Definition - What does 

Tank Farm mean?
A tank farm refers to an area or facility used exclusively for the storage of chemicals
such as petroleum. It includes all of the tanks and equipment of this area. Liquid
petrochemicals are stored in a tank farm before being sent to end consumers or retail
facilities. Tank farms are also common when producing or handling acid of varying
concentrations and qualities.
Tank farms may be affected by corrosion and fire, so proper corrosion and fire
protection is necessary.
In the petroleum industry, a tank farm is also known as an oil depot, installation or oil
terminal.

Tank Farm
A tank farm is an area used mostly for the storage of oil and/or petrochemical products
in large tanks. From the tank farm, petroleum products are distributed to end users or
further storage facilities. Tank farms consist of:

 Tankage, either above ground or underground

 Gantries for the discharge of products into road tankers or other vehicles (such
as barges) or pipelines.

These farms are traditionally installed close to oil refineries or in locations where marine
ships and tankers can take on or discharge their products. Some oil depots have
facilities to draw petroleum products through pipelines and are fed by rail, barge and
road tankers. Selecting suitable locations for tank farms includes making it easy to
transport liquid products from tanks.
A tank farm is relatively simple, and in most cases no processing or other
transformation on site is required. Sometimes additives are added to the tanks to
ensure that the liquid will flow.
Corrosion in a tank farm can be controlled by using cathodic protection systems.

1. Introduction:
Petroleum and chemical products
are primary resources in our life
and considered one of the most
important basic building blocks for
sustainable development. The
growing demand of hazardous
chemicals has
brought a significant increase in
risk to human and its
environment [1].Hazardous
chemicals have intrinsic
hazards for the environment,
which may damage it the human
and properties around the accident
area [2].
OSHAhas defined a hazardous
chemical as any chemical, which
has a physical hazard such as
(fire and
explosion) or a health hazard
such as (acute or chronic effects)
[3].The results of a historical
analysis have
shown that 17% of major accidents
in the chemical industries were
during storage processes[4].
According to
the NFPA report in 2009 [5], 13%
of the fire accidents that occurred
in the USA took place in storage
farms,
causing death or injury for
workers, tens million dollars as
losses and cause huge
environmental pollution.
Many catastrophic accidents
happened in the history such as
Bhopal disaster in 1984,which
caused thousands of
fatalities and tens of thousands of
people were injured[6].
Thepossible hazards are a
function of both the
inherent nature and the involved
quantity of the
chemical[7].Therefore, it is
important to conductaprofound and
adequate hazard analysis of the oil
storage facility to figure out the
potential scenarios having damage
to life
and property as well as provides a
clear picture for the decision
makers to be satisfied with the
safety levels in
the storage tank farm.Hazard
Analysis is animportant process
and has a vital role in studies
related to hazardous
chemicals handling. Hazard
identification(HAZID) is the initial
step in any hazard analysis process
and includes
the identification of all possible
accidents in the facility. The most
used technique in HAZID is
HAZOP study
[8]. HAZOP is a systematic review
of the design and operation of the
system to predict the possible
accidental
leaks of hazardous material[9].
The defined hazards can be
analyzed using many tools such as
FTA and ETA. FTA is a
systematic and
deductive approach that focuses on
hazardous outcomes (top event)
and develops further to the basic
causes
(bottom event) that lead to such
unwanted outcomes [10]. FTA is
also used widely in hazard analysis
of the
various storage facilities [10-15].
ETA is agraphical and inductive
tool that presents all the final
consequencesresulting from a
particular initiating event, with
considering the states
(failure/success) of the
installed safety barriers [9]. The
accidents frequencies can be
estimated by ETA if the data about
initiating and
heading events are known.
Otherwise, it can be derived from
databases such as OGP [16]or HSE
[17]. The
major goals of this studyare (i)
preventive goals to provide all
possibilities, which assistto prevent
accidents and
injuries in the crude oil storage
tank farm, (ii) protective goals
toprovide protection for
workers,equipment and
maintain workplace safety.
2. Hazard Identification (HAZID):
HAZID phase involved a review of
the storage conditions andthe
layout of storage tanks. Using this
information, a review of relevant
accident histories, knowledge,
experience with similar facilities,
and good
engineering practices, the possible
hazardous events in the facility
were determined. The potential
hazards
associated with the crude oil tank
are almost same to similar
facilities throughout the world.
The class of
hazards depends on the materials
being stored (physical and
chemical properties), type of
storage tank, storage
conditions, and protection and
mitigation measures provided.
HAZOP process is implemented
by applying a set
of guidewords to identify the
potential all parameters
deviations design intent, which
may adversely
affectpersonnel and plant safety.
Figure.1 presents a schematic
diagram for the fixed roof tank.
HAZOP study was conductedfor
a
deviation of three parameters
(pressure, level,and flow). HAZOP
resultsfor crude oil storage
tankwere presented
in Tables 1,2,3.
Figure1.Fixed roof tank diagram
for HAZOP study.

