An integrated risk-based inspection approach for enhancing process safety in hydrocarbon storage tanks

Abstract

Petroleum hydrocarbon releases from storage facilities represent a major environmental risk, particularly under harsh operating conditions where corrosion can compromise asset integrity. Our study presents an integrated framework combining hazard analysis and Risk-Based Inspection (RBI) to improve the environmental safety of petroleum storage tanks. The methodology was applied to the SP1/RTI storage terminal operated by SONATRACH-TRC (National Company for Research, Production, Transport, Transformation, and Marketing of Hydrocarbons) in In-Amenas, Algeria, which comprises ten atmospheric storage tanks with a documented operational incident history. First, a systematic hazard study conducted by INERIS identified and ranked the hazardous phenomena associated with storage operations, providing an objective basis for equipment prioritization. Based on the resulting risk ranking, Tank A12 was selected as the most critical asset, and a routine visual inspection confirmed degradation mechanisms consistent with the identified hazards. Subsequently, an RBI assessment was performed using complementary non-destructive testing techniques, including Magnetic Flux Leakage (MFL) and Ultrasonic Testing (UT). The inspection revealed severe corrosion damage that substantially reduced the remaining service life of the tank and increased the likelihood of hydrocarbon leakage with potentially significant environmental consequences. Based on these findings, corrective maintenance was implemented in accordance with API 653 requirements, restoring the tank to safe operating conditions. Our proposed framework demonstrates that integrating systematic hazard analysis with RBI enables objective asset prioritization, improves inspection planning, and supports proactive integrity management. This approach provides a practical strategy for reducing environmental risks and enhancing the long-term safety and reliability of petroleum storage facilities operating under severe environmental conditions.