Feb-2025

Vital role of tank gauging in refineries: Ensuring accuracy and safety

Refineries play a critical role in processing crude oil and producing various petroleum products.

Trident Consulting

Article Summary

Within these complex facilities, the storage and management of liquids, such as crude oil, intermediates, and finished products, are of utmost importance. To ensure efficient operations, accurate inventory management, and safe working conditions, refineries rely heavily on tank gauging systems. This article explores the significance of tank gauging in refineries and how it contributes to the overall success of these facilities.

Different tank gauging methods
Tank gauging techniques vary depending on the type of tank and the unique properties of the liquid being stored. These methods can be broadly classified into two categories: manual and automatic. An automatic tank gauge (ATG) is an electronic device designed to monitor liquid levels continuously. ATGs provide refinery operators with critical information, such as changes in level, warnings, water levels, volume, and temperature.

On the other hand, manual gauging can be performed using two techniques: innage (which measures the actual depth of liquid inside the tank) or outage (which measures the empty space in the tank). While ATGs provide continuous data, it’s important to calibrate all equipment for accuracy, as even small discrepancies (such as a quarter-inch difference) can result in significant volume errors.

The benefits of a combined approach
A combined approach using both ATG and manual tank gauging offers several advantages:
• Accurate inventory management: Tank gauging ensures precise measurement of liquid levels and volumes, which is essential for production planning, scheduling, and minimising product losses.
• Compliance with safety regulations: Refineries operate under strict safety regulations. Tank gauging ensures compliance with storage tank safety standards, preventing overfilling and reducing associated risks. Accurate inventory data also aids in mass balance reconciliation and identifying sources of loss (e.g., meter issues or density inaccuracies).
• Leak detection and environmental protection: Continuous tank level monitoring helps identify leaks early, minimising environmental impact and preventing product loss.
• Operational efficiency: Real-time monitoring allows operators to track inventory levels, detect bottlenecks, and optimise processes, leading to reduced downtime and increased efficiency.
• Maintenance and asset management: Continuous monitoring aids in predictive maintenance by identifying equipment issues early, reducing the risk of costly breakdowns.
• Integration with Control Systems: Tank gauging systems can be integrated with refinery control systems, providing seamless monitoring and facilitating real-time decision-making.
• Emergency response and contingency planning: Accurate tank data supports emergency response teams during incidents like fires or leaks, helping to develop effective contingency plans.
• Calibration and accuracy verification: Regular calibration and verification are essential to ensure accurate measurements and reliable data, confirming the system remains within acceptable limits.
• Operator safety and ease of operation: Automated tank gauging reduces the need for manual gauging, minimising operator exposure to hazards. Real-time information enhances situational awareness and safety.
• Continuous improvement and optimisation: Tank gauging data plays a key role in identifying optimisation opportunities. Analysing historical data helps refineries refine processes, reduce waste, and improve performance.

Conclusion
Tank gauging is an indispensable component of refinery operations. It ensures accurate inventory management, regulatory compliance, early leak detection, and operational efficiency. By investing in reliable tank gauging systems and embracing continuous improvement, refineries can optimise performance, maintain safety standards, and contribute to the sustainable growth of the industry.

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