H. A. Ibrahim
et al
/International Journal of ChemTech
Research, 2018,11(11): 300-308. 302

Table 1. HAZOP (Parameter:

Pressure)
Guide Word
Deviations
Possible Causes
Possible
Consequences
MORE
More pressure
inside the storage
tank
Tank exposed toan
external heat source
Thermal expansion of oil
in the storage tank due to
fire or strong sunlight
Outlet pipe ofthe storage
tankblocked duringtransfer
Failure of the
pressurerelief valve
poor ventilation
Failure of the automatic
pressure control system
Possible explosion
due to rising build up
pressure in the tank

Pressure increases in
the tank that could
lead to fire and
explosion
Table 2. HAZOP (Parameter:
Level)
Guide Word
Deviations
Possible Causes
Possible
Consequences

MORE

More level in
the storage
tank
Tank top unattended
The level indicator fails
The wrong valve opened
The alarm doesn’t work
properly
Expansion of oil in case of
exposure to higher
temperature

Crude oil leakage to the

atmosphere, which may
initiatethe fire if any
ignition source exists.
Consequently, this may
heat the nearby tanks or
cause burns toworkers
due to exposure to heat
radiation.
LESS
Less level in
the storage
tank
Cracking or corrosion of
the tank.
Damage of tank body seal
Weak joints between the
roof and tank shell
Damage of valve and
flange
Rupture of a tank due to
integrity loss
H. A. Ibrahim
et al
/International Journal of ChemTech
Research, 2018,11(11): 300-308. 303
Table 3. HAZOP (Parameter: the
flow of crude oil to or from the
storage tank)
Guide Word
Deviations
Possible Causes
Possible consequences

NO

No flow(A) of

Crude oil to the

Storage tank
Outlet line closed
Outlet valve blocked
Pump Fail
Rupture of Pipeline
Pressure increases
rapidly in the pipeline.
Consequently,the leak
and explosion
probabilities grow up.
Minor/major flammable
liquid release
LESS
Less flow(A) of
Crude oil to the
storage tank
Partial opening ofthe
outlet valve
Inlet pipeline rupture due
to mechanical damage
Minor leak from
thePipeline
Possibility of pressure
build up in the storage
line
Minor release of
crude oil to the
atmosphere

NO
 No flow (B) of

Crude oilfrom
the storage
tank

Tank empty
Outlet valve closed
Line fracture
Outlet line blocked
rupture of pipeline
No significant hazard
Pressure increase in
the storage tank and
probability of leak
Major flammable liquid
release
LESS
Less flow(B) of
Crude oil from
the storage
tank
Partial opening of
the unloading valve
Minor leak from the
Pipeline
Potential of excessive
pressurein the storage
line
Minor release of
Crude oil to the ambient
atmosphere nearby tank
3. Hazard Analysis:
The identified hazards by HAZOP
study have been analyzed by FTA
to determine their root causes. FT
usesBoolean logic symbols
(AND gates, OR gates).FT
construction [18] begins at the
top event; then, it
identifies level by level all the
root causes that initiate the top
event; after that, it determines
the logical
relationships between the causes
and the top event.
H. A. Ibrahim
et al
/International Journal of ChemTech
Research, 2018,11(11): 300-308. 304

Figure 2. Fault Tree of crude oil

tank fire and explosion.
 




