Tanker Inspection and Testing Procedure

Vessel Inspection Procedures

These procedures outline the critical steps for verifying the structural integrity and condition of tanker vessels. Thorough vessel inspection helps prevent leaks, structural failures, and ensures regulatory compliance.

External Shell Inspection

Position tanker on level ground with adequate lighting
Systematically examine entire shell for dents or deformation
Inspect all welds for cracks, corrosion, or deterioration
Check for signs of metal fatigue or stress fractures
Examine protective coatings for bubbling or peeling
Look for evidence of previous repairs or modifications
Check mounting points and supports for security
Document any abnormalities with photos and measurements

Internal Vessel Inspection

Verify confined space entry permit and safety protocols
Test atmosphere for oxygen levels and hazardous vapors
Use explosion-proof lighting for thorough examination
Inspect internal surfaces for corrosion or erosion
Check baffles and bulkheads for structural integrity
Examine internal lining or coating if applicable
Look for product residue, contamination, or buildup
Verify drain system functionality and cleanliness

Weld Seam Examination

Clean weld areas to ensure clear visibility
Conduct visual inspection of all accessible welds
Use dye penetrant testing for surface crack detection
Look for pitting, porosity, or undercutting in welds
Check for misalignment or improper weld profiles
Examine heat-affected zones for signs of weakness
Verify documentation of previous weld repairs
Document any weld defects with precise location notes

Thickness Testing Procedure

Calibrate ultrasonic thickness testing equipment
Establish grid pattern for systematic testing
Clean test points to ensure good contact
Take readings at predetermined locations
Pay special attention to high-wear areas
Compare readings to minimum thickness requirements
Document all measurements with precise locations
Flag any areas below threshold for further evaluation

Valve & Piping System Procedures

These procedures focus on the critical components that control product flow and containment. Proper valve and piping inspection prevents leaks, ensures proper operation, and maintains system integrity.

Discharge Valve Testing

Visually inspect valve for external damage or corrosion
Check valve operation through full range of motion
Verify proper seating and sealing when closed
Test for smooth operation without binding
Examine valve seals and gaskets for deterioration
Ensure all mounting hardware is secure
Verify valve locks and safety features function properly
Test for leakage using appropriate methods

Emergency Valve Verification

Locate and identify all emergency shut-off valves
Test manual operation of emergency valves
Verify remote activation systems function properly
Check that valves close completely and rapidly
Ensure valve controls are clearly marked and accessible
Test interlocks and fail-safe mechanisms
Verify emergency valve responds within time standards
Document emergency valve test results with timestamps

Piping System Inspection

Trace entire piping system from inlet to discharge
Check all pipes for external damage or corrosion
Inspect all connections, flanges, and fittings
Verify appropriate gaskets are installed and intact
Test all flexible connections for wear or damage
Check pipe supports and mounting brackets
Look for signs of leakage at all connection points
Verify pipe system matches approved configuration

Pressure Relief System Check

Verify pressure relief valves are correctly rated
Check that tamper-evident seals are intact
Confirm calibration records are current and available
Inspect pressure relief valve mounting
Ensure discharge paths are unobstructed
Verify pressure settings match specification
Test manual release mechanisms if equipped
Document pressure relief system condition and settings

Pressure Testing Procedures

Pressure testing is critical for validating vessel and system integrity. These procedures ensure that proper testing methods are followed to verify containment capabilities while maintaining safety throughout the testing process.

