No one really looks forward to an API 653 inspection. It’s one of those necessary-but-stressful parts of owning or operating aboveground storage tanks (ASTs). You know it’s coming, and you know it’s important, but the prep work? That’s where things can get messy (literally and figuratively).
Still, doing it right can save you weeks of frustration, unplanned downtime, and costly repairs. Whether you’re dealing with a routine inspection, a major repair, or a full-on reconstruction, being prepared isn’t just about ticking boxes—it’s about keeping your tank in compliance, extending its life, and making your inspector’s job (and yours) a whole lot easier.
So, let’s walk through what it actually takes to prep for an API 653 inspection the right way—without the usual stress and chaos.
1. Start with the Paperwork (Yes, Really)
Before anyone even shows up on-site, your first job is to gather your tank’s documentation. Think of this as the inspection’s “pre-game warm-up.”
You’ll need:
- The original construction records (usually built to API 650).
- Previous inspection reports and repair history.
- Material test certificates and weld maps.
- Any alteration or reconstruction records, if applicable.
Why is this so important? Because API 653 inspectors use these records to evaluate how the tank has changed over time—and whether its current condition still meets design standards. Missing paperwork can slow the whole process down or force re-testing.
If your documentation is scattered across binders, email threads, and someone’s old desktop folder—now’s the time to organize it. Trust me, your future self (and your inspector) will thank you.
2. Clean the Tank and the Site
A dirty tank is an inspector’s nightmare. Corrosion, sludge, residue—these can all hide potential issues or make accurate readings impossible.
Before inspection, make sure to:
- Drain and clean the tank thoroughly (if it’s an internal inspection).
- Ventilate it properly to remove any gases.
- Pressure-wash or wipe down accessible surfaces.
If you’re preparing for a repair or reconstruction, this step becomes even more critical. You can’t safely weld or assess structural integrity on a surface coated with grime or product residue.
It might sound obvious, but you’d be surprised how often inspections by tank inspection companies are delayed because the tank wasn’t fully cleaned or safe for entry.
3. Give Inspectors Safe, Easy Access
Here’s one that often gets overlooked: accessibility. Inspectors can’t assess what they can’t reach.
That means:
- Setting up scaffolding or ladders to reach higher sections.
- Installing lighting inside for internal inspections.
- Providing confined space entry permits and rescue plans.
If you have large tanks with floating roofs or internal liners, consider using robotic crawlers or drones for initial assessments. It saves time and keeps people out of potentially hazardous spaces.
4. Handle Repairs Before the Inspection—If You Can
If you already know something’s wrong (like thinning shell plates or visible corrosion), deal with it before the API 653 inspector arrives.
Small proactive repairs—done by a certified tank repair company—can keep the inspection focused on evaluation rather than discovery. It also helps you avoid that awkward “yeah, we knew about that issue” moment during the walkthrough.
But keep it compliant: any repairs or alterations must follow API 653 Section 9 (Repairs) and Section 10 (Alterations). Don’t cut corners, because unauthorized fixes can cause bigger headaches later.
5. Double-Check Equipment and Support Systems
The inspector isn’t just looking at your tank walls—they’re looking at everything connected to it. That includes foundations, piping, nozzles, vents, and even the cathodic protection system.
A quick pre-check of these systems can reveal small problems before they become inspection findings. It also makes you look well-prepared and professional (which never hurts).
6. Communicate and Coordinate
This one might sound simple, but good communication can make or break your inspection process.
Make sure everyone—operators, safety personnel, and contractors—knows when and how the inspection will happen. Define roles, safety procedures, and access restrictions ahead of time. Nothing slows an inspection down like confusion on-site.
Also, if your facility runs multiple tanks, coordinate schedules to minimize downtime. A little planning goes a long way in avoiding operational chaos.
FAQs
- How often should API 653 inspections be done?
Typically, internal inspections occur every 10 to 20 years, depending on the tank’s condition and corrosion rate. External inspections are more frequent, usually every 5 years. - What’s the difference between repair, alteration, and reconstruction under API 653?
- Repair fixes defects (like cracks or corrosion) without changing the tank’s design.
- Alteration changes the tank’s structure or capacity (like adding a nozzle).
- Reconstruction means rebuilding the tank after major dismantling or relocation.
- Can I do repairs before the API 653 inspector arrives?
Yes, absolutely—but only if they follow API 653 standards and are documented properly. Unauthorized work can void compliance. - What safety measures should be in place before inspection?
Proper ventilation, gas testing, confined space permits, and rescue readiness. Safety is non-negotiable. - How long does a typical API 653 inspection take?
It depends on tank size and condition. A small inspection might take a few days; a large or complex one can take weeks, especially if major findings arise.
Final Thoughts
At the end of the day, preparing for an API 653 inspection is all about being proactive rather than reactive. It’s not just some regulatory formality—it’s a chance to understand your tank’s real condition and catch problems before they turn catastrophic.
If you approach it with organization, transparency, and respect for the process, you’ll not only pass the inspection—you’ll extend your tank’s life, stay compliant, and maybe even sleep better at night knowing your operation is solid.
Because when it comes to tank integrity, “good enough” just doesn’t cut it. Preparation does.