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Study and Analysis of Storage Tank Hazards and

its Mitigation Measures Using Bow Tie Diagram
Vaibhav Sharma*, Abhishek Nandan and Nihal Anwar Siddiqui
Department of Health, Safety and Environment, University of Petroleum and Energy
Studies, Dehradun, Uttrakhand, India

*Corresponding Author:
Vaibhav Sharma
Department of Health
Safety and Environment
University of Petroleum and Energy Studies
Dehradun, Uttrakhand, India
Tel: +91-8200993138
E-mail: [email protected]
Received Date: 10/01/2018; Accepted
Date: 12/02/2018; Published Date: 30/03/2018

Visit for more related articles at Research & Reviews:

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Abstract

Petroleum and petrochemical industry may lead to hazard

condition by means of fire, explosion, explosive chemical
noise, electrical shock and etc. which result in health,
environment and economic loss. These hazards can be a
result of the presence of cleaning chemicals, hazardous
gases, improper or insufficient lockout-tag out, vapors,
fumes, dusts, or excessive heat or cold. Atmospheric
storage tank fire very common in industrial facilities. In
this work various accidents of storage tanks that taken
place in Industrial facilities in Asia over last 40 years.
Bowtie Diagram is applied to depict causes and factors
responsible which led to various types of storage tank
fires. Prevention and mitigation measures are also
provided to help operating engineers handling similar
types of situations in the future. The results show that
70% of accidents occurred in oil terminals or storage,
petroleum refineries and Fire and explosion account for
90% of the accidents. There were accidents caused by
lightning, by human errors, including poor operations and
maintenance. Other causes were equipment failure, static
electricity, sabotage, crack and rupture, leak and line
rupture, open flames, etc. Most of these accidents would
have been avoided if proper safety management
programs, good engineering practices implemented.

Keywords
Good engineering practices, Fire and explosion, Safety
management program, Bowtie diagram

Introduction
Flammable and combustible liquid storage tanks are
found in refineries, petrochemical plants, bulk storage of
petroleum products and marine terminals. Airports, local
fuel companies, power plants and large manufacturing
facilities such as automobiles and steel plants may also
have bulk storage of flammable and combustible liquids
[1].

Storage tanks store flammable and combustible liquids in

various ways, depending on the facilities. These tanks
can vary from 5 meters to 150 meters in diameter and can
have an average height of 15 meters. These flammable
liquids such as heavy oil, petrol, diesel, kerosene, ATF,
etc. are stored in tanks at atmospheric temperature or
under low pressure of 0.5 bar [2]. If they found sufficient
amount of energy, they may get ignite and can lead to fire
or explosion. If an explosion occurs it may have a
devastating effect with waves or overpressure created
during explosion, which affects nearby tank also and can
be a catastrophic situation. Such tanks can store huge
volume of crude and other petroleum products of
flammable and combustible liquids. Larger industrial
facilities may own more than 300 Tanks of varying sizes
which contain various products. These tanks may be
placed very near to each other and have serval other
thanks within a common dyke.

The storage tank is covered by the peripheral boundary

called dykes which acts as barriers to prevent the spilled
liquid due to overflow or structural failure of the tank.
Every tank is separated and segregated according to their
classification. They are usually made of compacted dirt or
concrete similar type materials. The dyke of height is
considered 2 m. It can be extended on the special
recommendation to prevent overflow of flammable liquids.
Dykes are made consideration of the total capacity of the
tank and additional certain percentage above this as a
safety margin. If there is more than one tank in one dyke,
the dyke capacity should be at least the volume of the
largest tank in consideration a safety margin [3].

The Types of Tanks

• Fixed roof tanks

• Internal floating roof

• Open top floating roof tanks

Fixed Roof Tanks

Tanks with fixed roofs include cone roof tanks, dome roof
tanks, and column supported roof tanks, all of which are
of either welded, riveted (other types), or bolted (other
types) construction. Fixed roof tanks are typically used to
store a range of refined products, from volatile materials
to heavy fuel oils.

