Ultracargo – an integrated logistics solutions provider and the largest independent liquid bulk storage company in Brazil – conducted the cleaning and inspection of one of its tanks without the need to empty it for the first time. This process took place at the company’s terminal in Itaqui (MA), lasted approximately a week, and was authorized by the Planning and Maintenance Control (PCM) team with support from other company departments and partner company technicians.

The entire operation was carried out using specialized robots and equipment, lifted to the top of the tank. The devices entered through an inspection hatch located on the roof, allowing full access to the tank’s interior without interrupting operations. During the process, the cleaning robot navigated along the reservoir floor, detecting and removing sediment that had accumulated over the years.

“Bathymetry was one of the solutions used to map sediment distribution for later removal, allowing visual and ultrasonic inspection of the tank bottom plates in accordance with API653, a standard that sets minimum requirements for the inspection, repair, alteration, and reconstruction of storage tanks,” explained Everaldo Silva Sena, Ultracargo’s Planning and Maintenance Control Manager. He noted that the data collected generated a heat map, showing that sediment depth varied from one centimeter in the shallowest areas to 23 centimeters in the most critical spots. During the operation, the robot traversed the floor four times, precisely removing only the detected residue. “If not removed, the sediment could compromise the pumps and piping of the firefighting system. With data obtained through ultrasonic thickness measurement of the tank bottom plates performed by a remotely controlled submersible vehicle, we could calculate the corrosion rate and the remaining lifespan of the plates, ensuring the asset’s operation until the next inspection.”

Leopoldo Gimenes, Ultracargo’s Executive Director of Operations and Engineering, explained that sediment formation in the tank is primarily due to impurities in the water, which, over nearly a decade, settled and accumulated at the bottom of the reservoir. He also emphasized that the company aims to implement this same procedure for future cleanings and inspections, expanding this new process to other terminals. “With the project’s completion, we reinforce our commitment to innovation, safety, and the integrity of our assets, employees, and the environment,” he added.

Watch the video to see how this process was carried out!