Ammonia Storage Tanks Decommissioning and Recommissioning Training: 5-Day Professional Course

Course Overview

This intensive 5-day ammonia storage tank decommissioning and recommissioning training provides specialized knowledge for safely managing the complete lifecycle of ammonia storage facilities. Participants gain practical expertise in handling one of the most critical and hazardous operations in ammonia facilities.

Target Audience: Maintenance managers, project engineers, HSE professionals, plant operators, integrity engineers, turnaround coordinators, contractors, and facility managers responsible for ammonia storage systems.

Course Objectives:

• Master safe decommissioning and recommissioning procedures

• Implement comprehensive safety protocols for tank entry

• Apply regulatory compliance frameworks (API 653, OSHA, IIAR)

• Execute inspection, testing, and certification procedures

• Manage contractors and multi-disciplinary teams safely

Day 1: Fundamentals and Regulatory Framework

Morning Session: Ammonia Storage Systems Overview

Understanding Storage Infrastructure

Foundation knowledge of ammonia storage tank systems:

• Storage tank types: Refrigerated atmospheric, pressurized vessels, semi-refrigerated

• Typical capacities: 1,000 to 50,000+ tons

• Critical components: shell, foundation, refrigeration, relief devices, instrumentation

• Operating conditions: -33°C atmospheric or ambient at 8-10 bar

• Safety systems: fire protection, secondary containment, emergency isolation

Afternoon Session: Regulatory Compliance

Standards and Documentation Requirements

Understanding the regulatory landscape:

Key Standards:

• API 653: Tank Inspection, Repair, Alteration, and Reconstruction

• API 620: Design and Construction of Large, Welded, Low-Pressure Storage Tanks

• IIAR 2 & 6: Ammonia refrigeration systems

• OSHA 29 CFR 1910.111: Anhydrous Ammonia Storage

• OSHA PSM 1910.119: Process Safety Management

• ASME Section VIII: Pressure Vessel Code

Documentation Requirements:

• Original design specifications and drawings

• Historical inspection and repair records

• Material test reports and welding procedures

• Pressure vessel certifications

• Permitting and regulatory notifications

Day 2: Pre-Decommissioning Planning and Risk Assessment

Morning Session: Project Planning

Strategic Decommissioning Planning

Developing comprehensive project plans:

• Scope definition: Temporary versus permanent decommissioning

• Pre-decommissioning tank condition assessment

• Team assembly: project manager, API 653 inspector, HSE specialists

• Timeline development and resource allocation

• Equipment inventory: vacuum trucks, neutralizing agents, PPE

• Contractor selection and qualification

• Waste disposal arrangements and permits

Afternoon Session: Hazard Analysis

Comprehensive Risk Assessment

Conducting thorough safety analysis:

Hazard Identification:

• Ammonia residual hazards: liquid heel, absorbed ammonia, scale deposits

• Oxygen-deficient atmospheres

• Confined space entry risks

• Hot work and ignition sources

• Chemical incompatibilities during neutralization

Risk Mitigation:

• Job Safety Analysis (JSA) for critical tasks

• Energy isolation requirements (LOTO)

• Atmospheric testing protocols

• Emergency response planning

• Environmental protection measures

• Spill containment procedures

Day 3: Decommissioning Execution and Tank Entry

Morning Session: Ammonia Removal and Cleaning

Safe Tank Decontamination

Executing systematic ammonia removal:

Ammonia Inventory Reduction:

• Coordinated transfer to other facilities

• Vapor recovery and heel removal

• Temperature and pressure management

• Final draining procedures

Tank Purging and Neutralization:

• Nitrogen purging strategies (displacement versus dilution)

• Achieving safe ammonia concentration (<25 ppm)

• Water washing and acid neutralization techniques

• Steam cleaning for absorbed ammonia

• Multiple wash cycles and verification

• Wastewater treatment and disposal

Afternoon Session: Confined Space Entry

Safe Tank Entry Protocols

Implementing rigorous confined space procedures:

Pre-Entry Requirements:

• Atmospheric testing: oxygen, ammonia, LEL, toxics

• Continuous monitoring during entry

• Ventilation system setup (minimum 10 air changes/hour)

