Maintenance
Please refer to the following guidelines concerning equipment inspections and make sure to perform regulars checks on your tanks, fittings, and piping. If you discover anything out of the ordinary, please immediately stop using the equipment and contact us right away.
*For tanks that have been in use about 10 years or longer, please use our FTIR (tank life diagnostics) service.
Notes on Maintenance Inspections
Preventing Oxygen Deficiency and Poisoning Accidents
The inside of tanks must be a dangerous place due to oxygen deficiency and gas poisoning. When entering inside a tank please follow the directions of someone who has completed the skills training course to become an operation chief of oxygen deficiency/hydrogen sulfide dangers and carry out your operations.
- Before entering inside a tank, make sure to wash with water and dry thoroughly.
- When working inside a tank, use a fan or other device to make sure it is properly ventilated.
- When entering inside a tank, make sure to first measure oxygen concentration levels (18% or more) and detect for hydrogen sulfide gas (10ppm or under) to confirm the tank's safety.
- When the above guidelines cannot be taken, please use an air-line mask or hose mask and use goggles as well.
- Make sure someone is present to supervise at all times when entering inside a tank.
If you do not follow the above guidelines, there is the risk of an accident occurring due to oxygen deficiency or gas poisoning.
Preventing Accidents and injuries due to Falling down
- Please carefully confirm there is no corrosion and/or looseness before using a ladder or handrail.
- When the top of a tank has deteriorated due to chemicals or gases, either do not climb on top of the tank or build a scaffold.
- Do not stand on top of the tank without supervision as this presents a falling hazard.
Do not stand on top of tanks containing chemicals. If you must stand on top of a tank for any reason, please take into consideration potential degradation due to aging as well as the chemical properties of the substances stored within the tank. Also, make sure to wear a safety harness and take any other necessary safety measures to prevent falling when on the tank, and assign someone to watch over the person on the tank at all times. In particular, 3,000 liter-sized tanks and smaller were not designed for a person to stand on top. Doing so can cause damage to the tank's nozzles due to deforming the top of the tank. - Make sure to close any manholes, inspection ports, or other covers after finishing your operations.
- If you detect any damage or abnormalities on any manholes, inspection port covers, or lift equipment, please replace the parts or equipments concerned immediately.
- Make sure someone is necessary to supervise at all times when performing operations from high places.
If you do not take the above measures, there is the risk of an accident occurring due to falling or other injury.
Equipment Inspection Guidelines
Daily inspections
| Location | Item of inspection | Expected cause | Specific example cause | Measure taken for defect |
|---|---|---|---|---|
| Tank | Check for cracks or fissures on the surface | Product lifespan | UV degradation due to sunlight | Replace (FTIR test) |
| Environmental stress cracking due to chemicals | Surfactant, nitric acid content of 50% or more and others | Replace, chemical test | ||
| Check for abnormal shapes (Expansion, depression) | Abnormally high temperature of storing liquid | Heating due to chemical reaction | Replace depending on the degree of damage | |
| Rising ambient temperatures *Tank itself expands in changing seasons from winter to summer |
Tightened too much the clamping bolts for the reinforcing frame | Adjust the tightness of the clamping bolts for the frame | ||
| Swelling due to chemicals | Swelling due to the mixing of oil and organic solvents with the liquid stored | Replace depending on the degree of damage, chemical test | ||
| Pressurization or decompression of the tank | Clogged air vent, closed piping | Inspect air vent and/or piping Exchange parts if necessary | ||
| Nozzle | Check for leaks from nozzle or connecting parts | Gasket lifespan | Chemical degradation or deformation of the gasket | Exchange gasket |
| Check for cracks or fissures on the nozzle (fitting, flange, valve) |
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Periodical inspections
| Location | Item of inspection | Expected cause | Specific example cause | Measure taken for defect |
|---|---|---|---|---|
| Tank | Check for cracks inside of the tank | Product lifespan | Chemical degradation | Replace |
| Check for clouding of the glossy of inner surface of the tank | Product lifespan | Chemical degradation | Replace depending on the degree of damage | |
| Check for damage on the surface | Scratching due to external forces | Scratching due to cutting tools, etc. | Replace depending on the degree of damage | |
| Piping | Check if PVC parts are turning white | Product lifespan | UV degradation due to sunlight | Replace depending on the degree of damage |
| Reinforcing frame | Check for rust or corrosion | Rust or corrosion due to the environment | Corrosion due to gases or mist | Recoat after removing the corrosion or exchange |
| Check for missing bolts or nuts on frames, ladders, and handrails | Replace | |||
| Valve | Check if the handle moves smoothly | Wearing down or degradation of the gasket | Chemical degradation | Exchange |
| Check if coupling parts are missing | Wearing down or degradation of the gasket | Chemical degradation | Exchange |
List of support information