraging TCR's comprehensive storage tank integrity inspection services, asset owners can plan maintenance cycles and act on corrosion before it becomes a leak. Our commitment to current-generation NDT technology, regulatory compliance, and operational safety supports TCR's work for tank owners in India and Saudi Arabia.
For more information, contact TCR Engineering to plan the inspection of your aboveground storage tanks.
TCR Engineering | Assessing Structural Integrity, One Tank at a Time
FAQ
Can a storage tank floor be inspected without taking the tank out of service?
Partly. Acoustic emission testing screens the floor for active corrosion and leaks while the tank stays in service, and partner-delivered robots measure floor thickness with the tank full. Magnetic flux leakage floor scanning needs the tank emptied and cleaned, so it is run when the tank is opened for internal inspection.
Which standards govern above ground storage tank inspection?
API 653 covers the inspection, repair, alteration and reconstruction of above ground storage tanks in service, and API RP 575 sets out recommended inspection practices for them. TCR also applies EEMUA 159 where the owner asks for it, and reports each tank against the acceptance criteria of the code the owner names.
What does an API 653 inspection report contain?
It records the condition of the floor, shell, roof, nozzles and foundation, the thickness and NDT results, and how each compares with the API 653 acceptance criteria. It ends with an action plan for repairs and maintenance and the next inspection date, so the owner can schedule the work around operations.
Which NDT method finds corrosion on a tank floor?
Magnetic flux leakage scanning finds pitting and general metal loss on floor and annular plates once the tank is open, and ultrasonic testing proves up each indication. In service, acoustic emission testing locates zones of active corrosion and leaks, and robotic ultrasonic scanning measures the remaining plate thickness.