• Entry permit completion

• Rescue equipment positioning

Personal Protective Equipment:

• Respiratory protection: SCBA versus supplied air

• Chemical protective clothing

• Intrinsically safe equipment

• Fall protection systems

Entry Procedures:

• Attendant and entrant roles

• Time limits and rotation schedules

• Emergency extraction procedures

• Internal inspection activities: visual, NDT, corrosion documentation

Day 4: Integrity Assessment and Repair

Morning Session: Inspection and Testing

Comprehensive Integrity Evaluation

Conducting thorough mechanical integrity assessment:

Non-Destructive Examination (NDE):

• Ultrasonic thickness testing (UTT): systematic measurements

• Magnetic particle testing (MT) for cracks

• Radiographic testing (RT) for critical welds

• Vacuum box testing for leaks

• Phased array ultrasonic testing (PAUT)

Critical Inspection Areas:

• Shell-to-bottom weld (most critical zone)

• Shell courses and welds

• Roof structure and nozzles

• Foundation settlement assessment

• Internal structures and supports

Assessment Criteria:

• Minimum thickness calculations per API 653

• Corrosion rate determination

• Remaining life estimation

• Fitness-for-service evaluation (API 579)

• Pressure testing requirements

Afternoon Session: Repair Procedures

Tank Repair Execution

Implementing approved repair techniques:

Common Repairs:

• Shell and bottom plate replacement

• Weld repair and overlay procedures

• Corrosion pit repair

• Nozzle replacement or reinforcement

Welding Requirements:

• Qualified welding procedures (WPS/PQR)

• Welder qualification and certification

• Pre-heat and PWHT requirements

• Weld inspection and NDE

Coating and Protection:

• Internal coating system selection

• Surface preparation standards (SSPC, NACE)

• Application and inspection requirements

• External coating restoration

• Cathodic protection systems

Day 5: Recommissioning and Documentation

Morning Session: Recommissioning Procedures

Safe Return to Service

Executing systematic recommissioning protocols:

Pre-Commissioning Activities:

• Completion verification of repairs

• Final cleaning and drying

• Instrumentation calibration

• Safety device testing (PSVs, emergency valves)

• Electrical and control system testing

System Integrity Verification:

• Leak testing of all repairs

• Pressure vessel recertification

• Vacuum testing for refrigerated tanks

• Insulation integrity verification

Inerting and Commissioning:

• Nitrogen blanketing and moisture removal

• Dew point testing for dryness

• Gradual ammonia introduction

• Temperature conditioning and cool-down

• Initial filling protocols

• Operational readiness verification

Afternoon Session: Documentation and Future Planning

Closeout and Lifecycle Management

Completing comprehensive project documentation:

Required Documentation:

• API 653 inspection report and certification

• Repair procedures and material certifications

• NDE and pressure test records

• As-built drawings and updated P&IDs

• Regulatory compliance documentation

Long-Term Management:

• Risk-based inspection (RBI) program development

• Inspection interval optimization

• Corrosion monitoring programs

• Emerging technologies: robotics, drones, advanced NDE

• Tank life extension strategies

Case Studies:

• Real-world project reviews

• Incident analysis and lessons learned

• Emergency scenario planning exercises

Course Deliverables

Participants Receive:

• Comprehensive decommissioning/recommissioning manual

• Procedure templates and checklists

• API 653 reference guide

• Safety protocol templates

• Inspection report forms

• Professional certificate of completion

• Continuing education credits

Interactive Learning:

• Virtual tank inspection simulations

• Atmospheric monitoring exercises

• PPE demonstrations

• Emergency response drills

• Project planning workshops

Why This Training Matters

Key Benefits:

• Prevent catastrophic failures and ammonia releases

• Ensure regulatory compliance

• Protect worker safety in hazardous operations

• Optimize project timelines and costs

• Extend tank life through proper maintenance

• Reduce liability and insurance costs

ROI:

• Reduced incident rates

• Improved project execution efficiency

• Extended asset life

• Enhanced compliance posture

• Knowledge retention and workforce development