Fixed roof tanks are welded to the curb at the top of the
shell and covered from top section and shell is formed in
such a way that the forces are resisting downwards, such
as dome roof and conical shape (Figure 1). The tanks
have one or more structural section called wind girders
which are placed around the tank from the top for
resisting bulking and wind loads. The minimum thickness
of the roof plating is 5 mm on the new tank. The minimum
thickness of the roof plating is 5 mm of a new tank. To
support the roof plating in tanks up to about 30 meters
diameter [4].
Figure 1: Fixed roof tank.

Roof trusses often extend downwards below the curb and

therefore may lead to a reduction in storage capacity if, at
a later stage. The fixed roof tank is made to hold an
internal floating roof cover. The roof plating is attached to
the curb, by welding, and if specified the weld may be
minimal to make the joint frangible as a protection against
accidental overpressure.

All fixed roof should be vented by open vents or through

pressure/vacuum valves. For liquids to get in, air and
vapor must be pushed out. The pressure in the tank must
be slightly above atmospheric.

For a liquid to get out, air and vapor must be sucked in for
this the pressure in the tank must be slightly below
atmospheric (Figure 2).
Figure 2: Dome roof tanks.

Dome roof tanks are similar to internal floating roof tanks

are designed as a cover over the external floating roof
tank. The main purpose of dome rook is to provide
protection from fugitive emission to the environment.

Internal Floating Roof Tank

Internal floating roof tank consists of a permanently fixed
roof with a floating roof inside the tank. The internal roof
floats on pontoons or has a double deck for floatation
over the liquid surface (Figure 3). These tanks will
generally be found in service conditions where high
volatility (Low Flash Point) or toxic liquids are stored. In a
fixed roof tank without a floating cover, the liquid surface
is in direct contact with the airspace above it.
Figure 3: Internal floating roof tank.

The presence of an internal floating cover reduces these

vapor losses by at least 95%, a very important feature
where high cost, toxic or flammable materials are
concerned. The tank will normally be fitted with open
vents around the fixed roof (as Specified in BS 2654 and
API 650), but PV vents are often used in practice.

External Floating Roof Tank

External floating roof tank consists of a roof which floats
on the surface of the liquid, but the roof is exposed to the
atmosphere. The roof goes up and down with the change
in liquid level. The external floating roof consists of rim
seal which prevents the vapors from escaping. Typically,
such tanks are used for the storage of crude oil and all
volatile (low flash point) products. Crude oil tends to be
self-protective where the open tank shell is concerned,
while white oils lack this property and the exposed shells
become roughened by exposure to the weather (Figure
4).
Figure 4: External floating roof tank.

Causes of Accidents
Lightning

Lightning is one of the most common sources of ignition

that may lead to a fire on atmospheric floating roof tanks.
In a survey 95% of fire events taken place with the
lightning-ignited rim seal fires [5]. It is not necessary that
lightning should directly strike on a tank for ignition to
occur, a strike in the immediate nearby can generate that
certain amount of static charge between the tank shell
and floating roof tank that may lead to a fire. The Recent
fire which took place on Diesel tank, due to thunder
stormed noticed on Butcher Island off Mumbai in Oct
2017 since no fatality was noticed but it took four hours
for fuel to completely burn off. This incident costs a nearly
financial loss of at least 60-70 crore. Another fire which
took place on crude oil tank at HPCL in July 2017 due to
the lightning strike at Vishakhapatnam [6].

Maintenance Error
Welding, Grinding during maintenance work is
responsible for some catastrophic failures of storage tank
vapor explode. Electric sparks and shocks can
ignite flammable liquids or vapors lead to fire or explosion
also. An incident caused at Lanjou, china refinery due to
electric shock generated from electric motors and an
incident in 1984 at Kaohsiung, Taiwan has resulted in the
same cause [7]. A chemical plant at Chaiyi, an accident
caused by sparks generated from the electric soldering
machine. To minimize electric hazards, each section,
rooms, and areas must be taken into account in
determining its classification defined in NFPA 70, National
Electrical Code, Article 500, and Hazards (Classified)
Locations [8].

