Evaluating integrity of storage tank bottoms based on advanced MFL/ET scanning: use case in Kazakhstan

Background: Ensuring the structural integrity of aboveground storage tanks (ASTs), especially their bottoms, is critical for the safe and efficient operation of oil and gas facilities. Traditional inspection methods often fail to detect early-stage corrosion and defects. Aim: This study aims to evaluate the effectiveness of advanced Magnetic Flux Leakage (MFL) and Eddy Current Testing (ET) techniques for assessing AST bottom integrity and optimizing predictive maintenance strategies in Kazakhstan. Materials and methods: A dataset of 27 ASTs across different regions of Kazakhstan was analyzed using ROSEN TBIT Ultra technology and ROSOFT for Tanks software. Over 97000 anomalies were detected and categorized by type, location, and corrosion depth. Analytical comparisons were made across tank sizes, regions, service life, and presence of galvanic protection systems. Results: The results indicate a strong correlation between anomaly density and tank service life, volume, and environmental conditions. MFL/ET scanning proved more effective than traditional ultrasonic methods in detecting internal and external corrosion. The application of galvanic protection showed only partial reduction in corrosion rates. Systematic scanning significantly enhanced defect localization and maintenance planning. Conclusion: The integration of MFL and ET into RBI strategies allows for early detection of defects, optimized maintenance, reduced downtime, and enhanced safety. This approach is especially beneficial for aging infrastructure in Kazakhstan’s oil and gas industry.