Hydrostatic Test Preparation

Review vessel specifications and test requirements
Verify test pressure does not exceed 150% of MAWP
Clean vessel interior thoroughly before testing
Fill vessel completely with water, eliminating air pockets
Install calibrated pressure gauges at appropriate points
Ensure all vents are closed and sealed
Set up proper barricades and warning signs
Brief all personnel on test procedures and safety protocol

Hydrostatic Test Execution

Increase pressure gradually in predetermined increments
Hold pressure at 25%, 50%, 75% of test pressure for checks
Inspect for leaks at each pressure increment
Once at full test pressure, maintain for required duration
Monitor pressure gauge for any pressure drops
Document pressure readings at regular intervals
Inspect all testable areas for signs of leakage
Release pressure gradually after successful completion

Pneumatic Testing (When Required)

Verify pneumatic testing is appropriate for the vessel
Limit test pressure to 110% of MAWP
Fill vessel with compressed air or inert gas
Apply soapy water solution to all connections
Increase pressure in small increments
Observe for bubble formation indicating leaks
Maintain heightened safety precautions due to stored energy
Release pressure very slowly after test completion

Leak Detection Methods

Apply soap solution to external surfaces for bubble testing
Use pressure decay testing for small leaks
Apply vacuum box testing for weld seam examination
Implement helium leak detection for precision testing
Use acoustic emission testing for pressure vessels
Apply tracer gas methods for system testing
Document all test methods and results systematically
Photograph any detected leaks for documentation

Cleaning Verification Procedures

Proper cleaning verification ensures product integrity and prevents contamination. These procedures outline the steps for validating cleanliness standards appropriate to the tanker's intended cargo.

Pre-Cleaning Inspection

Review records of previous cargo transported
Determine cleaning requirements based on next cargo
Identify potential cross-contamination concerns
Check for product compatibility issues
Document pre-cleaning condition with photos
Identify problematic residues requiring special attention
Develop cleaning plan based on inspection findings
Select appropriate cleaning methods and chemicals

Cleaning Verification Protocol

Ensure proper lighting for thorough visual inspection
Perform white-glove or wipe test on interior surfaces
Check for residual odors that may indicate contamination
Inspect all internal fittings and difficult-to-clean areas
Verify drain valves and low points are residue-free
Check for water or cleaning solution remaining in tank
Document all verification steps with date and time
Obtain verification signature from qualified inspector

Chemical Testing Methods

Select appropriate chemical testing based on previous cargo
Perform pH testing to verify neutrality if applicable
Conduct specific tests for chemical residues
Test for chloride content when required
Collect samples from multiple tank locations
Document all test results with location information
Compare results to established acceptance criteria
Maintain chain of custody for all test samples

Food Grade Verification

Implement stricter cleanliness standards for food transport
Verify absence of allergens from previous cargoes
Conduct ATP testing for biological contamination
Perform microbiological sampling when required
Check for cleaning chemical residues that could contaminate food
Issue food-grade cleanliness certification
Document cleaning methods and sanitization procedures
Maintain records for regulatory compliance

Regulatory Compliance Procedures

These procedures ensure that tanker inspections meet all applicable regulatory requirements and that proper documentation is maintained for compliance verification.

Documentation Verification

Check that inspection certification is current
Verify pressure test records meet required frequency
Confirm thickness test documentation is complete
Review repair and maintenance history records
Ensure all modifications have proper approvals
Verify cleaning certificates are appropriate for cargo
Check that specification plates are legible and current
Confirm all required documentation is readily available

Hazardous Materials Compliance

Verify hazardous materials placards are correct and visible
Check for proper UN/NA identification numbers
Confirm shipping papers are complete and accurate
Verify emergency response information availability
Check that pressure relief valves meet hazmat requirements
Ensure venting systems comply with product specifications
Verify tank test pressure rating meets product requirements
Document all hazardous materials compliance checks

DOT/TC Inspection Requirements

Verify current specification markings are correct
Check test date markings are within required intervals
Confirm test pressure markings match specifications
Verify inspector approvals for previous tests
Check that tank meets requirements for intended cargo
Verify owner/operator information is current
Ensure registration numbers are properly displayed
Document compliance with all applicable regulations

Certification Process

Complete all required inspection forms accurately
Document any deficiencies with corrective actions required
Obtain required signatures from qualified inspectors
Issue appropriate certification based on inspection results
Apply certification markings to tanker as required
Update electronic and physical documentation systems
Establish next inspection date based on requirements
File copies of all certifications per regulatory standards