Operational Error

Overfilling of tanks is about the frequent cause of this

category. Products came out releasing large volumes of
vapors into the atmosphere and finding some ignition
source lead to fire or explosion. If the tank is filled with
flammable liquid and if it overfills, fire or explosion is
almost non avoidable. In 2001, Wuyi, Zhejiang, China, 50
Kg of Benzene leaked due to overfilling of tank leads to
46 Children and 2 villagers hospitalized [9].

Eight out of Ten accidents take place in leakage due to

Operational Error. In 2009, Jaipur fire at Indian Oil
Corporation, Terminal, is caused due non availability of
Standard procedure and Absence of Leakage stop device
from a remote location i.e., remote operated valve [10].

Sabotage

Sabotage is the fourth cause which can have an impact

on any incident on the storage tank. Any terrorist activity
or theft operation can lead to major emergencies. The
Serval tank farm was put on fire during the Iraqi
occupation of Kuwait in 1991. Few burnt tanks were
fought for Extinguishment; the rest was left for complete
burnout due to the war situation [11].

Equipment Failure

An external floating roof tank of the tank consists of roof

drain, breather Valve, and emergency roof drain. There
were cases where roof drain found chocked and water
gets accumulated on the surface of roof resulting in rook
sunken case. Sometimes the excess pressure develops
inside the, to relive breather valve is provided; it is found
that valve failure leads to buckling of the tank. There is a
seal, which is provided on the perimeter of the tank which
slides up and down with the tank roof and protects the
vapor from escaping out. Failure of seal or material
integrity loss leads to Serval incidents of vapor escape
[12].

Static Electricity

Taking samples of storage tanks containing flammable

liquids in open area results in static electricity. An
accident in Japan in 1992 used metal devices or
container for taking sample connected with conductive
threads [9]. To minimize the hazard, avoid taking a
sample in open access. If the open access sample is
unavoidable, better use nonconductive materials
sampling gauges. Avoid using any device made of metal.
The maximum static charge is developed during
transferring of material. Bonding of containers should be
done to make potential equal.

Leak and Line Rupture

The incident took place in 1977, there is LPG leaked at

Vishakhapatnam for without detected for Serval hours
and after tanker ship pumped at the shore of
Vishakhapatnam, resulting in a thick blanket of smokes
which overwhelming the entire port city resulting in 37
deaths and 100 injuries [13].

Open Flames

Open Flames resulting from cigarette smoking, ground

fires, and hot particles also ignite flammable vapors
around storage tanks.

Natural Disasters

Due to Impact of seismic motions in earthquake

phenomenon on the structure of storage tank leads to
cracking of its structure which leads to leakage of
flammable liquid due to a disturbance in equilibrium. As
Asia comes in an earthquake-prone area, there is always
a fear of some catastrophic failure of a tank. Fortunately,
there are only a few cases which result from an
earthquake. The fire involved in Japan Refinery in 1964 in
Niigata, resulted from sparks ignited hydrocarbon vapors
released due to an earthquake [14].

Runaway Reactions

Runaway reaction may take place when impurities mixed

with material stored in tanks resulting in an exothermic
reaction. One of biggest disaster that took place in India,
Bhopal gas Tragedy, 1984, caused due to water got
mixed with methyl isocyanate stored in underground
storage tank releasing huge volume of toxic gas killing
hundreds of people [15].

Types of Incident Scenarios

Boil Over

Boil over is a phenomenon which occurs in storage tank

fire consist of heavy hydrocarbon or a blend of
hydrocarbon liquids e.g. Crude is released in explosive
form when burning oil comes in contact with water, which
settled at bottom of the tank. The heat is dissipated
downwards and converts water into steam which expands
1500 times and carries burning crude with it. A boil over in
tank covers an area of approximately 10D of the tank in
downwind direction and 5D of the tank in crosswind
directions [16].

Slopover

Slopover is a phenomenon which occurs when water is

applied to full surface fire tank and the water gets
accumulated downwards results in overfill of product from
the tank.

Vent Fire

Vent fire takes place in the fixed roof tank when one or
more of vents get ignited due to vapor flammable vapor
released. The presence of flammable vapors has been
always there either due to tank filling operation or tank’s
daily breathing cycle. More of vent fire found due to
lightning strikes or found some ignition source nearby.

Full Surface Fire (Fixed Roof Tank)

A full surface of the fixed roof can occur due to vent fire
escalation. A vapor cloud explosion can occur is
flammable vapor is found within flammable range during
the flame flashback, mainly if flame arrestors/PV is not in
working condition. If a tank is constructed as per API 650,
it should separate from weal seam. Depending on the
vapor space explosion force, the roof may remove
partially (“Fish's mouth” opening) or fully removed.

Full Surface Fire (Open Floating Roof Tank)

Full surface fire is one where the tank roof has lost its
buoyancy and some or the entire liquid surface has been
exposed and involved in fire.

Rim Seal Fire

A rim seal fire takes place where the seal between the
tank shell and roof has lost its integrity and released
vapors exposed to an ignition source and involved in fire.

Bund Fire

A fire in the band is a type that occurs outside the tank

shell within the containment area. These types of fire
involved small spillage fill up to fire covering whole bund
area.

Methodology
The major tank accidents that had been occurring in Asia
in last few decades have been reviewed in this
paperwork. The data are collected from various published
reports. It has been found the major accidents have taken
place in Oil & Gas sector as compared to a petrochemical
plant, storage terminals and other facilities like gas plants,
power plants, and fertilizer industry. This work explains
with the help of a Bow Tie diagram (Figure 5) using
BowTie XP Software for different causes of events that is
explained above which was responsible for incidents
happened that lead to the different fire scenarios as
worse case which can be prevented if proper mitigation
measures have been taken into account or proper SOPs
and SMPs is followed Various Preventive barriers have
been taken into account with different threats and
proactive/recovery barriers or mitigation measures with
consequences with escalation factors for both threats and
consequences.
Figure 5: Bowtie diagram.

Results and Discussion

This section covers Causes and consequences of storage
tank hazards with their mitigation measures. Various
preventive barriers which related to the particular threat
through bow tie diagram has been identified and
expressed which also includes its escalation factors that
have acted as an additive to hazards. After identifying all
types of threats such as equipment failure, lightning,
operational factors, etc., the consequence has been
described with their mitigation measures such Automatic
deluge system, Portable foam monitors application,
Product pump out etc. which have decreased the effect of
consequence that has taken place.

As there is mitigation measure which act as proactive

/recovery barriers also have an escalation factor of
consequence that have put a stop or act as a hurdle in
extinguishment or reducing the consequence, such as
inadequate supply of foam which is a hurdle for
application of foam monitors or chocking of nozzle for
automatic deluge system etc. It has been found that if
proper maintenance of these equipment’s, better and
efficient equipment is used this can prevent the escalation
factors for consequences.

Conclusion
In this paperwork accident taken place in industrial
facilities on various tanks has been reviewed. The Cause
and factor responsible that led to catastrophic
consequences were expressed with the help of a Bowtie
diagram in a systematic way. Most of the accidents would
have avoided if maintenance and operation, good
engineering in design, construction has been practiced
and proper safety management programs, SOPs, SMPs
implemented and executed.

References

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4. McGrath RV. Stability of API standard 650 tank shells.

Proceedings of the American Petroleum Institute,
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5. Mansour KA. Fires in large atmospheric storage tanks

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countermeasures in the design of large size petroleum
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8. Keller K, Electrical safety code manual: A plain

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9. Chang JI, et al. A study of storage tank accidents.

Journal of Loss Prevention in the Process
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10. Gupta K. Design of district emergency operations

centres, and the case study of Indian Oil Corporation
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11. Ghabra S. The Iraqi occupation of Kuwait: An

eyewitness account. Journal of Palestine Studies.
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12. Hellemans M. The safety relief valve handbook:

Design and use of process safety valves to ASME and
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13. Arefi M, et al. What is public about public space: The

case of Visakhapatnam, India.Cities. 2003;20:331-339.

14. Moshashaei P, et al. Investigate the causes of fires

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15. Broughton E. The Bhopal disaster and its aftermath: a

review. Environmental Health. 2005;4:6.

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operation of large atmospheric storage tanks. Journal
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